JPH11227081A - Fire resistant composite floor material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an ideal fire resistant composite floor material having a low cost, a high strength, a light weight, excellent fire resistance and excellent processability by using a gypsum for the floor material. SOLUTION: In the fire resistant composite floor material 7 comprising a reinforcing layer 4 made of a thermosetting resin and an inorganic fiber and provided at least on one of a front side surface 71 and a rear side surface 72 of a porous inorganic core material 3, the material 3 is obtained by laminating and adhering a plurality of gypsum boards 31, 32. An overall thickness T of the material 3 is 9.5 to 30.0 mm. Its specific weight is preferably 0.9 to 1.5. And, the gypsum plate may be used instead of a gypsum board.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fire-resistant composite flooring material used for building materials and the like, which has fire resistance and strength as a flooring material, and has a free access floor (FA floor). )).

[0002]

2. Description of the Related Art The base material of an FA floor on which a computer or the like is installed is required to withstand the weight of the computer and not be damaged by an impact even if the computer or the like falls over during an earthquake. Therefore, it is necessary to have excellent fire resistance so that it can withstand cable fires. The base materials of such FA floors include those using metals such as steel and aluminum, those made of resins such as polyvinyl chloride, ABS resin and polypropylene, those made of concrete reinforced with fibers, and calcium silicate plates. And a wood-based material such as a particle board.

[0003]

However, those using a metal, those made of concrete, and those obtained by attaching a metal to a calcium silicate plate are heavy and have poor workability.
Resin and particle board are inferior in fire resistance. Therefore, it has high strength, light weight and excellent fire resistance,
No practical flooring material with excellent workability has been developed so far. By the way, as a building material, gypsum board is excellent in terms of cost, and is used for wall materials and the like.
For example, Japanese Patent Application Laid-Open No. 7-3292 discloses a wall in which a prepreg made of a thermoplastic resin is adhered to a gypsum board, and a building material for a partition.
No. 36.

[0004] However, this is not a use as flooring. It was common knowledge in the construction industry that gypsum board could not be used for flooring because of its low strength.

[0005] In view of the conventional problems, the present invention overturns such common sense and uses gypsum as a flooring material to provide high strength,
An object of the present invention is to provide an ideal fire-resistant composite flooring that is inexpensive, light, excellent in fire resistance, and excellent in workability.

[0006]

The present invention relates to a fire-resistant composite floor material comprising a porous inorganic core material and a reinforcing layer comprising a thermosetting resin and inorganic fibers provided on at least one of a front surface and a back surface. The porous inorganic core material is a fire-resistant composite floor material characterized in that a plurality of gypsum plates are laminated and bonded.

In the present invention, the above-mentioned porous inorganic core material comprises:
A plurality of gypsum plates are laminated and bonded. Thin gypsum boards are more productive and cheaper than thick gypsum boards. for that reason,
The production cost can be reduced by laminating a plurality of thin gypsum plates as the porous inorganic core material rather than using a single layer of the thick gypsum plate as the porous inorganic core material. The reinforcing layer is made of a thermosetting resin and inorganic fibers. Unlike a thermoplastic resin, a thermosetting resin has excellent fire resistance and does not soften even at a high temperature, so that the function as a reinforcing layer is not lost.

[0008] The porous inorganic core material is composed of a plurality of gypsum plates. Gypsum board is low cost and has excellent compressive strength, but on the other hand, when a force is applied, the gypsum board generates a tensile force on the side opposite to the side where the force is applied, and the point at which this force is generated Destruction occurs as a starting point.

Therefore, in the refractory composite flooring material of the present invention, a plurality of gypsum plates are laminated and used as a porous inorganic core material, and a reinforcing layer is adhered to the front and / or back surfaces thereof. This improves the strength of the gypsum board against tensile force. Therefore, even when a tensile force is applied to the fire-resistant composite flooring material of the present invention, no destruction occurs. The reinforcing layer is made of a thermosetting resin and inorganic fibers, and has excellent workability. Further, the refractory composite flooring material of the present invention is composed of the refractory composite flooring material, thermosetting resin, and inorganic fibers, so that it is lightweight, excellent in workability, and low in cost.

Next, the details of the present invention will be described. The overall thickness of the porous inorganic core material is preferably 9.5 to 30.0 mm. The reason is that in this range, sufficient rigidity and impact resistance can be obtained, a sufficient wiring space under the floor can be secured, and high workability can be obtained. On the other hand, if it is less than 9.5 mm, sufficient rigidity and impact resistance may not be obtained. On the other hand, if it exceeds 30.0 mm, it is difficult to obtain an effect corresponding thereto. Especially,
The total thickness of the porous inorganic core material is preferably 19 to 25 mm. Thereby, more excellent rigidity, impact resistance and workability can be obtained.

The total thickness of the porous inorganic core material refers to the total thickness of the porous inorganic core material obtained by laminating a plurality of gypsum plates. When it is present, it refers to the thickness including the thickness of the board base paper.

Further, the overall specific gravity of the porous inorganic core material is 0.1.
It is preferably from 9 to 1.5. Thereby, it is relatively lightweight, and can exhibit excellent rigidity and impact resistance. on the other hand,
If it is less than 0.9, it may become brittle. If it exceeds 1.5, weight reduction may be hindered.

The overall specific gravity of the porous inorganic core material refers to the overall thickness of the porous inorganic core material obtained by laminating a plurality of gypsum plates, and the board base paper to be described later is adhered thereto. In this case, the specific gravity includes the thickness of the base paper.
The specific gravity is a value representing a volume density having a ratio based on a volume density of water at 4 ° C.

[0014] The porous inorganic core material is a laminate of a plurality of gypsum plates. The number of layers depends on the thickness of each gypsum board, but generally 2 to 10 layers are preferable. This further improves the strength of the refractory composite flooring.

It is preferable that the porous inorganic core material is obtained by sticking board base paper to at least one of the front surface and the back surface. As a result, the flexural strength of the refractory composite flooring,
The mechanical strength such as rigidity, impact resistance and water resistance is improved.
As the board base paper, for example, waste paper, pulp or the like is used as a main raw material, and a thickness of 0.3 to 0.5 m to which a water generating agent is added.
m thick paper can be used.

[0016] Board base paper can be interposed between the gypsum plates. In addition, a gypsum board in which board base paper is adhered to the front side and / or the back side of each gypsum board can be produced and laminated to use as a porous inorganic core material. The gypsum board is different from a gypsum board in which board base paper is adhered thereto in that it is made of gypsum.

Each gypsum plate is bonded with an interlayer adhesive, and the interlayer adhesive is one selected from the group consisting of a phenol resin, an epoxy resin, a urethane resin, a melamine resin, a resorcinol resin, and a vinyl acetate resin. Or it is preferable to consist of 2 or more types. This can prevent the entire fire-resistant composite floor material from bending.

A reinforcing layer is adhered to the front side and / or the back side of the porous inorganic core material. The reinforcing layer is preferably formed at least on the back side of the porous inorganic core material (opposite side of the floor). Further, the reinforcing layer may be formed on only one surface of the porous inorganic core material or on both surfaces thereof.

More preferably, the reinforcing layer is bonded to the back side of the porous inorganic core. Thereby, excellent strength can be exerted against the pressing force applied from above the fire-resistant composite floor material, that is, from the front side.

The reinforcing layer is composed of a thermosetting resin and inorganic fibers. The thermosetting resin is preferably one or more selected from the group consisting of a phenol resin, a melamine resin, an epoxy resin, a polyimide resin, and a urea resin.

As the inorganic fibers, glass fibers, rock wool and ceramic fibers are desirable. This is because it is low in price and has excellent heat resistance and strength. The inorganic fiber may be a non-continuous fiber formed into a mat shape, a continuous long fiber cut into 3 to 7 cm into a mat shape (chopped strand mat), or a continuous long fiber spiral shape It may be a material obtained by laminating into a mat, or a material obtained by weaving continuous filaments.

It is preferable that the content of the thermosetting resin contained in the reinforcing layer is 10% by weight to 65% by weight.
The reason is that in this range, sufficient rigidity and impact resistance can be obtained, and high fire resistance can be maintained.

The thickness of the reinforcing layer is from 0.3 mm to 3.5.
mm is desirable. The reason is that in this range, sufficient rigidity and impact resistance can be obtained, and high workability can be maintained.

When using the above-mentioned board base paper,
The ratio of the thickness of the reinforcing layer to the board paper is 0.01 to
It is preferably 0.63, and more preferably 0.03 to 0.3.
Preferably it is 36. Thereby, the fire resistance and strength of the fire resistant composite flooring are improved.

The reinforcing layer may contain a flame retardant such as aluminum hydroxide and magnesium hydroxide, and a commonly used inorganic binder such as silica sol, alumina sol and water glass. Silica sol and alumina sol are obtained by dispersing Al ₂ O ₃ particles having a size of 10 to 100 nm in water, and have a concentration of 20 to 4 nm.
It is preferably 0% by weight. Thereby, the reinforcing layer can be formed uniformly.

The reinforcing layer contains one or more elastic polymers selected from the group consisting of rubber latex, acrylic latex, acrylate latex, and urethane latex in order to impart nail strength. Is preferred.

[0027] The reinforcing layer may be bonded to the porous inorganic core material with a surface layer adhesive. Thereby, the reinforcing layer is firmly adhered to the porous inorganic core material. The surface layer adhesive may be either the same resin as the thermosetting resin contained in the reinforcing layer or a different resin. The surface adhesive is preferably composed of one or more selected from the group consisting of a phenol resin, an epoxy resin, a resorcinol resin and a melamine resin. Since these surface layer adhesives have little deflection after bonding, the deflection of the entire refractory composite flooring can be suppressed. In addition to the above, urethane resin, vinyl acetate resin, and the like can be used as the surface adhesive.

[0028] The fire-resistant composite flooring material of the present invention is preferably provided with a coating layer on the edge of the wood to prevent gypsum powder from scattering. The coating layer may be composed only of the coating material, or may be a layer in which the edge surface is impregnated with the coating material. Examples of the coating material include sodium silicate solution such as water glass, silica gel, and inorganic material such as alumina sol. Further, an organic material such as a rubber emulsion, an acrylic emulsion, or a resin emulsion such as a urethane emulsion can also be used.

As the rubber emulsion, nitrile-
It is preferable to use a solution in which a butadiene rubber solution is dispersed in water or a solution in which a styrene butadiene rubber solution is dispersed in water. The concentration of each emulsion is
It is preferably 30 to 60% by weight. This gives
The coating layer can be formed uniformly.

The coating layer is formed, for example, by applying these coating materials to a wooden edge or dipping a refractory composite flooring material in the coating material and drying at room temperature to 100 ° C. The thickness of the coating layer is preferably from 0.01 to 4.5 mm. Thereby, scattering of the gypsum powder generated by cutting the refractory composite floor material can be effectively suppressed. In addition, the weight of the refractory composite flooring can be suppressed, and the cost can be prevented from increasing. In addition, the tip end of the refractory composite flooring means an exposed surface exposed by cutting the refractory composite flooring. As shown in FIG. 5, such a fore-edge surface 30 is generally formed on the side surface of the refractory composite flooring 7 in many cases.

In the method for producing the refractory composite flooring material of the present invention, an inorganic fiber impregnated with an inorganic or organic binder or the like is preliminarily formed into a plate and impregnated with a thermosetting resin composition, dried and cured. There is a method of sticking the cured product to a porous inorganic core material via a surface adhesive. Also, a method of impregnating a resin composition into a mat of inorganic fibers, drying, heating and pressing a thermosetting resin to form a molded article, and attaching this to a porous inorganic core material via a surface adhesive. May be.

Alternatively, a method in which a resin composition is impregnated into a mat of inorganic fibers, dried if necessary, laminated on a porous inorganic core material, heated and pressed, and the thermosetting resin is cured to form a molded article. Good. Alternatively, a method may be used in which a thermosetting resin is applied to a porous inorganic core material, a mat of inorganic fibers is placed thereon, and hot pressing is performed.

Further, a method of coating a thermosetting resin such as a phenol resin on the fiber surface of glass fiber, rock wool, or ceramic fiber in a B stage, laminating the same on a porous inorganic core material, and hot pressing is also employed. it can. The method of coating the fiber surface with a thermosetting resin at the B stage is advantageous because the adhesion to the impregnated resin is improved, the fibers are easily bonded to each other, and the resin impregnation rate can be improved.

As a method of such a coating,
The raw material melt of glass fiber, rock wool, and ceramic fiber flows out of the nozzle and is made into fibers by blowing or centrifugal methods. At the same time as the fiberization, a solution of a thermosetting resin such as phenolic resin is sprayed to collect cotton. You do it. When glass fiber, rock wool, or ceramic fiber is used, a silane coupling agent is preferably coated.

[0035]

DESCRIPTION OF THE PREFERRED EMBODIMENTS First Embodiment A fire-resistant composite flooring according to an embodiment of the present invention will be described.
This will be described with reference to FIG. As shown in FIG. 1, the fire-resistant composite flooring 7 of this embodiment comprises a reinforcing layer 4 made of a thermosetting resin 1 and inorganic fibers 2 on both the front side 71 and the back side 72 of the porous inorganic core 3. Is provided. The porous inorganic core material 3 is composed of 2
The gypsum boards 31, 32 are laminated and bonded.

Each of the gypsum boards 31 and 32 has a thickness of 9.5 mm. Further, the overall thickness T of the porous inorganic core material 3 which is a laminate thereof is 19 mm, and its overall specific gravity is 1.3. The gypsum boards 31 and 32 are obtained by attaching board base paper 8 to the front and back sides of a gypsum board 301. The gypsum boards 31 and 32 are bonded by a phenol resin as the interlayer adhesive 6.

The reinforcing layer 4 is composed of 25% by weight of the thermosetting resin 1
And 75% by weight of the inorganic fibers 2. The thermosetting resin 1 is a phenol resin. As the inorganic fiber 2, a mat-like glass fiber (weight 1000 g / m ² ) is used. The thickness t of the reinforcing layer 4 is 2 mm. Reinforcement layer 4
Are adhered to the porous inorganic core material 3 by a surface adhesive 5. The surface layer adhesive 5 is made of a phenol resin.

A method for manufacturing the fire-resistant composite flooring of this embodiment will be described. (1) Matt-like glass fiber (weight 100) to which an uncured phenolic resin adheres (the amount of adhesion is 13% in solid content).
0 g / m ² ) was pressed at a temperature of 200 ° C. for 5 minutes to obtain a 1.5 mm-thick sheet glass fiber. (2) After impregnating the sheet-like glass fiber with a phenol resin solution containing a curing agent (impregnation amount: 12% in terms of solid content), the sheet glass fiber was pressed at a temperature of 80 ° C. for 20 minutes to obtain a thickness of 1.
A 5 mm phenol resin impregnated sheet was obtained.

(3) As the board base paper 8, cardboard (thickness of 0.1 mm) containing waste paper, pulp or the like as a main raw material and adding a water generating agent or the like.
35 mm). Next, a mixture of calcined gypsum and water is poured onto the board base paper 8, and the board base paper 8 is further placed thereon, and the gypsum is dried and hardened. In this way,
Gypsum board 3 with board base paper 8 adhered to gypsum board 301
2 pieces of 1 and 32 are produced.

(4) Of the two gypsum boards (specific gravity: 1.3, thickness: 9.5 mm) 31, 32 of the front side or the back side,
A phenol resin solution containing a curing agent (interlayer adhesive) is applied at a rate of 100 g / m ² (in terms of solid content) on the side facing both, and the two are laminated to obtain a porous inorganic core material 3. Was.

(5) A phenol resin solution containing a curing agent (surface adhesive) was added to both sides of the porous inorganic core material 3 by 100
g / m ² (in terms of solid content), and the phenolic resin-impregnated sheets prepared in (2) above were stacked. Further, 175 g of a phenol resin solution to which a curing agent was added was further added.
/ M ² (in terms of solid content), and then marketed glass fiber chopped strand mat (weight 450 g / m 2
² , 0.5 mm thick) and pressed at 100 ° C. for 10 minutes. As a result, as shown in FIG. 1, a 23 mm thick fire-resistant material composed of a porous inorganic core material 3 composed of two layers of gypsum boards 31 and 32 and a coating layer 4 covering the front and back surfaces thereof. The composite flooring 7 was obtained.

The obtained refractory composite flooring 7 is, for example, 5
Cut into squares of 0 cm square, attach legs on the back side,
A plurality of these are combined and used as a fire-resistant composite floor material. In addition, a coating layer can be formed by applying a resin emulsion to the cut surface 30 formed by cutting.

Next, the operation and effect of this embodiment will be described. Gypsum board is low in cost and excellent in compressive strength, but insufficient in bending strength and tensile strength. Therefore,
In this example, as shown in FIG. 1, two layers of gypsum boards 31 and 32 are laminated, and further, a reinforcing layer 4 is adhered to both surfaces of a porous inorganic core material 3 which is a laminate thereof. for that reason,
The refractory composite flooring 7 comprising the porous inorganic core material 3 and the reinforcing layer 4 does not break even when a tensile force is applied,
Exhibits excellent bending strength and tensile strength. The reinforcing layer 4 is made of a thermosetting resin 1 and inorganic fibers 2 (glass fibers) and has excellent workability.

Further, unlike the thermoplastic resin, the thermosetting resin 1 has excellent fire resistance and does not soften even at a high temperature, so that the function as the reinforcing layer 4 is not lost. Furthermore, since the refractory composite flooring 7 of this example is composed of the gypsum board 3, the thermosetting resin 1, and the inorganic fibers 2, it is inexpensive, lightweight, and excellent in workability.

In the refractory composite flooring material of this embodiment, the reinforcing layers 4 are formed on both sides of the porous inorganic core material 3 as shown in FIG. 1, but as shown in FIG. It may be formed. Also, it may be formed on the front surface. Also in these cases, it is possible to prevent the destruction of the fire-resistant composite flooring when a tensile force is applied.

In this example, the gypsum boards 31 and 32 of 9.5 mm are used.
You may use the thing of 5.0 mm. Further, the thicknesses of the two layers of gypsum boards 31, 32 may be different. For example, gypsum board 31 and gypsum board 32 are each 9.5 mm,
In the case of 12.5 mm, 12.5 mm, 15.0 mm, 9.5 mm, and 15.0 mm may be used. Furthermore,
What adhere | attached the gypsum board of three or more layers can also be used. Further, a reinforcing layer may be provided on the surface of only one gypsum board. The thickness of the gypsum board in this case is 9.5m
m, 12.5 mm, and 15.0 mm, but not limited thereto.

Embodiment 2 As shown in FIG. 3, the fire-resistant composite flooring 7 of this embodiment is composed of a front surface 71 and a rear surface 72 of a porous inorganic core material 3 in which two gypsum boards 31 and 32 are laminated. In addition, a reinforcing layer 4 is directly provided without interposing a surface adhesive. Gypsum board 31, 32
Are 15 mm each.

In manufacturing the refractory composite flooring material of this embodiment, first, two gypsum boards 3 were used in the same manner as in the first embodiment.
A porous inorganic core material 3 made of 1, 32 is produced. Next, the uncured phenol resin is impregnated into the glass fiber mat (weight: 500 g / m ² ), and then dried at 50 ° C. to impregnate the resin material by impregnating 100 parts by weight of the phenol resin with 100 parts by weight of the fiber material. A mat was manufactured.

Next, this resin-impregnated mat is laminated on the front side surface 71 and the back side surface 72 of the porous inorganic core material 4, and
It was hot-pressed at 0 ° C. for 10 minutes at a pressure of 1 kg / cm ² . Thus, a refractory composite flooring 7 having a thickness of 30 mm in which the reinforcing layer 4 was directly adhered to the porous inorganic core 3 was obtained. Also in this example, the same effect as in the first embodiment can be obtained.

Embodiment 3 As shown in FIG. 4, the fire-resistant composite flooring 7 of this embodiment uses a porous inorganic core material 3 in which two gypsum plates 301 are laminated and bonded. The gypsum plate 301 is made of gypsum, and the thickness of one of them is 12.5 mm. The two gypsum plates 301 are adhered by a phenol resin as the interlayer adhesive 6. Other configurations are the same as those of the first embodiment. Also in this example, the same effect as that of the first embodiment can be obtained.

[0051]

As described above, according to the present invention, it is lightweight and inexpensive, and has excellent workability, fire resistance and strength.
An inexpensive fire-resistant composite flooring material that has impact resistance at both room temperature and high temperature and is excellent as a flooring material can be provided.

[Brief description of the drawings]

FIG. 1 is a schematic cross-sectional view of a fire-resistant composite flooring provided with reinforcing layers on both surfaces according to a first embodiment.

FIG. 2 is a schematic cross-sectional view of a fire-resistant composite flooring provided with a reinforcing layer on a back side surface according to the first embodiment.

FIG. 3 is a schematic cross-sectional view of a refractory composite floor material according to a second embodiment.

FIG. 4 is a schematic cross-sectional view of a fire-resistant composite floor material according to a third embodiment.

FIG. 5 is a perspective view of a fire-resistant composite flooring for showing a wood-cut surface according to the present invention.

[Explanation of Codes] . . 1. thermosetting resin, . . 2. inorganic fiber, . . 30. porous inorganic core material, . . Kiguchi surface, 31, 32. . . Gypsum board, 301. . . Gypsum board, 4. . . 4. reinforcement layer; . . 5. Surface adhesive, . . Adhesive, 7. . . Refractory composite flooring, 71. . . Front side, 72. . . 7. back side, . . Board paper,

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI E04F 15/024 601 E04F 15/024 601G

Claims (7)

[Claims] 1. A fire-resistant composite floor material comprising a porous inorganic core material and a reinforcing layer made of a thermosetting resin and inorganic fibers provided on at least one of a front surface and a back surface of the porous inorganic core material. A fire-resistant composite flooring material characterized by a plurality of layers of gypsum plates laminated and bonded together. 2. The fire-resistant composite flooring material according to claim 1, wherein the entire thickness of the porous inorganic core material is 9.5 to 30.0 mm. 3. The fire-resistant composite flooring material according to claim 1, wherein the whole specific gravity of the porous inorganic core material is 0.9 to 1.5. 4. The method according to claim 1, wherein:
Each of the plurality of layers of gypsum plates is adhered by an interlayer adhesive, and the interlayer adhesive is one or a member selected from the group consisting of phenolic resin, epoxy resin, urethane resin, melamine resin, resorcinol resin, and vinyl acetate resin. A fire-resistant composite flooring comprising at least two types. 5. The method according to claim 1, wherein:
A fire-resistant composite flooring material, wherein the reinforcing layer is bonded to the porous inorganic core material with a surface adhesive. 6. The method according to claim 5, wherein the surface adhesive is
A fire-resistant composite flooring comprising at least one member selected from the group consisting of a phenolic resin, an epoxy resin, a resorcinol resin and a melamine resin. 7. The method according to claim 1, wherein:
A fire-resistant composite flooring material, characterized in that the porous inorganic core material is obtained by sticking board base paper to at least one of the front surface and the back surface.