JP7479852B2 - Urethane filling structure - Google Patents

Description

The present invention relates to a urethane filling structure for gaps that arise when combining building materials to form spaces in buildings.

In buildings such as apartment buildings, office buildings, and schools, spaces are created by combining building materials such as ceilings, walls, and floors. When building materials such as ceilings, walls, and floors are installed in a building, it is desirable to install them without gaps, but gaps may occur due to poor fit due to unevenness of the contact surfaces of the building materials. If there are gaps in a building, they can cause a fire to spread in the event of a fire, so it is necessary to properly seal the gaps. As a method of sealing gaps, a method has been proposed in which gaps in a building are filled with non-flammable and fire-resistant fillers such as plastering materials such as cement and mortar, dry materials such as putty, and semi-dry materials such as sprayed rock wool (see, for example, Patent Document 1).

JP 2010-24811 A

However, wet methods that use plastering materials such as cement and mortar as fillers require time to harden, making them difficult to work with, while dry materials such as putty can fall off due to vibration, and semi-dry materials such as sprayed rock wool require special equipment and are difficult to work with in detailed areas.

Therefore, the objective of the present invention is to provide a urethane-filled structure that is easy to install and has excellent fire resistance.

The present invention has been made to solve the above problems, and the gist of the present invention is as follows.
[1] A urethane-filled structure comprising a building base material having a non-flammable material and a urethane foam that fills a gap between both ends of the building base material, the urethane foam containing a filler.
[2] The urethane filled structure of [1], wherein the urethane foam is adhered to the building base material.
[3] A urethane filling structure of [1] or [2], wherein the thickness of the urethane foam in the direction of communication of the gap is 30 mm or more and 300 mm or less.
[4] The urethane filling structure according to any one of [1] to [3], wherein the gap is a gap formed between a plurality of the building base materials.
[5] The urethane filling structure according to any one of [1] to [4], wherein the gap is a hole provided in the building base material.
[6] The urethane filling structure of any one of [1] to [5], wherein the width of the gap is 1 mm or more and 100 mm or less.
[7] The urethane filling structure of any one of [1] to [6], wherein the width of the gap is 1 mm or more and 50 mm or less.
[8] The urethane filling structure according to any one of [1] to [7], further comprising a pad that serves as a base for the urethane foam provided in the gap.

The present invention provides a urethane-filled structure that is easy to install and has excellent fire resistance.

1 is a cross-sectional view of a urethane filling structure according to a first embodiment of the present invention. FIG. 4 is a cross-sectional view of a urethane filling structure according to a second embodiment of the present invention. FIG. 11 is a cross-sectional view of a urethane filling structure according to a third embodiment of the present invention. FIG. 13 is a cross-sectional view of a urethane filling structure according to a first modified example of the third embodiment of the present invention. FIG. 13 is a cross-sectional view of a urethane filling structure according to a second modified example of the third embodiment of the present invention. FIG. 13 is a cross-sectional view of a urethane filling structure according to a third modified example of the third embodiment of the present invention. FIG. 13 is a cross-sectional view of a urethane filling structure according to a fourth modified example of the third embodiment of the present invention. FIG. 11 is a cross-sectional view of a urethane filling structure according to a fourth embodiment of the present invention. FIG. 13 is a cross-sectional view of a urethane filling structure according to a modified example of the fourth embodiment of the present invention. FIG. 13 is a cross-sectional view of a urethane filling structure according to a fifth embodiment of the present invention. FIG. 13 is a cross-sectional view of a urethane filling structure according to a sixth embodiment of the present invention. A cross-sectional view of a urethane filling structure related to a first modified example of the sixth embodiment of the present invention. A cross-sectional view of a urethane filling structure according to a second modified example of the sixth embodiment of the present invention. FIG. 13 is a cross-sectional view of a urethane filling structure according to a seventh embodiment of the present invention. A cross-sectional view of a urethane filling structure according to a modified example of the seventh embodiment of the present invention.

The present invention will be described in more detail below using an embodiment.

[First embodiment]
As shown in FIG. 1, the urethane filling structure according to the first embodiment of the present invention comprises building base materials 10a, 10b having a non-flammable material, and urethane foam 20 that fills a gap 30 between both ends of the building base materials 10a, 10b, and the urethane foam 20 contains a filler.

(Building base material)
The building base materials 10a and 10b are building base materials that divide the space of a building, and constitute at least a part of, for example, a ceiling, a wall, a floor, etc. Specifically, when the building base material 10a in Fig. 1 is a wall, the building base material 10b constitutes a ceiling or a floor, and when the building base material 10a is a ceiling or a floor, the building base material 10b constitutes a wall.
The building base materials 10a, 10b are components that separate the spaces of the building (a first space A and a second space B), and by having a gap 30 with the building base materials 10a, 10b at both ends, the first space A and the second space B are connected to each other.
Space A and space B communicate with each other through gap 30, so that in the event of a fire, the flame will advance from space A to space B, or from space B to space A. In this manner, the direction in which the two spaces A and B communicate with each other is the direction in which the flame advances, and is also referred to as the communication direction in this specification.

By including the noncombustible material in the building base materials 10a and 10b, the fire retardancy of the space including the gap 30 can be improved, and the fireproof structure can be made stronger. The noncombustible material in the building base materials 10a and 10b is specified in the Building Standards Act and the Enforcement Order of the Building Standards Act.
The building base materials 10a and 10b may contain a non-combustible material, but from the viewpoint of making the fireproof structure stronger, it is preferable that the building base material is composed of only a non-combustible material, or the non-combustible material is the main raw material. The term "main raw material" means that the non-combustible material occupies a large part of the building base material (for example, 50% or more by mass, preferably 70% or more by mass), and examples of the building base material include a combination of a non-combustible material and a material other than the non-combustible material, such as by covering a material other than the non-combustible material with a non-combustible material. Note that a combination of a non-combustible material and a material other than the non-combustible material, such as a metal sandwich panel that exhibits non-combustibility as a composite material, can be treated as a single material.
Examples of materials other than non-flammable materials include wood materials such as OSB, particle board, chipboard, hardboard, and MDF, paper materials such as corrugated cardboard, paperboard, and kraft paper, and foams such as urethane foam and styrene foam.
The building base materials 10a and 10b are preferably plate-shaped members (also called "surface materials"). In this case, the non-combustible materials used are specifically gypsum boards, ALC boards, extrusion-molded cement boards, lightweight wood-wool cement boards, wood-chip cement boards, metal sandwich panels, calcium silicate boards, slate boards, concrete, bricks, glass, and metal boards (e.g., aluminum, iron), etc. The non-combustible materials used in the building base materials 10a and 10b may be one of these alone or two or more of them may be used in combination. From the viewpoint of fire resistance and workability, the non-combustible materials used in the building base materials 10a and 10b are preferably gypsum boards, ALC boards, extrusion-molded cement boards, lightweight wood-wool cement boards, wood-chip cement boards, metal sandwich panels, calcium silicate boards, concrete, metal boards, etc.

(Urethane foam)
The urethane foam 20 fills and closes the gap 30 between the building base materials 10a and 10b at both ends, thereby forming a fireproof structure. In order to properly close the gap 30 with the urethane foam 20, it is preferable that the urethane foam 20 is adhered to the building base materials 10a and 10b. By adhering the urethane foam 20 to the building base materials 10a and 10b, the urethane foam 20 is in close contact with the building base materials 10a and 10b, thereby improving fire resistance. The urethane foam 20 is chemically adhered to the building base materials 10a and 10b. Here, chemical adhesion refers to adhesion to the building base materials 10a and 10b based on the self-adhesiveness of the urethane foam 20. Specifically, the chemical adhesion of the urethane foam 20 refers to the urethane foam 20 obtained by mixing a polyol-containing composition and a polyisocyanate, curing and foaming the mixture, and then curing and foaming the mixture on the surface of the building base materials 10a and 10b to form a layer adhered to the building base materials 10a and 10b, and adhering based on the self-adhesiveness of the layer.
The urethane foam 20 also contains a filler. By containing a filler, the properties of the filler can be imparted to the urethane foam 20. For example, by containing a filler having flame retardancy, the flame retardancy of the urethane foam 20 can be improved.

The width W of the gap 30 blocked by the urethane foam 20 is preferably 1 mm or more and 50 mm or less, more preferably 3 mm or more and 45 mm or less, and even more preferably 5 mm or more and 40 mm or less. When the width W of the gap 30 blocked by the urethane foam 20 is equal to or more than the above lower limit, it becomes easy to fill the gap 30 with the urethane foam 20, and workability becomes good. Furthermore, when the width W of the gap 30 blocked by the urethane foam 20 is equal to or less than the above upper limit, the gap 30 can be appropriately blocked by the urethane foam 20, and fire resistance can be improved.

The thickness T of the urethane foam 20 in the communication direction of the gap 30 is preferably 30 mm or more and 300 mm or less, more preferably 40 mm or more and 275 mm or less, and even more preferably 50 mm or more and 250 mm or less. When the thickness T of the urethane foam 20 in the communication direction of the gap 30 is equal to or more than the above-mentioned lower limit, the urethane foam 20 is less likely to burn out in the event of a fire, making it easier to ensure fire resistance in the gap 30. In addition, when the thickness T of the urethane foam 20 in the communication direction of the gap 30 is equal to or less than the above-mentioned upper limit, the material and cost required to form the urethane foam 20 can be reduced.

The density 20 of the urethane foam is not particularly limited, but is preferably in the range of 20 to 200 kg/m ^3. By making the density 200 kg/m ³ or less, the urethane foam becomes lightweight, and it becomes easier to install a structure in which the urethane foam 20 is filled in the gaps 30 in a building. In addition, by making the density 20 kg/m ³ or more, it becomes easier to achieve the desired flame retardancy and non-combustibility. From these viewpoints, the density of the urethane foam is more preferably in the range of 25 to 100 kg/m ³ , and even more preferably in the range of 30 to 80 kg/m ^3. The density of the urethane foam 20 can be measured in accordance with JIS K7222.

The urethane foam 20 may be provided with at least one of flame retardancy, semi-nonflammability, and nonflammability. More specifically, the urethane foam 20 is preferably one that has a total heat generation amount of 8 MJ/m2 or less after 5 minutes when heated with a radiant heat intensity of 50 kW/ ^m2 in accordance with the ISO-5660 test method. More preferably, one that has a total heat generation amount of 8 MJ/m2 or ^less after ¹⁰ minutes is used, and even more preferably, one that has a total heat generation amount of 8 MJ/ ^m2 or less after 20 minutes is used.

The gap 30 is preferably a gap formed between multiple building base materials 10a, 10b. An example of a gap formed between multiple building base materials 10a, 10b is a gap formed between a surface of the building base material 10a and an end of the building base material 10b, as shown in Fig. 1. The gap 30 is not limited to this configuration, and may be a gap formed between ends of the building base material, or may be a gap formed between surfaces of the building base material.
Among these, it is preferable that at least one of the building base materials 10a, 10b is the above-mentioned facing material, and it is more preferable that the gap 30 is formed between the end (end face) of the facing material constituting the building base material 10b and the building base material 10a. In this case, the building base material 10a may be a facing material or a building base material other than a facing material (e.g., concrete, etc.). In addition, when the building base material 10a is a facing material, for example, the gap 30 may be a gap formed between the end face of the facing material and the main surface of the facing material.
The gaps 30 can be formed between the multiple building base materials 10a, 10b by, for example, butting the building base materials 10a, 10b together or bringing the building base materials 10a, 10b close to each other. By making the gaps 30 by butting the multiple building base materials 10a, 10b together or bringing them close to each other, the width W can be narrowed, and fire resistance in the gaps 30 can be easily ensured.
The building base materials 10a, 10 forming the gap 30 may be a combination of the same building base material such as a ceiling, a wall and a floor, or may be a combination of different building components such as a wall and a floor, or a wall and a roof.

The gaps 30 may also be holes provided in the building base materials 10a and 10b. The gaps 30 provided by holes provided in the building base materials 10a and 10b can be provided in desired locations, improving comfort in the building.

The method of applying the urethane foam 20 to fill and close the gap 30 is preferably discharge-filling, in which a liquid urethane resin composition is discharged, and more specifically, discharge-filling using a spray or caulking gun is preferred.
Specifically, it is preferable to dispense a liquid urethane resin composition into the gaps 30 between the building base materials 10a, 10b that have been installed in advance, and then harden the composition to form the urethane foam 20, thereby closing the gaps 30.
Alternatively, it is preferable to dispense a liquid urethane resin composition onto one of the pre-installed architectural base materials 10a, 10b, and then, before the urethane resin composition hardens, bring the other architectural base material 10a, 10b into contact with or close to each other, and harden the urethane resin composition to form urethane foam 20 and close the gap 30.
Alternatively, a liquid urethane resin composition can be dispensed onto one of the pre-installed building base materials 10a, 10b, and after hardening, the other building base material 10a, 10b can be pressed against the urethane foam 20. It is expected that the gap 30 can be blocked by deforming the urethane foam 20, but if the degree of blocking is insufficient, additional urethane foam 20 can be applied.

The filling material that forms the urethane foam 20 is a urethane resin composition that contains a filler. The urethane resin composition generally contains a polyisocyanate compound and a polyol compound, and in the present invention, it further contains a filler.

<Polyisocyanate Compound>
Examples of the polyisocyanate compound used in the urethane foam 20 include aromatic polyisocyanates, alicyclic polyisocyanates, and aliphatic polyisocyanates.
Examples of aromatic polyisocyanates include phenylene diisocyanate, tolylene diisocyanate, xylylene diisocyanate, diphenylmethane diisocyanate, dimethyldiphenylmethane diisocyanate, triphenylmethane triisocyanate, naphthalene diisocyanate, polymethylene polyphenyl polyisocyanate (polymeric MDI), and the like.

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, and hexamethylene diisocyanate.
The polyisocyanate compounds may be used alone or in combination of two or more.
As the polyisocyanate compound, diphenylmethane diisocyanate (MDI), polymeric MDI, etc. are preferred because they are easy to use and readily available.

<Polyol Compound>
Examples of the polyol compound include polycarbonate polyols, aromatic polyols, alicyclic polyols, aliphatic polyols, polyester polyols, polymer polyols, and polyether polyols.
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, and the like.

Examples of aromatic polyols include bisphenol A, bisphenol F, phenol novolac, and cresol novolac. Examples of alicyclic polyols include cyclohexanediol, methylcyclohexanediol, isophoronediol, dicyclohexylmethanediol, and dimethyldicyclohexylmethanediol. Examples of aliphatic polyols include ethylene glycol, propylene glycol, butanediol, pentanediol, and hexanediol. Hydroxycarboxylic acids such as castor oil can also be used.

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, and condensates of hydroxycarboxylic acids and the above-mentioned polyhydric alcohols.
Specific examples of the polybasic acid include adipic acid, azelaic acid, sebacic acid, terephthalic acid, isophthalic acid, succinic acid, etc. Specific examples of the polyhydric alcohol include bisphenol A, ethylene glycol, 1,2-propylene glycol, 1,4-butanediol, diethylene glycol, 1,6-hexane glycol, neopentyl glycol, etc.
Specific examples of hydroxycarboxylic acids include castor oil and reaction products of castor oil and ethylene glycol.

Examples of the polymer polyol include polymers obtained by graft polymerizing the above-mentioned aromatic polyols, alicyclic polyols, aliphatic polyols, polyester polyols, etc. with ethylenically unsaturated compounds such as acrylonitrile, styrene, methyl acrylate, and methacrylate; polybutadiene polyols; modified polyols of polyhydric alcohols; and hydrogenated products thereof.
Examples of modified polyols of polyhydric alcohols include those obtained by reacting a raw material polyhydric alcohol with an alkylene oxide to modify it.
Examples of polyhydric alcohols used in the modified polyol include trihydric alcohols such as glycerin and trimethylolpropane; tetrahydric to octahydric alcohols such as pentaerythritol, sorbitol, mannitol, sorbitan, diglycerin, and dipentaerythritol; sucrose, glucose, mannose, fructose, methyl glucoside, and derivatives thereof; phenol, phloroglucine, cresol, pyrogallol, catechol, hydroquinone, bisphenol A, bisphenol F, bisphenol S, phenol polybutadiene polyols such as 1-hydroxynaphthalene, 1,3,6,8-tetrahydroxynaphthalene, anthrol, 1,4,5,8-tetrahydroxyanthracene, and 1-hydroxypyrene; castor oil polyols, polymers or copolymers of hydroxyalkyl (meth)acrylates, and polyvinyl alcohol; and polyfunctional (e.g., functional groups of 2 to 100) polyols; and condensates (novolaks) of phenol and formaldehyde.

The method for modifying the polyhydric alcohol is not particularly limited, but a method in which alkylene oxide (hereinafter abbreviated as AO) is added thereto 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-propylene oxide, 1,2-butylene oxide, and 1,4-butylene oxide.
Among these, from the viewpoints of properties and reactivity, PO, EO and 1,2-butylene oxide are preferred, and PO and EO are more preferred.
When two or more kinds of AO are used (for example, PO and EO), the addition method may be block addition or random addition, or a combination of these.

Examples of polyether polyols include polymers obtained 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 of low molecular weight active hydrogen compounds having two or more active hydrogens for use in polyether polyols include diols such as bisphenol A, ethylene glycol, propylene glycol, butylene glycol, and 1,6-hexanediol; triols such as glycerin and trimethylolpropane; and amines such as ethylenediamine and butylenediamine.

The polyol compound is preferably at least one selected from polyester polyols and polyether polyols, and more preferably polyester polyols, because they have a large effect of reducing the total heat generated when burned. Among these, it is preferable to use polyester polyols with a molecular weight of 200 to 800, and even more preferable to use polyester polyols with a molecular weight of 300 to 500.

The urethane resin composition may contain a mono-ol compound having only one hydroxyl group. Examples of the mono-ol compound include 3-bromo-2,2-bis(bromomethyl)propan-1-ol.

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. If the isocyanate index is 120 or more, the isocyanate groups will be in excess of the hydroxyl groups, making it easier for trimerization to occur. If the isocyanate index is 300 or more, it becomes easier to impart non-flammability. If the isocyanate index is 1,000 or less, a good balance between non-flammability and manufacturing costs will be achieved. The isocyanate index can be calculated using a conventional method.

<Filler>
The filler contained in the urethane foam 20 is a solid component contained in the urethane resin composition, and is generally a component present in the form of particles or powder in the urethane resin composition.
The filler contained in the urethane foam 20 is preferably a solid flame retardant. In the present invention, the use of a solid flame retardant can effectively improve the flame retardancy of the urethane foam 20. The solid flame retardant is usually in a state of being dispersed as a powder component in a polyol liquid, a urethane resin composition, or the like. The solid flame retardant is a flame retardant that becomes solid at room temperature (23° C.) and normal pressure (1 atm).
Specific examples of solid flame retardants include red phosphorus-based flame retardants, phosphate-containing flame retardants, bromine-containing flame retardants, chlorine-containing flame retardants, antimony-containing flame retardants, boron-containing flame retardants, metal hydroxides, and needle-shaped fillers. These may be used alone or in combination of two or more.

Red phosphorus flame retardant
The red phosphorus-based flame retardant may be made of red phosphorus alone, may be red phosphorus coated with a resin, a metal hydroxide, a metal oxide, or may be red phosphorus mixed with a resin, a metal hydroxide, a metal oxide, or the like. The resin that coats the red phosphorus or mixes with the red phosphorus is not particularly limited, but examples thereof include thermosetting resins such as phenol resin, epoxy resin, unsaturated polyester resin, melamine resin, urea resin, aniline resin, and silicone resin. As the compound to be coated or mixed, a metal hydroxide is preferable from the viewpoint of flame retardancy. The metal hydroxide to be used may be appropriately selected from those described later.

Phosphate-containing flame retardants
Examples of the phosphate-containing flame retardant include phosphates formed from salts of various phosphoric acids and at least one metal or compound selected from metals in Groups IA to IVB of the periodic table, ammonia, aliphatic amines, aromatic amines, and heterocyclic compounds containing nitrogen in the ring.
The phosphoric acid is not particularly limited, but examples thereof include monophosphoric acid, pyrophosphoric acid, and polyphosphoric acid.
Examples of metals in Groups IA to IVB of the periodic table include lithium, sodium, calcium, barium, iron (II), iron (III), and aluminum.
Examples of the aliphatic amine include methylamine, ethylamine, diethylamine, triethylamine, ethylenediamine, piperazine, etc. Examples of the aromatic amine include aniline, o-triidine, 2,4,6-trimethylaniline, anisidine, 3-(trifluoromethyl)aniline, etc. Examples of the heterocyclic compound containing nitrogen in the ring include pyridine, triazine, melamine, etc.

Specific examples of phosphate-containing flame retardants include monophosphates, pyrophosphates, polyphosphates, etc. Here, the polyphosphates are not particularly limited, but examples include ammonium polyphosphate, piperazine polyphosphate, melamine polyphosphate, ammonium amide polyphosphate, aluminum polyphosphate, etc. The phosphate-containing flame retardants may be one or more of the above.

Bromine-containing flame retardants
The bromine-containing flame retardant is not particularly limited as long as it contains bromine in its molecular structure and is a solid at room temperature and pressure. Examples of the bromine-containing flame retardant include brominated aromatic ring-containing aromatic compounds.
Examples of the brominated aromatic ring-containing aromatic compound include monomeric organic bromine compounds such as hexabromobenzene, pentabromotoluene, hexabromobiphenyl, decabromobiphenyl, decabromodiphenyl ether, octabromodiphenyl ether, hexabromodiphenyl ether, bis(pentabromophenoxy)ethane, ethylene bis(pentabromophenyl), ethylene bis(tetrabromophthalimide), and tetrabromobisphenol A.

The brominated aromatic ring-containing aromatic compound may be a bromine compound polymer.Specific examples of the brominated aromatic ring-containing aromatic compound include brominated polycarbonates such as polycarbonate oligomers produced from brominated bisphenol A as a raw material, copolymers of the polycarbonate oligomers and bisphenol A, and diepoxy compounds produced by the reaction of brominated bisphenol A and epichlorohydrin.Further examples include brominated epoxy compounds such as monoepoxy compounds obtained by the reaction of brominated phenols with epichlorohydrin, poly(brominated benzyl acrylate), brominated phenol condensates of brominated polyphenylene ether, brominated bisphenol A, and cyanuric chloride, brominated (polystyrene), poly(brominated styrene), brominated polystyrenes such as crosslinked brominated polystyrene, crosslinked or non-crosslinked brominated poly(-methylstyrene), and the like.
In addition, compounds other than brominated aromatic ring-containing aromatic compounds such as hexabromocyclododecane may be used.
These bromine-containing flame retardants may be used alone or in combination of two or more.

<Chlorine-containing flame retardants>
Chlorine-containing flame retardants include those commonly used in flame-retardant resin compositions, such as polychlorinated naphthalenes, chlorendic acid, and dodecachlorododecahydrodimethanodibenzocyclooctene sold under the trade name "Dechlorane Plus."

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

Boron-containing flame retardants
Examples of boron-containing flame retardants include borax, boron oxide, boric acid, borates, etc. 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 Groups 4, 12, and 13 of the periodic table, and ammonium. Specific examples include 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, zirconium borate, zinc borate, aluminum borate, and ammonium borate.
The boron-containing flame retardants may be used alone or in combination of two or more.
The boron-containing flame retardant used in the present invention is preferably a borate, more preferably zinc borate.

Metal hydroxides
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, tin hydroxide, talc, etc. Among these, aluminum hydroxide, magnesium hydroxide, calcium hydroxide, and talc are preferred. The metal hydroxides may be used alone or in combination of two or more.

Needle-shaped filler
Examples of the needle-like filler include potassium titanate whiskers, aluminum borate whiskers, silicon-containing whiskers, wollastonite, sepiolite, zonolite, elestadite, boehmite, glass fibers, asbestos fibers, carbon fibers, graphite fibers, slag fibers, silica fibers, alumina fibers, silica alumina fibers, zirconia fibers, boron nitride fibers, and stainless steel fibers. Of these, wollastonite is preferred. The aspect ratio (length/diameter) of the needle-like filler is preferably in the range of 5 to 50, and more preferably in the range of 10 to 40.

<Inorganic filler>
The urethane foam 20 may contain an inorganic filler other than the above-mentioned solid flame retardant as a filler. By containing an inorganic filler, the urethane foam 20 can be endowed with various functions, such as improving the mechanical strength of the urethane foam 20.
The inorganic filler is not particularly limited, but examples thereof include silica, diatomaceous earth, alumina, titanium oxide, calcium oxide, magnesium oxide, iron oxide, tin oxide, antimony oxide, ferrites, basic magnesium carbonate, calcium carbonate, magnesium carbonate, zinc carbonate, barium carbonate, dawsonite, hydrotalcite, calcium sulfate, barium sulfate, gypsum fiber, potassium salts of calcium silicate and the like, clay, mica, montmorillonite, bentonite, activated clay, seviolite, imogolite, sericite, glass beads, silica balloon, aluminum nitride, boron nitride, silicon nitride, carbon black, graphite, carbon balloon, charcoal powder, various metal powders, potassium titanate, magnesium sulfate, lead zirconate titanate, aluminum borate, molybdenum sulfide, silicon carbide, various magnetic powders, and fly ash.
The inorganic filler may be used alone or in combination of two or more kinds. The inorganic filler may be used in combination with the solid flame retardant described above, but is not necessarily required to be used in combination.

Filler content:
In the present invention, the content of the filler in the urethane foam 20 (i.e., the urethane resin composition) is preferably 4 parts by mass or more, more preferably 6 parts by mass or more, and even more preferably 12 parts by mass or more, per 100 parts by mass of the urethane resin. By making the content of the filler equal to or more than these lower limits, it becomes easier to impart various properties, such as flame retardancy and mechanical strength, to the urethane foam 20 according to the type of filler.
The amount of the filler is preferably 80 parts by mass or less, more preferably 60 parts by mass or less, and even more preferably 40 parts by mass or less, relative to 100 parts by mass of the urethane resin. By making the amount of the filler equal to or more than these upper limits, the viscosity of the urethane resin composition becomes appropriate, and it becomes easier to form the urethane foam 20 by spraying or the like.

The urethane foam is formed by the reaction of the polyol component and the polyisocyanate component contained in the urethane resin composition. Therefore, in this specification, "100 parts by mass of urethane resin" in the urethane resin composition means 100 parts by mass of the total amount of the polyol component and the polyisocyanate component in the urethane resin composition. However, when the urethane resin composition contains at least one type of a prepolymer in which the polyol component and the polyisocyanate component have been reacted in advance, and a monol component, 100 parts by mass of urethane resin means 100 parts by mass of the total amount of the polyol component, the polyisocyanate component, the prepolymer, and the monol component.

As described above, the filler in the urethane foam 20 is preferably a solid flame retardant from the viewpoint of imparting flame retardancy, and the solid flame retardant may be used alone as a filler or may be used in combination with other fillers such as inorganic fillers. From the viewpoint of improving flame retardancy, the solid flame retardant is preferably 50% by mass or more of the total amount of the filler, more preferably 70% by mass or more, even more preferably 85 to 100% by mass, and most preferably 100% by mass.

<Liquid flame retardant>
The urethane foam 20 (i.e., the urethane resin composition) preferably further contains a liquid flame retardant. The use of a liquid flame retardant can improve the flame retardancy of the urethane foam 20 without significantly increasing the viscosity of the urethane resin composition. It is more preferable to use the liquid flame retardant in combination with the above-mentioned solid flame retardant. The liquid flame retardant is a flame retardant that becomes liquid at normal temperature and pressure. A specific example of the liquid flame retardant is a phosphoric acid ester.
As the phosphate ester, a monophosphate ester, a condensed phosphate ester, etc. can be used. The monophosphate ester is a phosphate ester having one phosphorus atom in the molecule. The monophosphate ester is not limited as long as it is liquid at room temperature and normal pressure, and examples thereof include trialkyl phosphates such as trimethyl phosphate, triethyl phosphate, tributyl phosphate, and tri(2-ethylhexyl)phosphate, halogen-containing phosphate esters such as tris(β-chloropropyl)phosphate, trialkoxy phosphates such as tributoxyethyl phosphate, aromatic ring-containing phosphate esters such as tricresyl phosphate, trixylenyl phosphate, tris(isopropylphenyl)phosphate, cresyl diphenyl phosphate, and diphenyl(2-ethylhexyl)phosphate, and acidic phosphate esters such as monoisodecyl phosphate and diisodecyl phosphate.

Examples of the condensed phosphate ester include aromatic condensed phosphate 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, "CR-733S", "CR-741", and "CR747" manufactured by Daihachi Chemical Industry Co., Ltd., and "ADEKA STAB PFR" and "FP-600" manufactured by ADEKA Corporation.

The liquid flame retardant may be one of the above-mentioned compounds, or two or more of them may be used in combination. Among these, from the viewpoint of easily adjusting the viscosity of the urethane resin composition to an appropriate level and from the viewpoint of improving the flame retardancy of the urethane foam 20, monophosphate esters are preferred, and halogen-containing phosphate esters such as tris(β-chloropropyl)phosphate are more preferred.
The content of the liquid flame retardant in the urethane foam 20 (i.e., the urethane resin composition) is preferably 1 to 40 parts by mass, more preferably 2 to 30 parts by mass, and even more preferably 4 to 20 parts by mass, per 100 parts by mass of the urethane resin. By making the blending amount of the liquid flame retardant equal to or greater than these lower limits, the effect of including the liquid flame retardant is easily exhibited. In addition, by making the blending amount equal to or less than the upper limits, the foaming of the urethane resin composition is not inhibited by the liquid flame retardant.

As described above, the urethane foam 20 is formed by hardening and foaming the urethane resin composition. As described above, the urethane resin composition contains a polyol compound, an isocyanate compound, and a filler, but generally also contains a catalyst, a foaming agent, etc.

<Catalyst>
The urethane resin composition of the present invention may contain, as a catalyst, for example, a trimerization catalyst, a resinification catalyst, or both of these, and it is preferable to contain both.
The trimerization catalyst is a catalyst that reacts with the isocyanate groups contained in the polyisocyanate to trimerize them and promote the formation of isocyanurate rings. By using the trimerization catalyst, the flame retardancy of the urethane foam 20 is further improved.
Examples of the trimerization catalyst that can be used 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 salts of carboxylic acids such as potassium acetate, potassium 2-ethylhexanoate, and potassium octylate, tertiary ammonium salts such as trimethylammonium salt, triethylammonium salt, and triphenylammonium salt, and quaternary ammonium salts such as tetramethylammonium salt, tetraethylammonium, tetraphenylammonium salt, and triethylmonomethylammonium salt. Examples of the ammonium salt include ammonium salts of carboxylic acids such as 2,2-dimethylpropanoic acid, and more specifically, quaternary ammonium salts of carboxylic acids.
These may be used alone or in combination of two or more.
Among these, one or more selected from alkali metal carboxylates and quaternary ammonium carboxylates are preferred, and an embodiment in which both of these are used is also preferred.

The amount of trimerization catalyst is preferably 0.6 to 10 parts by mass, more preferably 0.8 to 8 parts by mass, and even more preferably 1.0 to 6 parts by mass, per 100 parts by mass of urethane resin. If the amount is equal to or greater than these lower limits, the trimerization of isocyanate proceeds appropriately, making it easier to impart flame retardancy. If the amount is equal to or less than the upper limits, an appropriate foaming speed can be maintained, making the composition easier to handle.

The resinification catalyst is a catalyst that promotes the reaction between a polyol compound and a polyisocyanate. Examples of the resinification catalyst include amine-based catalysts such as imidazole compounds and piperazine compounds, and metal-based catalysts.
Examples of the imidazole compound include tertiary amines in which the secondary amine at the 1-position of the imidazole ring is substituted with an alkyl group, an alkenyl group, or the like. Specific examples include N-methylimidazole, 1,2-dimethylimidazole, 1-ethyl-2-methylimidazole, 1-methyl-2-ethylimidazole, 1,2-diethylimidazole, and 1-isobutyl-2-methylimidazole. In addition, imidazole compounds in which the secondary amine in the imidazole ring is substituted with a cyanoethyl group may also be used.
Furthermore, 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 the resinification catalyst include various tertiary amines such as pentamethyldiethylenetriamine, triethylamine, N-methylmorpholinebis(2-dimethylaminoethyl)ether, N,N,N',N",N"-pentamethyldiethylenetriamine, N,N,N'-trimethylaminoethyl-ethanolamine, bis(2-dimethylaminoethyl)ether, N,N-dimethylcyclohexylamine, diazabicycloundecene, triethylenediamine, tetramethylhexamethylenediamine, and tripropylamine.

Examples of the metal catalyst include metal salts of lead, tin, bismuth, copper, zinc, cobalt, nickel, etc., and preferably organic acid metal salts of lead, tin, bismuth, copper, zinc, cobalt, nickel, etc. More preferred are dibutyltin dilaurate, dioctyltin dilaurate, dioctyltin versatate, bismuth trioctate, bismuth tris(2-ethylhexanoate), tin dioctylate, lead dioctylate, etc., and among these, organic acid bismuth salts are even more preferred.
The resinification catalyst may be used alone or in combination of two or more kinds.

The amount of resinification catalyst blended is preferably 0.6 to 10 parts by mass, more preferably 0.8 to 8 parts by mass, and even more preferably 1.0 to 6 parts by mass, per 100 parts by mass of urethane resin. If the amount of resinification catalyst blended is equal to or greater than these lower limits, urethane bonds are more easily formed and the reaction proceeds quickly. On the other hand, if the amount is equal to or less than these upper limits, the reaction rate is easier to control.

<Foaming Agent>
The foaming agent contained in the urethane resin composition foams the urethane resin. Specific examples of the foaming agent include water, organic physical foaming agents, and inorganic physical foaming agents.
Examples of the organic physical blowing agent include low-boiling point hydrocarbons such as propane, butane, pentane, hexane, heptane, cyclopropane, cyclobutane, cyclopentane, cyclohexane, and cycloheptane; ether compounds such as dimethyl ether and diisopropyl ether; chlorinated aliphatic hydrocarbon compounds such as dichloroethane, propyl chloride, isopropyl chloride, butyl chloride, isobutyl chloride, pentyl chloride, and isopentyl chloride; and fluorine compounds such as trichloromonofluoromethane and trichlorotrifluoroethane.

In addition, hydrofluorocarbons and hydrofluoroolefins are also included. Examples of hydrofluorocarbons include compounds having 1 to 4 carbon atoms, and may be fluoroalkanes such as CHF ₃ , CH ₂ F ₂ , and CH ₃ F, or hydrochlorofluorocarbon compounds having chlorine atoms. Examples of hydrochlorofluorocarbon compounds include dichloromonofluoroethanes such as HCFC22 (chlorodifluoromethane) and HCFC141b (1,1-dichloro-1-fluoroethane), monochlorodifluoroethanes such as HCFC142b (1-chloro-1,1-difluoroethane), HFC-245fa (1,1,1,3,3-pentafluoropropane), and HFC-365mfc (1,1,1,3,3-pentafluorobutane).
Examples of hydrofluoroolefins include fluoroalkenes having about 3 to 6 carbon atoms. The hydrofluoroolefins may be hydrochlorofluoroolefins having chlorine atoms, and therefore may be chlorofluoroalkenes having about 3 to 6 carbon atoms.
More specific examples include trifluoropropene, tetrafluoropropenes such as HFO-1234, pentafluoropropenes such as HFO-1225, chlorotrifluoropropenes such as HFO-1233, chlorodifluoropropenes, chlorotrifluoropropenes, and chlorotetrafluoropropenes. More specific examples include 1,3,3,3-tetrafluoropropene (HFO-1234ze), 1,1,1,2,3-pentafluoropropene (HFO-1225yez), 1-chloro-3,3,3-trifluoropropene (HFO-1233zd), and 1,1,1,4,4,4-hexafluorobut-2-ene (HFO-1336mzzZ).
Examples of inorganic physical foaming agents include nitrogen gas, oxygen gas, argon gas, and carbon dioxide gas.
Among these, water, hydrofluorocarbons, and hydrofluoroolefins are preferred from the viewpoints of foaming property, handling property, etc., and hydrofluoroolefins and water are more preferred, and hydrofluoroolefins are even more preferred, from the viewpoints of low environmental load and good foaming property. It is also preferable to use water and hydrofluorocarbons, or water and hydrofluoroolefins in combination.

The amount of foaming agent used in the urethane resin composition is preferably 0.1 to 30 parts by mass, more preferably 0.5 to 20 parts by mass, and even more preferably 1 to 15 parts by mass, per 100 parts by mass of urethane resin. When the foaming agent content is equal to or greater than the lower limit, foaming is promoted and the density of the resulting urethane foam 20 can be reduced. When the foaming agent content is equal to or less than the upper limit, the foam can be prevented from breaking and not being formed.

<Foam stabilizer>
The urethane resin composition preferably further contains a foam stabilizer. The foam stabilizer contained in the urethane resin composition is one that improves the foamability of the urethane resin composition and is preferably one that has high foaming stability. By using a foam stabilizer with high foaming stability, a urethane foam with a high closed cell ratio can be obtained. Examples of the foam stabilizer include surfactants such as polyoxyalkylene-based foam stabilizers such as polyoxyalkylene alkyl ethers and silicone-based foam stabilizers such as organopolysiloxanes.
Among these, silicone-based foam stabilizers are preferred. Examples of silicone-based foam stabilizers include graft copolymers of polyoxyalkylene glycol, which is a polymer of ethylene oxide or propylene oxide, and polydimethylsiloxane. Also usable are those having a chemical structure of a block copolymer of polydimethylsiloxane and polyether.
Commercially available foam stabilizers that may be contained in the urethane resin composition include "SH-193,""SZ-1671," and "SZ-1642" manufactured by Dow Corning Toray Co., Ltd.
In the urethane resin composition, the amount of the foam stabilizer blended relative to the urethane resin is, for example, preferably 0.1 to 5 parts by mass, more preferably 0.3 to 3 parts by mass, and even more preferably 0.5 to 2 parts by mass, per 100 parts by mass of the urethane resin.

The resinification catalyst, trimerization catalyst, blowing agent and foam stabilizer may each be used alone or in combination of two or more.

Furthermore, the urethane resin composition may contain additives such as phenol-based, amine-based, or sulfur-based antioxidants, antisettling agents, heat stabilizers, metal damage inhibitors, antistatic agents, stabilizers, crosslinking agents, lubricants, softeners, and tackifying resins, as necessary, within the scope of the present invention.

The urethane resin composition is preferably a two-component curing type, and may be divided into one and two components before forming the urethane foam 20. The use of a two-component curing type improves foaming properties and makes it easier to increase the closed cell ratio. Specifically, it may be divided into a polyol liquid (one component) containing a polyol compound and an isocyanate liquid (two components) containing a polyisocyanate compound. In this case, the components other than the polyol compound and the polyisocyanate compound contained in the urethane resin composition may be mixed into either the polyol liquid or the isocyanate liquid as appropriate, but are preferably mixed into the polyol liquid. This is because the polyol compound has low reactivity and is unlikely to cause side reactions even when mixed with components other than the polyol compound and the polyisocyanate compound.

The urethane resin composition is prepared by storing a first liquid containing a polyisocyanate compound and a second liquid containing a polyol compound in separate storage chambers, and mixing the first liquid and the second liquid supplied from each storage chamber in a mixing section or the like to initiate a reaction, and the viscosity increases over time, hardening and foaming progress, the fluidity is lost, and the urethane foam 20 is produced. Each storage chamber may be provided in a separate container, or two storage chambers may be provided in one container.
The urethane resin composition is usually cured and foamed by leaving it at about room temperature (for example, about 10 to 40° C.), but may be heated as necessary.

According to the urethane filling structure of the first embodiment, the urethane foam can fill gaps that occur when building base materials are butted together or placed close to each other, or gaps in holes in the building base materials, resulting in a fireproof structure with excellent fire resistance. In addition, the urethane foam can be formed by dispensing and filling using a spray or caulking gun, making it easy to install.

Second Embodiment
The second embodiment differs from the first embodiment in that, as shown in Fig. 2, a pad 40 is further provided in the gap 30 and serves as a base for the urethane foam 20. The differences between the first embodiment and the second embodiment will be described below. In the following description of different embodiments, the same reference numerals will be used to designate members having the same configuration.

The pad 40 receives the liquid urethane resin composition and serves as a base for the urethane foam 20, helping to close the gap 30.
Examples of the backing material 40 include fibrous materials such as rock wool, glass wool, and cellulose fiber; inorganic materials such as gypsum board, ALC board, extrusion-molded cement board, potassium silicate board, slate board, concrete, brick, glass, and mortar; wood materials such as plywood, OSB, and particle board; metal materials such as metal panels and metal sandwich panels; organic materials such as waterproof sheets such as asphalt, EPDM, and TPO, and urethane foam insulation. Among them, the backing material 40 is preferably a fibrous material from the viewpoint of conformity to the installation location and workability. Since the backing material 40 remains in the urethane foam 20 even after receiving the filler by discharge filling, it is preferable to adopt a non-combustible material that can impart functions to the urethane foam 20. The backing material 40 may be used alone or in combination of two or more types.
A plate-shaped member can be used as the backing material 40. When the backing material 40 is a plate-shaped member, the liquid urethane resin composition can be well received. The backing material 40, which is a plate-shaped member, preferably has a surface that is inclined with respect to the communication direction in the gap 30, a surface that is perpendicular to the axial direction, or a combination of these, and more preferably includes a perpendicular surface from the viewpoint of well receiving the filler.

In a urethane filling structure equipped with a pad 40, the method of applying urethane foam 20 to fill and close gap 30 is preferably discharge-filling in which a liquid urethane resin composition is discharged, and more specifically, discharge-filling using a spray and caulking gun is preferred.
Specifically, it is preferable to place a patch 40 in the gap 30 between pre-installed building base materials 10a, 10b, and then eject a liquid urethane resin composition and harden it to form urethane foam 20, thereby sealing the gap 30.
Alternatively, it is preferable to place a patch 40 on one of the pre-installed building base materials 10a, 10b, then dispense a liquid urethane resin composition, and before the urethane resin composition hardens, butt the other building base material 10a, 10b against or bring them close to each other, and harden the urethane resin composition to form urethane foam 20 and close the gap 30.
Alternatively, a patch 40 may be placed on one of the building base materials 10a, 10b that have already been installed, and then a liquid urethane resin composition may be dispensed onto one of the building base materials 10a, 10b, and after hardening, the other building base material 10a, 10b may be pressed against the urethane foam 20. It is expected that the gap 30 will be blocked by deforming the urethane foam 20, but if the degree of blocking is insufficient, additional urethane foam 20 may be applied.

The thickness of the urethane foam 20 in the communication direction of the gap 30 is the sum of the thickness _T1 and the thickness _T2 from the pad 40. From the above viewpoint, the sum of the thicknesses _T1 and _T2 is preferably 30 mm or more and 300 mm or less, more preferably 40 mm or more and 275 mm or less, and even more preferably 50 mm or more and 250 mm or less. Moreover, the thicknesses _T1 , T2 of the urethane foam 20 in the communication direction of the gap ₃₀ are preferably 15 mm or more and 150 mm or less, more preferably 20 mm or more and 125 mm or less, and even more preferably 25 mm or more and 100 mm or less.

According to the urethane filling structure of the second embodiment, the provision of a patching material makes it easier to install the urethane foam, and gaps can be more reliably blocked with the urethane foam, resulting in a fireproof structure with excellent fire resistance. In addition, the provision of a patching material makes it easier to block gaps formed between multiple building base materials or gaps in holes provided in the building base materials with the urethane foam, improving workability.

[Third embodiment]
The third embodiment differs from the first embodiment in that, as shown in Figures 3(a) and (b), architectural base materials 11a, 11b and architectural base materials 12a, 12b form a hollow floor, and a gap 30 between both ends of the architectural base materials 11a, 11b or 12a, 12b that form the hollow floor is blocked with urethane foam 21a or urethane foam 21b. The following describes the differences between the first embodiment and the third embodiment. In the following description of different embodiments, the same reference numerals are used for components having the same configuration.

The building base materials 11a, 11b and the building base materials 12a, 12b are hollow floors serving as building components that separate the upper and lower floors of a building (a first space A and a second space B). Specifically, the building base materials 11a, 11b in Fig. 3 are floors on the upper floor side, and the building base materials 12a, 12b are ceilings on the lower floor side.
The building base materials 11a, 11b and the building base materials 12a, 12b can be made of the same materials as the building base materials 10a, 10b described in the first embodiment, and the details are the same as those described above, so a description thereof will be omitted.

As shown in Fig. 3(a), the urethane foam 21a fills and closes the gap 30 between the building base materials 11a and 11b to form a fireproof structure. Alternatively, as shown in Fig. 3(b), the urethane foam 21b fills and closes the gap 30 between the building base materials 12a and 12b to form a fireproof structure.
The urethane foams 21a and 21b can be made of the same material as the urethane foam 20 described in the first embodiment, and the details are the same as those described above, so a description thereof will be omitted.

The gap 30 is preferably a gap formed between multiple building substrates 11a and 11b, or between 12a and 12b. An example of the gap formed between multiple building substrates 11a and 11b is a gap formed between an end of the building substrate 11a and an end of the building substrate 11b, as shown in Fig. 3(a). Alternatively, an example of the gap formed between multiple building substrates 12a and 12b is a gap formed between an end of the building substrate 12a and an end of the building substrate 12b, as shown in Fig. 3(b). More specifically, an example of the gap formed between end faces of facing materials is a gap formed between the end faces of facing materials.
Among these, it is preferable that at least one of the architectural base materials 11a, 11b, or at least one of the architectural base materials 12a, 12b is the above-mentioned surface material, and it is more preferable to form a gap 30 between the end (end face) of the surface material constituting the architectural base materials 11a, 12a and the end (end face) of the surface material constituting the architectural base materials 11b, 12b.
The gap 30 can be formed between multiple building base materials 11a, 11b or between multiple building base materials 12a, 12b, for example, by butting different building base materials 11a, 11b or 12a, 12b together, or by bringing the building base materials 11a, 11b or 12a, 12b close to each other. By forming the gap 30 by butting multiple building base materials 11a, 11b or 12a, 12b together or by bringing them close to each other, the width W can be narrowed, making it easier to ensure fire resistance in the gap 30.

The gap 30 may also be a hole provided in one building base material, in which case the building base materials 11a, 11b or 12a, 12b are configured to be divided by the hole that is the gap 30. The gap 30 formed by the hole provided in the building base materials 11a, 11b or 12a, 12b can be provided in any desired location, improving the comfort of the building.

In a urethane filling structure in which the communication direction in the gap 30 is the vertical direction, the method of construction of the urethane foams 21a, 21b that fill and close the gap 30 is preferably discharge-filling, in which a liquid urethane resin composition is discharged, and specifically, discharge-filling using a spray and caulking gun is preferred.
Specifically, it is preferable to eject a liquid urethane resin composition into the gap 30 between pre-installed architectural base materials 11a, 11b or architectural base materials 12a, 12b, and harden it to form urethane foam 21a or urethane foam 21b, thereby blocking the gap 30.
Alternatively, a liquid urethane resin composition is discharged onto one of the pre-installed architectural substrates 11a, 11b or 12a, 12b, and the other architectural substrate 11a, 11b or 12a, 12b is butted against or brought close to the other architectural substrate 11a, 11b or 12a, 12b before the urethane resin composition hardens. Then, the urethane resin composition hardens to form urethane foam 21a or urethane foam 21b, which preferably closes gap 30.
Alternatively, a liquid urethane resin composition can be dispensed onto either the pre-installed architectural base material 11a, 11b or the architectural base material 12a, 12b, and after hardening, the other architectural base material 11a, 11b or the architectural base material 12a, 12b can be pressed against the urethane foam 21a, 21b. It is expected that the gap 30 can be blocked by deforming the urethane foam 21a, 21b, but if the degree of blocking is insufficient, additional urethane foam 21a, 21b may be applied.

According to the urethane filling structure of the third embodiment, when the building base material forms a hollow floor, the gaps between both ends of the building base material are blocked by urethane foam, resulting in a fireproof structure with excellent fire resistance. In addition, the urethane foam can be formed by dispensing and filling using a spray or caulking gun, making it easy to install.

[First Modification of the Third Embodiment]
In a first modified example of the third embodiment, as shown in Fig. 4, not only is the gap 30 between the building base materials 11a and 11b closed with urethane foam 21a, but the gap 30 between the building base materials 12a and 12b is closed with urethane foam 21b. In other words, the urethane filling structure according to the first modified example of the third embodiment closes the gaps 30 on both sides of the hollow floor formed by the building base materials 11a and 11b and the building base materials 12a and 12b with urethane foam 21a and 21b.

According to the urethane filling structure of the first modified example of the third embodiment, the gaps on both sides of the hollow floor formed by the building base material are blocked with urethane foam, making it possible to create a fireproof structure with better fire resistance.

[Second Modification of the Third Embodiment]
5(a) and (b), a second modified example of the third embodiment further includes a pad 41 that is provided in the gap 30 and serves as a base for the urethane foam 21a or urethane foam 21b. The urethane foam 21a or urethane foam 21b in the second modified example of the third embodiment is provided on both sides of the pad 41. The second modified example of the third embodiment will be described below with respect to differences from the third embodiment. In addition, in the following description of different embodiments, members having the same configuration will be given the same reference numerals.

Since the patch material 41 remains in the urethane foam 21a or urethane foam 21b even after the filling material is received by the discharge filling, it is preferable to adopt a non-flammable material that can impart functionality to the urethane foam 20a or urethane foam 21b. From the viewpoints of conformability to the installation location and ease of construction, the patch material 41 is preferably a fibrous material.
A plate-shaped member can be used as the backing material 41. The backing material 41 being a plate-shaped member can adequately receive the liquid urethane resin composition. The backing material 41, which is a plate-shaped member, preferably has a surface that is inclined with respect to the communication direction in the gap 30, a surface that is perpendicular to the axial direction, or a combination thereof, and more preferably includes a perpendicular surface from the viewpoint of adequately receiving the filler.

The thickness of the urethane foam 21a or urethane foam 21b in the communication direction of the gap 30 is the sum of the thickness _T1 and the thickness _T2 from the pad 41. From the above viewpoint, the sum of the thickness _T1 and the thickness _T2 is preferably 30 mm or more and 300 mm or less, more preferably 40 mm or more and 275 mm or less, and even more preferably 50 mm or more and 250 mm or less. Moreover, the thickness _T1 , _T2 of the urethane foam 21a or urethane foam 21b in the communication direction of the gap 30 is preferably 15 mm or more and 150 mm or less, more preferably 20 mm or more and 125 mm or less, and even more preferably 25 mm or more and 100 mm or less.

According to the urethane filling structure of the second modified example of the third embodiment, the provision of a patch makes it easier to install the urethane foam, and gaps can be more reliably blocked with the urethane foam, resulting in a fireproof structure with excellent fire resistance. In addition, the provision of a patch makes it easier to block gaps that occur when the building base material is installed with the urethane foam, improving workability.

[Third Modification of the Third Embodiment]
6(a) and 6(b), a third modified example of the third embodiment further includes a pad 41 that is provided in the gap 30 and serves as a base for the urethane foam 21a or urethane foam 21b. The urethane foam 21a or urethane foam 21b in the third modified example of the third embodiment is provided on one side of the pad 41. The third modified example of the third embodiment will be described below with respect to differences from the third embodiment. In addition, in the following description of different embodiments, members having the same configuration will be given the same reference numerals.

Since the patch material 41 remains in the urethane foam 21a or urethane foam 21b even after the filling material is received by the discharge filling, it is preferable to adopt a non-flammable material that can impart functionality to the urethane foam 20a or urethane foam 21b. From the viewpoints of conformability to the installation location and ease of construction, the patch material 41 is preferably a fibrous material.
A plate-shaped member can be used as the backing material 41. The backing material 41 being a plate-shaped member can adequately receive the liquid urethane resin composition. The backing material 41, which is a plate-shaped member, preferably has a surface that is inclined with respect to the communication direction in the gap 30, a surface that is perpendicular to the axial direction, or a combination thereof, and more preferably includes a perpendicular surface from the viewpoint of adequately receiving the filler.

From the above viewpoint, the thickness _T1 of the urethane foam 21a from the backing material 41 and the thickness _T2 of the urethane foam 21b from the backing material 41 in the communication direction of the gap 30 are preferably 30 mm or more and 300 mm or less, more preferably 40 mm or more and 275 mm or less, and even more preferably 50 mm or more and 250 mm or less.

According to the urethane filling structure of the third modified example of the third embodiment, the provision of a patch makes it easier to install the urethane foam, and gaps can be more reliably blocked with the urethane foam, resulting in a fireproof structure with excellent fire resistance. In addition, the provision of a patch makes it easier to block gaps that occur when the building base material is installed with the urethane foam, improving workability.

[Fourth Modification of the Third Embodiment]
As shown in Fig. 7, the fourth modified example of the third embodiment further includes a backing material 41 that is provided in the gap 30 and serves as a base for the urethane foam 21a and the urethane foam 21b. The urethane foam 21a or urethane foam 21b in the fourth modified example of the third embodiment is provided on one side of the backing material 41, and the gaps 30 on both sides of the hollow floor formed by the building base materials 11a, 11b and the building base materials 12a, 12b are blocked by the urethane foams 21a, 21b. The following describes the differences between the fourth modified example of the third embodiment and the third modified example of the third embodiment. In the following description of different embodiments, the same reference numerals are used for members having the same configuration.

In the fourth modified example of the third embodiment, the urethane foam 21a and the urethane foam 21b are provided only on the first space A side and the second space B side from the backing material 41 in the gap 30 on both sides of the hollow floor formed by the architectural base materials 11a, 11b and the architectural base materials 12a, 12b. The urethane foam 21a and the urethane foam 21b close the gap 30 on both sides of the hollow floor formed by the architectural base materials 11a, 11b and the architectural base materials 12a, 12b, so providing them only on the first space A side and the second space B side can provide sufficient fire resistance.

From the above viewpoint, the thickness _T1 of the urethane foam 21a from the pad 40 and the thickness T2 of the urethane foam _21b from the pad 40 in the communication direction of the gap 30 are preferably 15 mm or more and 150 mm or less, more preferably 20 mm or more and 125 mm or less, and even more preferably 25 mm or more and 100 mm or less.

According to the urethane filling structure of the fourth modified example of the third embodiment, the provision of a patch makes it easier to install the urethane foam, and gaps can be more reliably blocked with the urethane foam, resulting in a fireproof structure with excellent fire resistance. In addition, the provision of a patch makes it easier to block gaps that occur when the building base material is installed with the urethane foam, improving workability.

[Fourth embodiment]
The fourth embodiment differs from the third embodiment in that, as shown in Fig. 8, another building base material 13 is provided in the gap 30 between the building base materials 11a, 11b and the building base materials 12a, 12b at both ends. Differences between the fourth embodiment and the third embodiment will be described below. In the following description of different embodiments, the same reference numerals will be used to designate members having the same configuration.

The building base material 11a and the building base material 12a are hollow floors as building members that separate the upper and lower floors of the building (the first space A and the second space B), and the building base material 11b and the building base material 12b are hollow floors as building members that separate the upper and lower floors of the building (the third space C and the fourth space D). Specifically, the building base materials 11a and 11b in FIG. 8 are floors on the upper floor side, and the building base materials 12a and 12b are ceilings on the lower floor side. The building base material 13 is a member such as a wall that separates the spaces (the first space A and the third space C) (the second space B and the fourth space D) of the building. At least one of the building base materials 11a, 11b, the building base materials 12a, 12b, and the building base material 13 may be the above-mentioned surface material, or all of them may be surface materials.
The building base materials 11a, 11b, 12a, 12b, and 13 can be made of the same materials as the building base materials 10a, 10b described in the first embodiment, and the details are the same as those described above, so they will not be described again.

The urethane foam 22a fills and closes the gap 30 between the building base material 11a and the building base material 13, thereby providing a fireproof structure. The urethane foam 22b fills and closes the gap 30 between the building base material 11b and the building base material 13, thereby providing a fireproof structure.
The urethane foams 22a, 22b can be made of the same material as the urethane foam 20 described in the first embodiment, and the details are the same as those described above, so a description thereof will be omitted.

From the above viewpoint, the width _W3 of the gap 30 blocked by the urethane foam 22a and the width W4 of the gap ₃₀ blocked by the urethane foam 22b are preferably 1 mm or more and 50 mm or less, more preferably 3 mm or more and 45 mm or less, and even more preferably 5 mm or more and 40 mm or less.

From the above viewpoint, the thickness _T3 of the urethane foam 22a and the thickness _T4 of the urethane foam 22b in the communication direction of the gap 30 are preferably 30 mm or more and 300 mm or less, more preferably 40 mm or more and 275 mm or less, and even more preferably 50 mm or more and 250 mm or less.

The gap 30 is preferably a gap formed between multiple building base materials 11a, 13, or between multiple building base materials 11b, 13. Examples of the gap formed between multiple building base materials 11a, 13, or between multiple building base materials 11b, 13 include a gap formed between a surface of the building base material 13 and an end of the building base material 11a, as shown in Fig. 8, and a gap formed between a surface of the building base material 13 and an end of the building base material 11b.
The gaps 30 can be formed between multiple building base materials 11a, 13 or multiple building base materials 11b, 13, for example, by butting different building base materials 11a, 11b against the surface of the building base material 13, or by bringing the building base materials 11a, 11b close to each other. By forming the gaps 30 by butting different building base materials 11a, 11b against the surface of the building base material 13 or by bringing the building base materials 11a, 11b close to each other, the widths _W3 and _W4 can be narrowed, making it easier to ensure fire resistance in the gaps 30.

The method of applying the urethane foams 22a, 22b to close the gap 30 is as follows: first, a liquid urethane resin composition is dispensed into the gap 30 between the building substrate 11a and the building substrate 13, and then cured or dried to form the urethane foam 22a, thereby closing the gap 30 between the building substrate 11a and the building substrate 13. Then, it is preferable to dispense a liquid urethane resin composition into the gap 30 between the building substrate 11b and the building substrate 13, and then cured or dried to form the urethane foam 22b, thereby closing the gap 30 between the building substrate 11b and the building substrate 13.
Alternatively, a method may be combined in which urethane foam 22a or urethane foam 22b is applied to the building material 13, and after hardening, the building material 11a or 11b is pressed against the urethane foam 22a or urethane foam 22b. It is expected that the gap 30 will be blocked by deforming the urethane foam 22a, 22b, but if the degree of blocking is insufficient, additional urethane foam 22a, 22b may be applied.

According to the urethane filling structure of the fourth embodiment, even if the building base material forms a hollow floor and another building base material is provided between the hollow floors, the gap between both ends of the building base material is blocked by urethane foam, resulting in a fireproof structure with excellent fire resistance. In addition, the urethane foam can be formed by dispensing and filling using a spray or caulking gun, making it easy to install.

[Modification of the fourth embodiment]
In a modified example of the fourth embodiment, as shown in Fig. 9, not only is the gap 30 blocked by urethane foam 22a, 22b, but the gap 30 between the building substrate 12a and the building substrate 13 and the gap 30 between the building substrate 12b and the building substrate 13 are blocked. In other words, the urethane filling structure according to the modified example of the fourth embodiment blocks the gaps 30 on both sides of the hollow floor formed by the building substrates 11a, 11b, the building substrates 12a, 12b, and the building substrate 13 with urethane foam 22a, 22b and urethane foam 23a, 23b.

The urethane foam 23a fills and closes the gap 30 between the building base material 12a and the building base material 13, thereby providing a fireproof structure. The urethane foam 23b fills and closes the gap 30 between the building base material 12b and the building base material 13, thereby providing a fireproof structure.
The urethane foams 23a and 23b can be made of the same material as the urethane foam 20 described in the first embodiment, and the details are the same as those described above, so a description thereof will be omitted.

From the above viewpoint, the width _W5 of the gap 30 blocked by the urethane foam 23a and the width W6 of the gap ₃₀ blocked by the urethane foam 23b are preferably 1 mm or more and 50 mm or less, more preferably 3 mm or more and 45 mm or less, and even more preferably 5 mm or more and 40 mm or less.

From the above viewpoint, the thickness _T5 of the urethane foam 23a and the thickness _T6 of the urethane foam 23b in the communication direction of the gap 30 are preferably 30 mm or more and 300 mm or less, more preferably 40 mm or more and 275 mm or less, and even more preferably 50 mm or more and 250 mm or less.

According to the urethane filling structure of the modified fourth embodiment, even if the building base material forms a hollow floor and another building base material is provided between the hollow floors, the gaps on both sides of the hollow floor formed by the building base material can be blocked with urethane foam, resulting in a fireproof structure with better fire resistance.

[Fifth embodiment]
The fifth embodiment differs from the first embodiment in that, as shown in Fig. 10, the insertion members 50 are inserted into different spaces by utilizing the gaps 30 between the building base materials 14a and 14b. The differences between the first embodiment and the fifth embodiment will be described below. In the following description of different embodiments, the same reference numerals will be used to designate members having the same configuration.

The insertion member 50 is a linear member that transmits electricity or light, and examples of such wiring include power cables and communication cables. The insertion member 50 has a transmission line body that transmits electricity or light, and an outer sheath that covers the transmission line body. Examples of materials for the transmission line body include metal materials such as copper, copper alloys, aluminum, and aluminum alloys. Examples of materials for the outer sheath include resin materials such as polyvinyl chloride (PVC), polyethylene (PE), and cross-linked polyethylene, and the outer sheath is provided around the transmission line body by extrusion molding or the like. The insertion member 50 may also have an outer tube that protects the transmission line body and the outer sheath. Examples of the outer tube include corrugated tubes and spiral tubes made of resin materials such as PVC, PE, polypropylene (PP), and polybutene (PB), as well as sheets made of metal foil, etc.

The building base materials 14a and 14b are members that separate the first space A for passing the insert member 50 between different spaces in the building, and the second space B and the third space C, which are indoor spaces through which the insert member 50 passes. Specifically, the building base materials 14a and 14b in FIG. 10 are floors and walls, etc., and form underfloor piping and in-wall piping, etc. The underfloor piping and in-wall piping, etc., formed by the building base materials 14a and 14b can be formed, for example, by a subway construction method using a raceway. The building base material 15 is a member such as a wall that separates the spaces (the second space B and the third space C) of the building.
The building base materials 14a, 14b and the building base material 15 can be made of the same materials as the building base materials 10a, 10b described in the first embodiment, and the details are the same as those described above, so a description thereof will be omitted.

The urethane foams 24a, 24b fill and close the gaps 30 between the building base materials 14a, 14b at both ends, thereby providing a fireproof structure.
The urethane foams 24a, 24b can be made of the same material as the urethane foam 20 described in the first embodiment, and the details are the same as those described above, so a description thereof will be omitted.

From the above viewpoint, the width _W10 of the gap 30 blocked by the urethane foam 24a and the width _W11 of the gap 30 blocked by the urethane foam 24b are preferably 1 mm or more and 50 mm or less, more preferably 3 mm or more and 45 mm or less, and even more preferably 5 mm or more and 40 mm or less.

From the above viewpoint, the thickness _T10 of the urethane foam 24a and the thickness _T11 of the urethane foam 24b in the communication direction of the gap 30 are preferably 30 mm or more and 300 mm or less, more preferably 40 mm or more and 275 mm or less, and even more preferably 50 mm or more and 250 mm or less.

In a urethane filling structure with an insertion member 50, the method of applying the urethane foam 24a, 24b that closes the gap 30 is to first place the insertion member 50 through the gap 30, and then eject a liquid urethane resin composition into each gap 30. It is preferable that the urethane resin composition hardens or dries to form the urethane foam 24a, 24b that contains the insertion member 50, thereby closing the gap 30.

According to the urethane filling structure of the fifth embodiment, even if the gap is used to pass an insertion member such as a wiring, the gap can be blocked with urethane foam, resulting in a fireproof structure with excellent fire resistance.

Sixth embodiment
The sixth embodiment differs from the first embodiment in that, as shown in Fig. 11, the insertion member 60 is passed through the different spaces by utilizing the gap 30 formed by forming holes in the building base materials 16a and 16b, which are partition members such as walls, and the partition penetration parts provided in the building base materials 16a and 16b are blocked with urethane foam 25a. The sixth embodiment will be described below in terms of the differences from the first embodiment. In addition, in the following description of different embodiments, the same reference numerals will be used to designate members having the same configuration.

The insert member 60 is a pipe or the like for transporting fluids such as liquids, gases, and powders. The material of the insert member 60 is not particularly limited, but is preferably one with excellent fire resistance, for example, metal materials such as iron, lead, copper, copper alloys, aluminum, and aluminum alloys. In addition, when a resin material with low fire resistance is used as the material of the insert member 60, it is preferable to arrange mortar and metal, etc., from the viewpoint of imparting fire resistance. When the insert member 60 is composed only of a pipe made of a resin material, from the viewpoint of obtaining fire resistance, the pipe thickness is preferably 2 mm or more, more preferably 4 mm or more, and even more preferably 6 mm or more.

The building base materials 16a and 16b are members such as walls that separate spaces (a first space A and a second space B) in a building.
The building base materials 16a, 16b can be made of the same materials as the building base materials 10a, 10b described in the first embodiment, and the details are the same as those described above, so a description thereof will be omitted.

The urethane foam 25a fills and closes the gap 30 between the building base materials 16a, 16b at both ends, thereby providing a fireproof structure.
The urethane foam 25a can be made of the same material as the urethane foam 20 described in the first embodiment, and the details are the same as those described above, so a description thereof will be omitted.

From the above viewpoint, the width _W7 of the gap 30 closed by the urethane foam 25a is preferably 2 mm or more and 100 mm or less, more preferably 6 mm or more and 90 mm or less, and further preferably 10 mm or more and 80 mm or less.

When the insert member 60 has fire resistance, the insert member 60 can be regarded as a part constituting the gap 30, and the gap 30 blocked by the urethane foam 25a can be regarded as having both ends at the insert member 60 and one of the building base materials 16a, 16b. From the above viewpoint, the width _W7a of the gap 30 blocked by the urethane foam 25a when the insert member 60 has excellent fire resistance is preferably 1 mm or more and 50 mm or less, more preferably 3 mm or more and 45 mm or less, and even more preferably 5 mm or more and 40 mm or less.

From the above viewpoint, the thickness _T7 of the urethane foam 25a in the communication direction of the gap 30 is preferably 30 mm or more and 300 mm or less, more preferably 40 mm or more and 275 mm or less, and even more preferably 50 mm or more and 250 mm or less.

In a urethane filling structure with an insertion member 60, the method of applying the urethane foam 25a to close the gap 30 is preferably as follows: first, the insertion member 60 is placed through the gap 30, and then a liquid urethane resin composition is dispensed into the gap 30 and cured or dried to form the urethane foam 25a containing the insertion member 60, thereby closing the gap 30.

According to the urethane filling structure of the sixth embodiment, even if the structure is such that the insertion member is passed through a gap formed by forming a hole in the building base material, which is a partition member such as a wall, the gap can be blocked with urethane foam, resulting in a fireproof structure with excellent fire resistance.

[First Modification of the Sixth Embodiment]
In a first modified example of the sixth embodiment, as shown in Fig. 12, not only is one end of the gap 30 between the building base materials 16a, 16b blocked with urethane foam 25a, but the other end of the gap 30 between the building base materials 16a, 16b is blocked with urethane foam 25b. In other words, the urethane filling structure according to the first modified example of the sixth embodiment blocks both sides of the gap 30 formed by the building base materials 16a, 16b with urethane foam 25a, 25b.

From the above viewpoint, the width _W8 of the gap 30 closed by the urethane foam 25b is preferably 2 mm or more and 100 mm or less, more preferably 6 mm or more and 90 mm or less, and further preferably 10 mm or more and 80 mm or less.

When the insert member 60 has fire resistance, the insert member 60 can be regarded as a part constituting the gap 30, and the gap 30 blocked by the urethane foam 25b can be regarded as having both ends at the insert member 60 and one of the building base materials 16a, 16b. From the above viewpoint, the width _W8a of the gap 30 blocked by the urethane foam 25b when the insert member 60 has excellent fire resistance is preferably 1 mm or more and 50 mm or less, more preferably 3 mm or more and 45 mm or less, and even more preferably 5 mm or more and 40 mm or less.

The thickness of the urethane foam 25a and the urethane foam 25b in the communication direction of the gap 30 is the sum of the thickness _T7 of the urethane foam 25a and the thickness _T8 of the urethane foam 25b. From the above viewpoint, the sum of the thicknesses _T7 and _T8 is preferably 30 mm or more and 300 mm or less, more preferably 40 mm or more and 275 mm or less, and even more preferably 50 mm or more and 250 mm or less. Moreover, the thickness _T1 of the urethane foam 25a and the thickness _T2 of the urethane foam 25b in the communication direction of the gap 30 are preferably 15 mm or more and 150 mm or less, more preferably 20 mm or more and 125 mm or less, and even more preferably 25 mm or more and 100 mm or less.

In a urethane filling structure with an insertion member 60, the method of applying the urethane foam 25a, 25b that closes the gap 30 is as follows: first, place the insertion member 60 through the gap 30. Then, a liquid urethane resin composition is discharged from one side of the gap 30, and cured or dried to form the urethane foam 25a that contains the insertion member 60, thereby closing the gap 30 on one side. Then, it is preferable to discharge a liquid urethane resin composition from the other side of the gap 30, and cured or dried to form the urethane foam 25b that contains the insertion member 60, thereby closing the gap 30 on the other side.

According to the urethane filling structure of the first modified example of the sixth embodiment, both sides of the gaps formed by the building base material are blocked with urethane foam, making it possible to create a fireproof structure with better fire resistance.

[Second Modification of the Sixth Embodiment]
13, in a second modification of the sixth embodiment, a gap 30 between building base materials 16a, 16b is filled entirely with urethane foam 26 to close the gap 30. In other words, in the urethane filling structure according to the second modification of the sixth embodiment, both sides and the inside of the gap 30 defined by building base materials 16a, 16b are closed with urethane foam 26.

From the above viewpoint, the width _W9 of the gap 30 closed by the urethane foam 26 is preferably 2 mm or more and 100 mm or less, more preferably 6 mm or more and 90 mm or less, and even more preferably 10 mm or more and 80 mm or less.

When the outer layer of the insertion member 60 is made of a non-combustible material, the insertion member 60 can be regarded as a part of the gap 30, and the gap 30 blocked by the urethane foam 26 can be regarded as having the insertion member 60 and either one of the building base materials 16a, 16b as both ends of the building base material. When the insertion member 60 has excellent fire resistance, the width _W9a of the gap 30 blocked by the urethane foam 26 is preferably 1 mm or more and 50 mm or less, more preferably 3 mm or more and 45 mm or less, and even more preferably 5 mm or more and 40 mm or less, from the above viewpoint.

From the above viewpoint, the thickness _T9 of the urethane foam 26 in the communication direction of the gap 30 is preferably 30 mm or more and 300 mm or less, more preferably 40 mm or more and 275 mm or less, and even more preferably 50 mm or more and 250 mm or less.

In a urethane filling structure including an inserting member 60, the method of applying urethane foam 26 to close gap 30 is to first place inserting member 60 through gap 30. Thereafter, a liquid urethane resin composition is discharged from one side of gap 30, and the filler is allowed to spread to the other side of gap 30, and then cured or dried to form urethane foam 26, which preferably closes both sides and the inside of gap 30.
In addition, in a urethane filling structure including an insertion member 60, the method of applying the urethane foam 26 to close the gap 30 is as follows: first, the insertion member 60 is placed through the gap 30. After that, a liquid urethane resin composition is discharged from one side of the gap 30, and cured or dried to form a part of the urethane foam 26 containing the insertion member 60. Then, a liquid urethane resin composition is discharged from the other side of the gap 30, filling up to a part of the already formed urethane foam 26, and the filling material is cured or dried to form the urethane foam 26 containing the insertion member 60, and the urethane foam 26 preferably closes both sides and the inside of the gap 30.

According to the urethane filling structure of the second modified example of the sixth embodiment, both sides and the inside of the gaps formed by the building base material are blocked with urethane foam, making it possible to create a fireproof structure with better fire resistance.

[Seventh embodiment]
The seventh embodiment differs from the sixth embodiment in that, as shown in Fig. 14, a pad 42 is provided in the gap 30 and serves as a base for the urethane foam 25a. The seventh embodiment will be described below in terms of the differences from the sixth embodiment. In the following description of different embodiments, the same reference numerals will be used to designate members having the same configuration.

The pad 42 receives the liquid urethane resin composition and contributes to closing the gap 30 as the base of the urethane foam 25a. The pad 42 preferably has a surface that is inclined with respect to the communication direction in the gap 30, a surface that is perpendicular to the axial direction, or a combination of these, and from the viewpoint of receiving the filling material well, it is more preferable that the pad 42 includes a perpendicular surface.

Since the pad 42 will remain on the urethane foam 25a even after receiving the filler by discharge filling, it is preferable to use a non-flammable material that can impart functionality to the urethane foam 25a.
The pad 42 can be made of the same material as the pad 40 described in the second embodiment, and the details are the same as those described above, so the description will be omitted.

The backing material 42 has a hole 42a near the center of the bottom, through which the insert member 60 passes. The hole 42a may be circular, or may be any shape other than circular depending on the shape of the insert member 60. The hole 42a may be smaller than the size of the insert member 60. Also, a cut may be provided instead of the hole 42a. Even if the size of the hole 42a is smaller than the insert member 60, or even if a cut is provided instead of the hole 42a, when the backing material 42 is made of rubber or resin material, when the insert member 60 is inserted into the hole 42a (or the cut), the bottom bends and the insert member 60 can be inserted inside the hole 42a (or the cut).

In a urethane filling structure with a backing material 42, the method of applying the urethane foam 25a to close the gap 30 is to first place the backing material 42 in the gap 30, and then place the insertion member 60 through the hole 42a at the bottom of the backing material 42. After that, a liquid urethane resin composition is discharged into the gap 30, and the backing material 42 receives the filling material and hardens or dries to form the urethane foam 25a containing the insertion member 60, thereby closing the gap 30.

According to the urethane filling structure of the seventh embodiment, even if the structure is such that the insertion member is passed through a gap, the gap can be blocked with urethane foam, resulting in a fireproof structure with excellent fire resistance.
Furthermore, according to the urethane filling structure of the seventh embodiment, by providing a padding material, gaps can be more reliably blocked with urethane foam, resulting in a fireproof structure with excellent fire resistance.

[Modification of the Seventh Embodiment]
In a modification of the seventh embodiment, as shown in Fig. 15, not only is one side of the gap 30 between the building base materials 16a, 16b blocked with urethane foam 25a using a patch material 42 as a base, but the other side of the gap 30 between the building base materials 16a, 16b is blocked with urethane foam 25b using a patch material 42 as a base, as shown in Fig. 15. In other words, the urethane filling structure according to the modification of the seventh embodiment blocks both sides of the gap 30 formed by the building base materials 16a, 16b with urethane foam 25a, 25b using a patch material 42 as a base.

In a urethane filling structure having a backing material 42 and an insert member 60, the construction method of the urethane foam 25a, 25b that closes the gap 30 is as follows: first, the backing material 42 is placed in the gap 30, and the insert member 60 is placed through a hole 42a at the bottom of the backing material 42. Then, a liquid urethane resin composition is discharged from one side of the gap 30, and the backing material 42 receives the filling material, and hardens or dries to form the urethane foam 25a that contains the insert member 60. Then, it is preferable to discharge a liquid urethane resin composition from the other side of the gap 30, and the backing material 42 receives the filling material, and hardens or dries to form the urethane foam 25b that contains the insert member 60, thereby closing the gap 30.

According to the urethane filling structure of the modified example of the seventh embodiment, by providing a patch, both sides of the gaps formed by the building base material can be more reliably blocked with urethane foam, resulting in a fireproof structure with better fire resistance.

10-16: Building base material 20-25: Urethane foam 30: Gap 40-42: Backing material 50, 60: Insertion member

Claims (7)

The present invention comprises a plurality of building base materials having a non-combustible material, and a urethane foam that closes gaps formed between the plurality of building base materials,
The building base material is a facing material,
The gap is formed between a surface of one building base material and an end of the other building base material,
The urethane foam contains a filler ,
A urethane filling structure comprising a pad arranged between the face of one of the building base materials and the end of the other building base material, and the urethane foam contacts the building base material and the pad to seal the gap. The urethane-filled structure according to claim 1, which has multiple gaps formed between the surface of the one building base material and the ends of multiple building base materials other than the one building base material. The urethane-filled structure according to claim 2, wherein all of the gaps are filled with the urethane foam. The urethane-filled structure according to any one of claims 1 to 3, wherein the urethane foam is adhered to the building base material. The urethane filling structure according to any one of claims 1 to 4, wherein the thickness of the urethane foam in the direction of communication of the gap is 30 mm or more and 300 mm or less. The urethane filling structure according to any one of claims 1 to 5, wherein the width of the gap is 1 mm or more and 100 mm or less. The urethane filling structure according to any one of claims 1 to 6, wherein the width of the gap is 1 mm or more and 50 mm or less.