JPH07268987A - Flame retardative block structure - Google Patents

Abstract

PURPOSE:To form indoor and outdoor floors, lawns, and sidewalks by bonding a prescribed quantity of an inorganic particle having a specified specific gravity with a rubber binder to provide a flame retardative earth and sand bonded layer on a foamed resin layer. CONSTITUTION:A foamed resin layer 2 such as polyolefin or polyurethane is provided as a lower layer, an earth and sand bonded layer 3 is laminated thereon as an upper layer, and the foamed resin layer 2 and the earth and sand bonded layer 3 are integrally bonded to each other. The earth and sand bonded layer 3 is formed of an inorganic particle such as calcium carbonate having a specific gravity of 1.15 or more and a rubber binder. The content of the inorganic particle is set to 60-95wt.% to the total weight of the inorganic particle and the rubber binder. Excellent flame resistance and sound preventing property can be provided, and the characteristics of lightweight property and compression strength possessed by the foamed resin material can be utilized to improve the impact resisting strength and bending strength of the foamed resin material.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flame-retardant block structure which can be used as a floor material in a room, an artificial turf on a roof or a driving range, or outdoors such as a sidewalk or a playground. .

[0002]

2. Description of the Related Art A foamed resin body such as a foamed polystyrene resin body is lightweight and has a high insulation property against heat and sound and a great compressive strength, and therefore its characteristics are widely used for building materials, civil engineering materials, packaging containers and the like. ing. However, the foamed resin body is vulnerable to impact on the one hand, for example, it is easily broken by the impact at the time of driving a nail, and since the bending strength is small, it is easily subjected to stress such as a slight twist. There is a problem that it cannot be used as a material as it is, such as breaking. Therefore, various types of structural materials, for example, floor materials, wall materials, and other surface layer materials, which utilize a foamed resin body such as expanded polystyrene as a part of the structural material, have been studied. For example, JP-A-5-138793
The publication discloses a composite material composed of a thermosetting resin foam and a thermosetting resin foam laminated on at least one surface thereof and reinforced by long fibers such as glass fibers. Further, Japanese Patent Application Laid-Open No. 5-171791 discloses a sound-insulating composite structural material in which a wood-based surface material is attached to a foamed sheet whose surface is uneven. Further, Japanese Utility Model Laid-Open No. 63-136146 discloses a tatami mat for a judo hall in which a straw layer, a foamed resin layer and a tatami layer are combined. Further, in Japanese Patent Laid-Open No. Hei 5-162226,
The foam layer is provided with a base fabric layer for fixing the leaf-like naps, for example,
A block structure used as an indoor rug or a wall covering is disclosed. However, these composite materials utilizing a foamed resin layer that has been publicly known or has been studied in the past are directly flammable foamed resin layers in which a flammable material is combined, and thus have poor flame retardancy, If there is a fire, it spreads easily, causing a fire. Therefore, conventionally, there has been a strong demand for a composite material having excellent flame retardancy, effectively utilizing the excellent characteristics of the foamed resin material, and capable of compensating for the drawbacks of the foamed resin material.

[0003]

Therefore, the present invention is excellent in flame retardancy and makes use of the excellent lightweight properties and compressive strength characteristics of the foamed resin material, and at the same time, improves the impact resistance and bending strength of the foamed resin material. An object is to provide an improved block structure. Further, the present invention provides a block structure which is excellent in flame retardancy and soundproofing, makes good use of the properties of the foamed resin material such as lightness and compressive strength, and has improved impact resistance and bending strength of the foamed resin material. The purpose is to provide.

[0004]

Means for Solving the Problems As a result of intensive studies to achieve the above object, the present inventor has constructed a block structure from a foamed resin layer and an earth and sand bonding layer integrally bonded thereon. In addition, the sediment-bonding layer is composed of inorganic particles having a specific gravity of 1.15 or more and a rubber binder, and the content of the inorganic particles is 60 to 95 with respect to the total weight of the inorganic particles and the rubber binder. The inventors have found that the above object can be achieved by setting the content by weight, and have reached the present invention.

[0005]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 shows a flame-retardant block structure 1 which is a preferred embodiment of the present invention. This block structure 1 has a foamed resin layer 2 as a lower layer and a earth and sand bonding layer 3 as an upper layer, and the foamed resin layer 2 and the earth and sand bonding layer 3 are integrally bonded to each other. As the foamed resin layer 2, resin layers formed of various foamed resin materials can be used.
As the foamed resin material, any resin conventionally used in the field of manufacturing foamed resins can be used without particular limitation. For example, as a typical resin,
Examples include polyolefin and polyurethane. Examples of the polyolefin include polystyrene, polyethylene, polypropylene, polyvinyl chloride (PVC) and the like. Also, copolymers of olefins such as AB
S, ethylene-propylene copolymer, etc. are also mentioned. As the foaming method that can be used in the present invention, various foaming methods that have been conventionally adopted can be used. Foaming methods that can typically be used in the present invention include bead foaming methods and injection or extrusion foaming methods. The bead foaming method is a method usually adopted for polystyrene, in particular, when foaming with a high expansion ratio (expansion ratio: about 30 to 60 times). In this method, polystyrene beads containing a foaming agent are preformed, aged for 3 to 6 hours, and then expanded. Then, after filling the foamed particles in a mold, the foamed resin is heated and melted to form a foamed resin, the mold is cooled, and then the foamed molded product is taken out. The injection or extrusion foaming method is to foam in the process of injection or extrusion molding,
In general, injection foaming gives a foam with a low expansion ratio (expansion ratio: usually 3 times or less), and extrusion foaming has a wide expansion ratio by adjusting the amount of the foaming agent injected during extrusion molding. The body is obtained. Since the obtained foam has closed cells inside, it is excellent in sound insulation and heat insulation,
Moreover, it is substantially impermeable to water. The color of the foamed resin layer used in the present invention can be variously changed depending on the application of the block structure. Color can be imparted by adding a pigment or dye in advance.

The earth and sand binding layer 3 is composed of sand and prevulcanized natural rubber. Based on its structure, the earth and sand bonding layer 3 has excellent impact resistance and bending strength, is heavy, and has flame retardancy. The earth and sand bonding layer 3 is integrally bonded to the foamed resin layer 2 so as to supplement the drawbacks of the foamed resin material, that is, low impact strength and bending strength, and
By appropriately adjusting the thickness of the earth and sand binding layer 3, the content of the inorganic particles, and the like, the block structure 1 having a weight according to the application can be configured. In the embodiment of FIG. 1, sand is used as the inorganic particles, but inorganic particles other than sand can also be used without limitation as long as the specific gravity is 1.15 or more, preferably 1.25 to 1.65. Here, when the specific gravity is less than 1.15, the difference in specific gravity from the foamed resin layer 1 becomes small, and the weight of the block structure 1 is adjusted when the weight of the block structure 1 is adjusted by changing the amount of the earth and sand binding layer 3 used. It is not preferable because adjustment becomes difficult. For example, when the block structure 1 is laid indoors without using a fixing means such as an adhesive, if the block structure 1 itself does not have a certain weight, the block structure 1 is spread during the laying operation. Is easily misaligned. In addition, for example, on the rooftop, when it is spread, it is agitated by the wind, which is not preferable for installation work. On the other hand, if the specific gravity is too large, the weight of the block structure 1 will be too large even if the use ratio of the earth and sand binding layer 3 is small, and the transportation of the block structure 1 will be hindered, which is preferable. Absent. As the inorganic particles, other than sand, for example, calcium carbonate, talc, or the like can be used. From an economical point of view, sand is preferable. The size of the inorganic particles is generally 0.002 to 2 mm, preferably 0.005 to 1.5 mm in terms of particle size. In this range, inorganic particles having a particle size distribution may be used, or inorganic particles having a narrow distribution may be used. Generally, the smaller the particle size, the narrower the particle gap, the smaller the amount of rubber entering, the lower the elasticity of the earth and sand binding layer, and the higher the hardness. On the other hand, as the particle size increases, the amount of rubber that enters between particles increases,
Elasticity increases and hardness decreases. Further, when the particle distribution is wide, generally, the inorganic particles are densely mixed, so that the amount of the rubber binder tends to be relatively decreased, and the earth and sand binding layer 3 having small elasticity is formed. On the other hand, when the inorganic particles having a narrow distribution are used, the amount of the rubber binder is relatively large, so that the one having high elasticity is obtained. Therefore, the width of the distribution can be appropriately adjusted depending on the place where the block structure 1 of the present invention is used.

As the rubber binder, in the above embodiment, an example using pre-vulcanized natural rubber has been explained.
Generally, natural rubber, synthetic rubber and derivatives thereof are used.
For example, there are pre-vulcanized or post-vulcanized natural rubber (sulfur-based, organic peroxide-based, etc.), natural rubber graft-polymerized with methyl methacrylate, depolymerized natural rubber, and synthetic rubber-based styrene-butadiene rubber ( SBR), carboxylated styrene-butadiene rubber (X-SBR), chloroprene (CR), acrylonitrile-butadiene rubber (NBR) and the like. These rubbers may be used in combination. From the viewpoint of bending strength and durability, natural rubber or its derivative, for example, vulcanized natural rubber, particularly prevulcanized natural rubber, is preferable. The proportion of the inorganic particles constituting the earth and sand binding layer 3 is generally 60 to 95% by weight, preferably 60 to 95% by weight, based on the total weight of the inorganic particles and the rubber binder.
70 to 90% by weight. If the amount of the inorganic particles is less than 60% by weight (the amount of the rubber binder is too large), the elasticity or bending strength is too strong, and the block structure 1 is lightweight, which is not preferable. Also, as the amount of rubber increases,
Flame retardance is reduced. On the contrary, when the amount of the inorganic particles is more than 95% by weight (when the amount of the rubber binder is too small), elasticity or bending strength is too small and hardness becomes high, which is not preferable as the surface layer structure. Further, as a result of the binding force of the inorganic particles being too small, the inorganic particles gradually scatter during use, which is not preferable.

In order to make use of the advantages of the foamed resin layer 2 and to make up for the drawbacks of the foamed resin layer 2 with the earth and sand bonding layer 3, the foamed resin layer 2 and the earth and sand bonding layer 3 are integrally bonded to each other. It is necessary. As a bonding method, there is a method of bonding both layers to each other with an adhesive, but as a simplified method, there is a method of performing this bonding simultaneously with the formation of the earth and sand bonding layer 3. More specifically, as shown in FIG. 7, first, a lower lid 61 having a hole 64 at a portion corresponding to the size of the block and a mold 62 having a discharge groove 63 on a side surface are shown in FIG. To arrange. A block-shaped foamed resin body 2 having a size substantially equal to the inner diameter of the mold 62 is put in the mold 62, a mixture of sand and rubber latex is filled on the block, and then a thickness adjusting plate is formed thereon. 69 and an upper lid 67 having holes 68 are sequentially placed, and while being pressurized from above the upper lid 67, in that state, natural drying or high-temperature drying is performed to simultaneously form the earth and sand binding layer 3 and the foamed resin layer. 2 and the earth-sand binding layer 3 are integrated. In this case, since the rubber binder contained in the earth and sand bonding layer 3 plays a role of an adhesive, the foamed resin layer 2 and the earth and sand bonding layer 3 are integrally bonded. The earth and sand bonding layer 3 is integrally bonded to the foamed resin layer 2 to greatly improve the impact resistance and bending strength, which are the drawbacks of the foamed resin layer 2. Therefore, when the nail is driven in from the earth and sand bonding layer 3 side, without breaking,
Since the block structure 1 can easily cope with a place where a nail can be easily driven or curved, the block structure 1 can be installed at a predetermined position of an arbitrary shape.

The pressure for forming the earth and sand binding layer 3 varies depending on the surface area and the viscosity of the mixture of earth and sand and rubber latex, but is generally 20 to 50 Kg / m ² , preferably 20 to 3
It is 0 Kg / m ² . If the pressure is less than 20 kg / m ² , a uniform thickness cannot be obtained, which is not preferable. On the other hand, 50 Kg / m ²
If it is larger, the loss of rubber latex increases, which is not economically preferable. The temperature in high temperature drying is generally 5
It is 0 to 80 ° C, preferably 60 to 70 ° C. Drying at a temperature lower than 50 ° C. is not preferable because the drying efficiency is poor and the cost is high. On the other hand, if the temperature is higher than 80 ° C., deterioration of the foamed resin material or the earth and sand binding layer is likely to occur, which is not preferable. The rubber latex used here is generally a dispersion liquid containing a rubber component and water. The rubber concentration in the rubber latex is generally in the range of 30 to 70% by weight. When the concentration is less than 30% by weight, the handling becomes easy, but the rubber content becomes too small, and the elasticity and bending strength of the earth and sand binding layer decrease, which is not preferable. On the other hand, when the concentration is more than 70% by weight, a film is immediately formed when mixed with sand, and it is difficult to form a uniform mixture, which is not preferable.

The thickness and size of the block structure 1 are not particularly limited. Generally, block structure 1
The thickness is 10 to 50 mm, preferably 20 to 30 mm in consideration of handling. Also, the block structure 1
The standard size is 30 mm × 30 mm to 50 mm × 50 mm, but it can be commercialized up to about 100 mm × 200 mm which is a plywood standard. The thickness ratio of the foamed resin layer 2 and the earth and sand bonding layer 3 in the block structure 1 varies depending on the use of the block structure 1. For example, when used for indoor floors, the thickness of the foamed resin layer: the thickness of the earth and sand binding layer is generally 5: 1 to 2: 1, preferably 4: 1 to
It is 3: 1. If the thickness of the earth and sand binding layer 3 is too small, it is difficult to sufficiently exhibit flame retardancy. From this viewpoint, the thickness of the earth and sand binding layer 3 is preferably 3 mm or more. On the other hand, if the thickness of the earth and sand binding layer 3 is too large,
In some cases, the weight of the earth and sand binding layer 3 becomes relatively large, and the lightweight characteristics of the foamed resin layer 2 may not be fully utilized.

In FIG. 2, another embodiment of the block structure 11 is shown.
It is shown. In this aspect, the foamed resin layer 12
1 is the same as the embodiment shown in FIG. 1, except that the same earth and sand binding layers 13 are integrally bonded to the upper and lower surfaces of the same. By integrally bonding the earth and sand binding layers 13 to both surfaces of the foamed resin layer 12, the occurrence of warpage is reduced and the strength is further increased as compared with the case where the earth and sand binding layers 13 are provided on only one surface. Can be used, which greatly improves the utilization. Thickness of foamed resin layer 12:
The earth-sand binding layer 13 and the entire thickness are the same as those described in the embodiment of FIG. The block structure 11 of this aspect is
The block structure 1 of the embodiment shown in FIG. 1 can be manufactured according to the manufacturing method described. That is, as in the case of manufacturing the block structure 1 of the embodiment of FIG. 1, except that a predetermined amount of a mixture of sand and rubber latex is introduced before the block-shaped foamed resin body is put into the mold. Can be manufactured. FIG. 3 shows another embodiment of the block structure 2
1 is shown. The block structure 21 of this aspect is
The block structure 1 is the same as that of the embodiment of FIG. 1 except that the surface layer material 24 is integrally bonded on the earth and sand bonding layer 23. Various materials can be used as the surface layer material 24, and various design effects are given to the block structure 21. As the surface layer material 24, for example, woven fabric,
Knitting, wallpaper, tatami mats, etc. can be used as appropriate. Surprisingly, even when such a flammable surface layer material 24 is used, the block structure 21 of the present invention can maintain flame retardancy as long as it is used directly on the earth-sand binding layer 23. . The reason is not always clear, but the earth and sand binding layer 2
It is considered that since the specific heat capacity of the inorganic particles contained in No. 3 is large, even if the surface layer material 24 is directly brought close to a fire, a rapid increase in the temperature of the surface layer material 24 is suppressed. The block structure 21 of this embodiment is also produced in the same manner as the block structure 1 of the embodiment of FIG. 1 except that the mixture of sand and rubber latex is filled and then the surface layer material is placed thereon. be able to.

FIG. 4 shows another embodiment of the block structure 31.
It is shown. The block structure 31 of this aspect is the same as the block structure 1 of the aspect of FIG. 1 except that an artificial grass structure 34 is further integrally bonded on the earth and sand bonding layer 33. As shown in FIG. 5, the artificial turf structure 34 includes a woven fabric base fabric 36 formed by plain weaving warp yarns 38 and weft yarns 39, and a plurality of pile yarns 37 formed of a thermoplastic synthetic resin in a tufting machine. The pile yarn 37 is formed by cutting the tip of the pile yarn 37 after the hair is planted by. The pile yarn 37 projects above the woven base fabric 36,
The tip is free. The block structure 31 of this aspect can be manufactured according to the production of the block structure 21 of the aspect of FIG. In this case, the root portion of the pile yarn 37 protruding below the woven base fabric 26 is fixed by the rubber binder in a state of biting in from the surface of the earth and sand binding layer 33 during the formation of the earth and sand binding layer 33, The artificial grass structure 34 and the earth and sand bonding layer 33 are integrally bonded. The block structure 31 is a sports facility indoors or outdoors,
Suitable for use as a playground. In particular, when it is used on the rooftop, if the block structure 31 is formed by penetrating a plurality of holes of an appropriate size, the block structure 31 can be made water-permeable to prevent rain. Even on a day, water does not collect on the surface of the block structure 31, which is very convenient for use.

When the block structure 31 is used in a golf driving range, sand may be filled between the pile threads 37 in order to give a natural appearance. The material of the pile yarn 37 used is not particularly limited as long as it is conventionally adopted in the field of artificial grass using the pile yarn. The length of the pile yarn 37 is generally up to about 40 mm, usually 5 to 30 mm, but is not limited to this. In this aspect,
Although described with respect to the artificial turf structure 34, it is clear that the same mechanism can be applied to a carpet or carpet. In this embodiment, the woven base fabric 36 is woven by plain weave, but other woven fabrics or knitted fabrics may be used. In particular,
Considering the handleability in manufacturing the block structure 31 of the present invention, it is preferable that the woven base fabric 36 is capable of supporting and fixing the piled yarns 37 that have been flocked and is water-permeable. The weight of the pile yarn 37 depends on the use of the block structure 31, but is generally 0.3 to 2.0 kg / m ² , preferably 0.
It is 4 to 1.5 kg / m ² . FIG. 6 shows a block structure 41 of another aspect. This block structure 41 is
The structure is the same as that of the embodiment of FIG. 1 except that the surface layer material 44 is integrally bonded to the upper surface of the earth and sand bonding layer 43 and the lower surface of the foamed resin layer 42. By configuring in this way,
It is designed to prevent warpage, improve strength, and be useful on both sides. By using a different surface layer material as the surface layer material 44, it is possible to exert different design effects by appropriately turning over the block structure 41.

FIG. 8 shows another embodiment of the block structure 81.
It is shown. In this block structure 81, four small foamed resin pieces 82 are arranged at regular intervals, and each foamed resin piece 82 is covered with a sand-sand bond layer 83 (see FIG. 10). In this aspect, since the partition portions 83a formed of the earth and sand binding layers formed between the foamed resin pieces 82 firmly bind the earth and sand binding layers existing on the upper and lower surfaces of the foamed resin pieces 82 to each other, the foamed resin The piece 82 and the earth and sand bonding layer 83 are integrally joined together, so that the earth and sand bonding layer 83 and the foamed resin piece 82 are largely prevented from peeling off. In this block structure 81, for example, first, a mixture of sand and rubber latex is introduced into a mold 62 on a lower lid 61 arranged as shown in FIG. 7, and then,
After arranging the foamed resin pieces 82 with a predetermined space not only between the foamed resin pieces 82 but also between the foamed resin pieces 82, a mixture of sand and rubber latex is completely covered with the foamed resin pieces 82. Reintroduced, thickness adjustment plate 69 on it
And the upper lid 67 are sequentially placed, and while being pressed from above the upper lid 67, in that state, natural drying or high-temperature drying can be performed to manufacture. If the pressure is large, a vinyl sheet may be interposed between the adjusting plate 69 and the upper lid 67 to minimize the loss of rubber latex.

FIG. 11 shows a block structure 91 of still another mode. This block structure 91 is 1
It has the size of a tatami mat and has a plurality of holes 94 shown in FIG.
The block-shaped foamed resin layer 92 having the
Is entirely covered by. In this aspect, the portion 95 corresponding to the hole 94 of the block structure 91.
Is composed of the material forming the earth-sand binding layer. Also in this case, it can be manufactured in the same manner as the block structure 81 of the embodiment shown in FIG. This block structure 9
In No. 1, since the earth and sand bonding layers 93 on the upper and lower surfaces of the foamed resin layer 92 are firmly and mutually bonded by the portion 95, the foamed resin layer 92 and the earth and sand bonding layer 93 are prevented from peeling off. Therefore, the earth-and-sand binding layer 93 can be handled without delamination even if it is handled roughly to some extent during handling such as transportation. The block structure may have various shapes such as a rectangular shape, a triangular shape, and a circular shape, depending on the application.

Test Example 1 A lower lid 61 equipped with a mold 62 (50 cm × 50 cm × 1 cm) shown in FIG. 7 was prepared, and a polystyrene foam having a thickness of 2 cm and a size substantially equal to the inner diameter of the lower cover 61 was prepared. (Expansion ratio: about 30 times, manufactured by the bead foaming method), and
Sand (sea sand) with an average particle size of 0.51 mm (0.005-1.5 mm distribution), 3.0 kg and pre-vulcanized natural rubber latex with a rubber concentration of 55.0% by weight, 0.69 liters (rubber weight 0.38
Kg) was kneaded for 2-3 minutes and the rubber / sand mixture was injected.
The sand loading in this rubber / sand mixture was 88.8% by weight, based on the total weight of sand and prevulcanized natural rubber.
Next, a braided base fabric (artificial grass) (unlined) on which pile yarns have been transplanted is placed on the rubber / sand mixture, a thickness adjusting plate 69 is placed on it, and an upper lid 67 is placed on it. The block structure A was manufactured by drying at 40 ° C. for 4 hours while applying a pressure of 10 kg / cm ² from above.

The characteristics of the block structure A are as follows. Size: 50 cm x 50 cm x 4 cm (thickness of earth-sand binding layer: 1 cm) Weight: 3.6 kg. The weight was increased by 1200% as compared with the case where the entire structure was formed of the foamed resin layer. Handling such as transportation was easy. Elasticity: Resilient and did not crack or crack when bent 45 °. Moreover, the walking feeling was also excellent. Workability: When this interior / exterior surface finishing material is laid on the floor indoors, it can be easily installed without fixing the block, and even after walking, walking on it or moving by bicycle etc. , Did not shift or move. Even when it was installed on the rooftop, it did not curl up due to the wind. Noise reduction: Sound did not reach the room below. In particular, it was excellent in sound insulation of high frequencies. For example, it was superior to the sound insulation of high sound when a wood material was attached to the foamed resin layer. Flameproofness: Although the fire of the cigarette was brought close to or pressed against the surface of the artificial turf structure material of the block structure A, some smoke might be generated, but practically no fire spread. On the other hand, in the case of being manufactured in the same manner (Comparative Example 1) except that the rubber layer or the wood material is used instead of the artificial grass structure, the cigarette fire is approached or pressed. , The rubber layer or wood material was burned and burned. Heat resistance: I didn't feel any heat when I installed it on the rooftop and walked on it during hot summer days. On the other hand, in Comparative Example 1 using the rubber layer or the wood material,
I couldn't walk because I felt a lot of heat while walking.

Test Example 2 A block structure was prepared in the same manner as in Test Example 1 except that SBR was used as a rubber binder and an ethylene-propylene copolymer (foaming ratio: 3 times) was used as a foamed resin layer. B was produced. The characteristics of this block structure B are as follows. Size: 50cm x 50cm x 4cm (thickness of earth and sand binding layer: 1cm) Weight: 5.6kg. The weight was increased by 200% as compared with the case where the whole was constituted by the foamed resin layer. Handling such as transportation was easy. Elasticity: Resilient and did not crack or crack when bent 45 °. Moreover, the walking feeling was also excellent. Workability: When this interior / exterior surface finishing material is laid on the floor indoors, it can be easily installed without fixing the block, and even after walking, walking on it or moving by bicycle etc. , Did not shift or move. Even when it was installed on the rooftop, it did not curl up due to the wind. Noise reduction: Sound did not reach the room below. In particular, it was excellent in sound insulation of high frequencies. For example, it was superior to the sound insulation of high sound when a wood material was attached to the foamed resin layer. It was also found that the silencing effect is enhanced by increasing the thickness of the earth and sand binding layer. Flameproofness: Although the fire of the cigarette was brought close to or pressed against the surface of the artificial turf structure material of the block structure A, some smoke might be generated, but practically no fire spread. Heat resistance: I didn't feel any heat when I installed it on the rooftop and walked on it during hot summer days.

Test Example 3 (1) Preparation of Samples The following samples were prepared. However, the size of these samples is 20 cm in length × 40 cm in width, and the thickness and the like are as follows. Sample A: The polystyrene foam (thickness 3 cm) used in Test Example 1. Sample B: Artificial grass with lining used in Test Example 1 (pile yarn length 6 mm (B-1) and 20 mm (B-2)). Sample C: Earth-sand bond layer used in Test Example 1 (thickness 10 mm (C
-1) and 20 mm (C-2)). Sample D: The polystyrene foam used in Test Example 1 (thickness 30 mm) and the earth-sand binding layer used in Test Example 1 (thickness 10 m
m) was laminated (D-1), and the polystyrene foam (thickness 30 mm) used in Test Example 1 was laminated with the earth and sand bonding layer (thickness 20 mm) used in Test Example 1 (D-).
2). Sample E: The polystyrene foam (thickness 30 mm) used in Test Example 1 and the earth and sand binding layer used in Test Example 1 (thickness 10 m
m) is laminated and a commercially available carpet (thickness 5 m
m, made by Izumiki textile) is bound to the earth and sand binding layer. Sample F: Structure manufactured in Test Example 1, that is, from the bottom, polystyrene foam (thickness 30 mm), earth and sand binding layer (thickness 1
0 mm) and artificial turf (pile yarn length 6 mm) with fixed layers. Sample G: The polystyrene foam (thickness 30 mm) used in Test Example 1 and the earth and sand binding layer (thickness 10 mm) used in Test Example 1 bonded to both sides. (2) Evaluation of flame retardancy A flame retardancy test was conducted on each of the above samples in accordance with JIS L-1091 A-1 (45 ° micro burner method) (however, the burner flame was applied for 10 hours). It was a minute). The test results are listed in the table below.

Table 1 Sample No. Ignition time Carbonization distance Carbonization area Observation result (sec) (cm) (cm ² ) A 4 21 137 Ignition occurred in 4 seconds, burned and had holes, major axis 9 cm in 27 seconds, minor axis in 27 seconds The fire was extinguished after expanding to a 6 cm oval hole. B-1 17 45 696 The turf started to melt in 11 seconds, ignited in 17 seconds, and continued to burn even if the heat source was taken. B-2 20 40 698 Turf began to melt in 10 seconds, ignited in 20 seconds, and then continued to burn. C-1 Without ignition 9 35 1 minutes and 50 seconds, rubber began to smoke, 5 minutes and 26 seconds darkened on the back side, 10 minutes later, the heat source was removed and 31 seconds later, rubber was smoked. A part of the sand collapsed and there was a hole. C-2 Without ignition ─────── The rubber gradually smoked, but there was no collapse of the sand and no holes. D-1 298 10 57 Smoke was emitted in 1 minute 47 seconds, and 4 minutes 5 (up to foam (Sand binding (sand started to collapse in the second binding second. Ignition time of 4 minutes 5) Layer) Layer) 8 seconds A hole was made in the sand, and the foam was spread to 19249, burned until it became an elliptical hole with a major axis of 12 cm and a minor axis (foam part) (foam part) of 7 cm, and then extinguished. D-2 Without igniting ─── ─── The rubber started to smoke in 1 minute 43 seconds, but the sand did not collapse. After 10 minutes, the sand where the rubber smoked was dark, but the sand did not collapse. E 33 22 247 Only the carpet ignited in 33 seconds (carpet, extinguished in 4 minutes and 2 seconds, ignited in car) Only pets were carbonized. No sand collapse. F 46 18 203 19 The turf started to melt in 19 seconds, 4 (to artificial turf (artificial turf) (artificial turf) ignites in 6 seconds, and turf burns in 2 minutes), and there was a hole. In 8 minutes and 30 seconds, the sand collapsed, holes were formed, and the foam 510 21 227 ignited, with a long diameter of 14 cm, short (to foam (foam) (foam) up to an elliptical size of 7 cm in diameter) combustion After that, I put out the fire. G ─── 17 127 1 minutes 53 seconds, rubber began to smoke (layers of sand (beginning of sand binding, 5 minutes 10 seconds, rubber was black layer) started to form, and sand began to collapse 349 25 243, 5 minutes The foam ignited in 49 seconds (to (foam) (foam) (foam) and ignited adjacent to the soil-bonding layer on the back side) burned, but the soil-bonding layer on the back side ignited. There wasn't.

[0021]

EFFECTS OF THE INVENTION The flame-retardant block structure of the present invention is not only excellent in flame retardancy, impact strength and bending strength machine particles due to the combination of the foamed resin layer and the earth-sand bond layer, but also the earth-sand bond to be combined. By adjusting the thickness of the layer and the content of the inorganic particles, the weight of the block structure can be freely adjusted according to the application. That is, according to the present invention, while making use of the characteristics of lightness and compressive strength of the foamed resin layer,
On the other hand, the impact resistance and bending strength, which are the drawbacks of the foamed resin layer, can be complemented by the characteristics of the earth and sand binding layer. Therefore, the block structure of the present invention can be used easily in various applications. Moreover, in the block structure of the present invention, even if the combustible surface layer material or the like is directly bonded to the earth and sand binding layer, it is possible to form a flame-retardant block structure. It is very advantageous for disaster prevention in various applications such as.

[Brief description of drawings]

FIG. 1 is a perspective view of a block structure which is one embodiment of the present invention.

FIG. 2 is a perspective view of a block structure according to another aspect of the present invention.

FIG. 3 is a perspective view of a block structure according to another aspect of the present invention.

FIG. 4 is a perspective view of a block structure according to another aspect of the present invention.

5 is a partially enlarged cross-sectional view of the block structure of FIG.

FIG. 6 is a perspective view of a block structure according to still another aspect of the present invention.

FIG. 7 is a view showing an apparatus used for manufacturing the block structure of the present invention.

FIG. 8 is a perspective view of a block structure according to still another aspect of the present invention.

9 is a perspective view of a foamed resin body used in the block structure of FIG.

10 is a cross-sectional view of the block structure of FIG.

FIG. 11 is a perspective view of a block structure according to still another aspect of the present invention.

FIG. 12 is a perspective view of a foamed resin layer used for manufacturing the block structure shown in FIG. 11.

[Explanation of symbols]

1, 11, 21, 31, 41, 81, 91 ... Block structure 2, 12, 22, 32, 42, 92 ... Foam resin layer 24, 44 ... Surface material 34 ...・ ・ Artificial grass structure 36 ・ ・ ・ ・ Woven fabric base 37 ・ ・ ・ ・ Pile yarn 38 ・ ・ ・ ・ Warp 39 ・ ・ ・ ・ Weft 82 ・ ・ ・ ・ Foam resin pieces

[Procedure amendment]

[Submission date] April 8, 1994

[Procedure Amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0010

[Correction method] Change

[Correction content]

The thickness and size of the block structure 1 are not particularly limited. Generally, block structure 1
The thickness of 10 to 50 mm, considering the convenience of handling,
It is preferably 20 to 30 mm. The size of the block structure 1 is 30 cm × 30 cm to 50 cm × 50.
The standard is cm, but the plywood standard is 100 cm x 20
It can be commercialized up to about 0 cm. The thickness ratio of the foamed resin layer 2 and the earth and sand bonding layer 3 in the block structure 1 varies depending on the use of the block structure 1.
For example, when used on an indoor floor, the thickness of the foamed resin layer: the thickness of the earth and sand binding layer is generally 5: 1 to 2: 1, preferably 4: 1 to 3: 1. If the thickness of the earth and sand binding layer 3 is too small, it is difficult to sufficiently exhibit flame retardancy. From this viewpoint, the thickness of the earth and sand binding layer 3 is preferably 3 mm or more. On the other hand, if the thickness of the earth and sand binding layer 3 is too large, the weight of the earth and sand binding layer 3 becomes relatively too large, and the lightweight characteristics of the foamed resin layer 2 may not be fully utilized. .

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Claims (7)

[Claims] 1. A foamed resin layer and an earth and sand binding layer integrally bonded thereon, wherein the earth and sand binding layer has a specific gravity.
Difficulty characterized in that it is composed of inorganic particles having 1.15 or more and a rubber binder, and the content of the inorganic particles is 60 to 95% by weight based on the total weight of the inorganic particles and the rubber binder. Flammable block structure. 2. The flame-retardant block structure according to claim 1, further comprising an earth and sand bonding layer integrally bonded under the foamed resin layer. 3. The flame-retardant block structure according to claim 1, wherein a braided base fabric is integrally bonded to the surface of the earth and sand bonding layer. 4. The flame-retardant block structure according to claim 1, wherein a braided base fabric is integrally bonded under the foamed resin layer. 5. The flame-retardant block structure according to claim 1, wherein an artificial turf structure in which pile yarns are planted on a braided base fabric is integrally bonded onto the earth and sand bonding layer. 6. Sand is sprinkled between the pile yarns,
The flame-retardant block structure according to claim 5. 7. The flame-retardant block structure according to claim 1, wherein the foamed resin layer has a circular plane or a square plane.