JPH11227095A - Fire-resistant composite flooring material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fire-resistant composite flooring material, which is lightweight, and excellent in fire resistance and processability, and has high hardness by using a gypsum for flooring material. SOLUTION: A fire-resistant composite flooring material 7 is composed by adhering a reinforcing layer 4 composed of a thermosetting resin and an inorganic fiber on a gypsum board 3, or at least one side of a front side 71 or a back side 72 of the gypsum sheet. A thickness of the gypsum board 3 or the gypsum sheet is 9.5-25.0 mm, and a specific gravity of the gypsum board 3 or the gypsum sheet is 0.9-1.5. And a bend strength of the gypsum board 3 is preferably 80-350 kgf/cm<2> , and a Young's modulus in flexure thereof is preferably 35,000-70,000 kgf/cm<2> .

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD 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 (hereinafter, referred to as a "floor access floor").
It is called "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 above-mentioned conventional problems, the present invention uses gypsum as a flooring material and has high strength, light weight, excellent fire resistance,
An object of the present invention is to provide a fire-resistant composite flooring material excellent in workability.

[0006]

A first invention is a fire-resistant composite flooring material in which a gypsum board or a gypsum board has a reinforcing layer made of a thermosetting resin and an inorganic fiber on at least one of a front surface and a back surface thereof. The gypsum board or gypsum board has a thickness of 9.5 to 25.0 mm.

In the first invention, since the thickness of the gypsum board or the gypsum board is 9.5 to 25.0 mm, the fire-resistant composite flooring using the gypsum board as a core exhibits excellent strength. On the other hand, if it is less than 9.5 mm, the required strength of the refractory composite flooring may not be provided in some cases. If it exceeds 25.0 mm, the effect corresponding to it cannot be expected.

[0008] Gypsum board or gypsum board is low in cost and excellent in fire resistance and compressive strength, but when a force is applied, a tensile force is generated on the side opposite to the side on which the force is applied, and this force is applied. Destruction starts from the point of occurrence. Therefore, in the first invention, the strength of the gypsum board or the gypsum board with respect to the tensile force is improved by bonding a reinforcing layer to the front side or the back side of the gypsum board or the gypsum board. That is, since the reinforcing layer made of the thermosetting resin and the inorganic fiber is formed on the front side or the back side of the gypsum board or the gypsum board, even if a tensile force is applied, no destruction occurs. Further, since the reinforcing layer is made of a thermosetting resin and inorganic fibers, it has excellent workability.

Further, 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. Further, the refractory composite flooring material of the first invention is made of gypsum board or gypsum board, thermosetting resin, and inorganic fiber, so that it is lightweight, has excellent workability, and is low in cost.

Next, the details of the first invention will be described. The gypsum board is obtained by sticking board base paper to the front side and / or the back side of the gypsum board. Further, the gypsum board refers to a plate-like body made of gypsum.

The thickness of the gypsum board or gypsum board is 9.
5 to 25.0 mm. The reason for this is that
This is because sufficient rigidity and impact resistance can be obtained, a sufficient wiring space under the floor can be secured, and high workability is obtained. On the other hand, if it is less than 9.5 mm, sufficient rigidity and impact resistance may not be obtained. Also, 25.0m
If it exceeds m, it is difficult to obtain the effect corresponding to it.

Particularly, the thickness of the gypsum board or the gypsum board is preferably 19 to 25 mm. Thereby, more excellent rigidity, impact resistance and workability can be obtained.
Also, a plurality of gypsum boards or gypsum boards may be laminated and adjusted to the above thickness. The thickness of the gypsum board or gypsum board is the thickness of one layer when using only one layer of gypsum board or gypsum board, and the thickness of a plurality of layers when a plurality of layers are stacked. When a board base paper described later is adhered, the thickness includes the thickness of the board base paper.

The specific gravity of the gypsum board or gypsum board is preferably 0.9 to 1.5. Thereby, it is relatively lightweight, and can exhibit excellent steel properties 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 specific gravity of the gypsum board or gypsum board refers to the specific gravity of one layer when only one layer of gypsum board or gypsum board is provided, and the specific gravity of a plurality of layers when a plurality of layers are stacked. When the board base paper to be bonded is attached, it refers to the specific gravity including the thickness of the board base paper. The specific gravity refers to the ratio of the volume density of gypsum board or gypsum board to the volume density of water at 4 ° C.

The gypsum board has a bending strength of 80 to 35.
0 kgf / cm ² and bending Young's modulus is 35,000
Preferably it is ~ 70,000 kgf / cm ² .
This further improves the strength of the refractory composite flooring. On the other hand, the bending strength is less than 80 kgf / cm ² of the gypsum board or, if the bending Young's modulus of less than 35,000kgf / cm ^2, there is a possibility that the strength of the refractory composite floor becomes insufficient. Further, when the bending strength exceeds 350 kgf / cm ² , or when the bending Young's modulus is 70,000 kgf / cm ^2.
When it exceeds cm ² , the strength becomes excessive as a floor material, and the effect corresponding thereto cannot be expected.

It is preferable that the gypsum board has a board base paper adhered to at least one of a front side and a back side of the gypsum board, and the reinforcing layer is adhered on the board base paper. As the board base paper, for example, thick paper having a thickness of about 0.3 to 0.5 mm obtained by using waste paper, pulp, or the like as a main raw material and adding a water generating agent or the like thereto can be used. By sticking the board base paper, the bending strength, impact resistance, water resistance and the like of the fire-resistant composite flooring material are improved.

The gypsum board or gypsum board may be a single layer or a plurality of layers. It is preferable that each gypsum board or gypsum board is bonded with an adhesive. As this adhesive, it is preferable to use a gypsum board or an adhesive similar to an adhesive bonding between the gypsum board and the reinforcing layer. That is, the above adhesive is a phenol resin, an epoxy resin, a urethane resin, a melamine resin,
It is preferable that the resin is composed of one or more selected from the group consisting of resorcinol resin and vinyl acetate resin.
This can prevent the entire fire-resistant composite floor material from bending.

The reinforcing layer is made of a thermosetting resin and inorganic fibers. The thermosetting resin is preferably a phenol resin, a melamine resin, an epoxy resin, a polyimide resin, a urea resin, or the like.

As the above-mentioned inorganic fibers, glass fibers, rock wool and ceramic fibers are desirable. This is because of its low price and high heat resistance and strength. The above inorganic fibers are
Non-continuous fibers may be formed in a mat shape, or continuous long fibers may be cut into 3 to 7 cm into a mat shape (chopped strand mat), or continuous long fibers may be spirally laminated and matted It may be made into a shape, or may be made by weaving continuous filaments.

The content of the thermosetting resin contained in the reinforcing layer is 20 to 200 parts by weight based on 100 parts by weight of the inorganic fibers.
Desirably, parts by weight are used. 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. Aluminum hydroxide,
A flame retardant such as magnesium hydroxide, and a commonly used inorganic binder such as silica sol, alumina sol, and water glass may be added.

The reinforcing layer is preferably formed at least on the back side of the gypsum board or the gypsum board (opposite the indoor side). Thereby, the fire-resistant composite flooring can be given resistance to a tensile force from above to below. In addition, the reinforcement layer is only on one side of gypsum board or gypsum board,
Alternatively, it may be formed on both sides.

It is preferable that the reinforcing layer is bonded to at least one of the front side and the back side of the gypsum board or the gypsum board with an adhesive. Thereby, the reinforcing layer is firmly adhered to the gypsum board or the gypsum board.
In addition, the above adhesive is a phenol resin, an epoxy resin,
It is preferable to be composed of one or more selected from the group of resorcinol resins and melamine resins. Since these adhesives have little bending after bonding, the bending of the entire refractory composite flooring can be suppressed. Also, as an adhesive,
In addition to the above, urethane resin, vinyl acetate resin and the like can be used.

Further, it is preferable that the open end of the refractory composite flooring material is covered with a coating layer. This can prevent the fire-resistant composite flooring material, particularly gypsum powder, from scattering and improve handling. The coating layer is, for example, a sodium silicate solution,
Inorganic materials such as silica sol and alumina sol, and organic materials composed of various resin emulsions such as rubber emulsion and acrylic emulsion can be used. Silica sol and alumina sol are S
It is obtained by dispersing particles of iO ₂ or Al ₂ O ₃ in water, and preferably has a concentration of 20 to 40% by weight.

It is preferable that the coating layer forms an impregnated layer impregnated on the surface of the wood edge. Thereby, the scattering of the powder can be effectively prevented. The thickness of the coating layer is preferably 0.01 to 4.5 mm both in the case of the impregnated layer and in the case of not being the impregnated layer. Thus, scattering of the gypsum powder can be prevented without increasing weight and cost. On the other hand, 0.01m
If it is less than m, the powder may be scattered. Further, if it exceeds 4.5 mm, an effect corresponding thereto cannot be expected.

The fire-resistant composite flooring of the first invention may be provided with a surface decorative layer on the outermost surface. Examples of the surface decorative layer include melamine decorative boards, vinyl chloride tiles, carpets such as cloth carpets, tatami mats, natural wood, decorative plywood,
Natural stone or artificial stone can be used. Further, the fire-resistant composite flooring material of the first invention may be provided with an electromagnetic wave shielding layer. Thereby, the electromagnetic waves emitted from the computer in the room can be absorbed, and the influence of the electromagnetic waves on the human body can be suppressed. The electromagnetic wave shielding layer includes, for example, a metal foil, a composite sheet made of a conductive filler and a resin, and the like. Metal foil and conductive filler are, for example,
Made of iron, aluminum, etc.

In the method for producing a fire-resistant composite flooring material of the first invention, first, a reinforcing layer is bonded to at least one of the front and back surfaces of a gypsum board or a gypsum board. As this bonding method, for example, an inorganic fiber impregnated with an inorganic or organic binder or the like is preliminarily formed into a plate shape, and a thermosetting resin composition is impregnated, dried, and cured through an adhesive. There is a method of sticking on a gypsum board or a gypsum board. Alternatively, a method of impregnating a resin composition into a mat of inorganic fibers and drying the same, followed by heating and pressing to form a thermosetting resin by curing, and then applying this to a gypsum board or a gypsum board via an adhesive may be used. . Alternatively, a method in which a resin composition is impregnated into a mat of inorganic fibers, dried, laminated on a gypsum board or a gypsum board, heated and pressed, and the thermosetting resin is cured to form the molded article. Alternatively, a thermosetting resin may be applied to a gypsum board or a gypsum board, a mat of inorganic fibers may be placed on the thermosetting resin, and hot pressing may be performed.

Further, a method in which a thermosetting resin such as a phenol resin is coated on the fiber surface of glass fiber, rock wool, or ceramic fiber at a B stage, and the resulting material is laminated on a gypsum board or a gypsum board and heated and pressed may be employed. . 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 coating, a raw material melt of glass fiber, rock wool, and ceramic fiber is discharged from a nozzle and fiberized by a blowing method or a centrifugal method.
At the same time as the fiberization, a solution of a thermosetting resin such as a phenol resin is sprayed to collect cotton. When glass fiber, rock wool, or ceramic fiber is used, a silane coupling agent is preferably coated.

Next, a second invention is a fire-resistant composite flooring material comprising a gypsum board or a gypsum board provided with a reinforcing layer made of a thermosetting resin and inorganic fibers on at least one of the front side and the back side. The specific gravity of the gypsum board or gypsum board is 0.9 to 1.5, which is a fire-resistant composite flooring.

In the second invention, the specific gravity of the gypsum board or gypsum board is 0.9 to 1.5. Therefore, a fire-resistant composite flooring using gypsum board or gypsum board as a core material has excellent strength. On the other hand, if the specific gravity of the gypsum board or the gypsum board is less than 0.9, the required strength of the fire-resistant composite flooring material may not be provided. On the other hand, when it exceeds 1.5, the weight reduction of the fire-resistant composite floor material is hindered.

Gypsum board or gypsum board is excellent in fire resistance and compressive strength. Further, since the surface of the porous inorganic core material is covered with the reinforcing layer, the tensile force can be further increased. In addition, the second invention can exhibit the same effects as the first invention.

Next, in the second invention, the thickness of the gypsum board or gypsum board is preferably 9.5 to 25.0 mm. The gypsum board preferably has a bending strength of 80 to 350 kgf / cm ² and a bending Young's modulus of 35,000 to 70,000 kgf / cm ² . Both are based on the same reason as in the first invention.
Other aspects of the second invention are the same as those of the first invention.

Next, a third invention is a fire-resistant composite flooring material in which a reinforcing layer made of a thermosetting resin and an inorganic fiber is adhered to at least one of a front surface and a back surface of a gypsum board, The gypsum board has a bending strength of 80 to 350k.
gf / cm ² , and the bending Young's modulus is 35,000 to 7
It is a fire-resistant composite flooring material having a weight of 000 kgf / cm ² .

In the third aspect, the gypsum board has a bending strength of 80 to 350 kgf / cm ² and a bending Young's modulus of 35,000 to 70,000 kgf / cm ² . Therefore, the refractory composite flooring using such a gypsum board as a core material has excellent strength. On the other hand, the bending strength is less than 80 kgf / cm ² of the gypsum board or, if the bending Young's modulus of less than 35,000kgf / cm ^2, there is a possibility that the strength of the refractory composite floor becomes insufficient. Also, if the bending strength is more than 350 kgf / cm ^2, or if the flexural Young's modulus greater than 70,000kgf / cm ² becomes excessive strength as a floor material, effect corresponding thereto can not be expected.

Further, the gypsum board is excellent in fire resistance and compressive strength. Further, since the surface of the porous inorganic core material is covered with the reinforcing layer, the tensile force can be further increased. In addition, the second invention can exhibit the same effects as the first invention.

Next, in the third invention, it is preferable that the thickness of the gypsum board is 9.5 to 25.0 mm. Further, the specific gravity of the gypsum board is preferably 0.9 to 1.5. Both are based on the same reason as in the first invention. Other aspects of the third aspect are the same as those of the first aspect.

[0036]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiment 1 A refractory composite flooring according to an embodiment of the present invention will be described with reference to FIG. The fire-resistant composite flooring 7 of this example is shown in FIG.
As shown in the figure, the front side 71 and the back side 7 of the gypsum board 3
A reinforcing layer 4 made of a thermosetting resin and inorganic fibers is adhered to both surfaces of the substrate 2. Gypsum board 3 consists of one layer,
Its thickness T is 12.5 mm and its specific gravity is 1.
2 g / cm ³ . The gypsum board 3 has a bending strength of 95 kgf / cm ² and a bending Young's modulus of 4700.
It is 0 kgf / cm ² .

The reinforcing layer 4 comprises 18% by weight of a thermosetting resin and 82% by weight of inorganic fibers. The thermosetting resin is a phenol resin. Glass fiber chopped strands (weight: 600 g / m ² ) are used as the inorganic fibers. The thickness of the reinforcing layer 4 is 0.7 mm.

The gypsum board 3 has a gypsum board 5 with a board base paper 8 adhered to a front side 71 and a back side 72. As the board base paper 8, a cardboard formed by using waste paper, pulp or the like as a main raw material and adding a water generating agent thereto is used. The reinforcing layer 4 is adhered to the board base paper 8 with an adhesive made of a phenol resin.

A method for manufacturing the fire-resistant composite flooring of this embodiment will be described. (1) 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.
Let it cure. As a result, the gypsum board 3 in which the board base paper 8 is adhered to the front side surface 71 and the back side surface 72 of the gypsum board 5 is produced.

(2) Next, a phenol resin solution containing a curing agent was applied on the surface of the board base paper 8 at a rate of 420 g / m ² (in terms of solid content), and then a commercially available glass fiber chopped strand mat (weight (600 g / m ² , thickness 0.7 mm) and pressed at a temperature of 100 ° C. for 15 minutes. Thereby, the reinforcing layer 4 is formed on the front side surface 71 and the back side surface 72 of the gypsum board 3.

(3) The fire-resistant composite flooring 7 is then cut with a circular saw to a size of several tens of cm square, and legs are attached to the rear side surface 72, and a plurality of these are combined to form a fire-resistant composite flooring. Used as a material. When the fire-resistant composite flooring 7 is installed on the floor of the office, office equipment can be arranged on the front side, and wiring equipment and air conditioning equipment for office equipment can be arranged on the back side. Wiring and air conditioning equipment may be provided with openings in fire-resistant composite flooring, from which they can be removed onto the floor.

Next, the operation and effect of this embodiment will be described. In this example, the gypsum board 3 has the physical properties of the above-mentioned thickness, specific gravity, bending strength and bending Young's modulus. Therefore, the fire-resistant composite flooring using the gypsum board as a core material exhibits excellent strength.

The gypsum board 3 is low in cost and excellent in fire resistance and compressive strength, but insufficient in tensile strength. Therefore, in this example, the tensile strength is improved by bonding the reinforcing layers 4 to both surfaces of the gypsum board 3. That is, the front side surface 71 and the back side surface 72 of the gypsum board 3
Since the high-strength reinforcing layer 4 is covered, no destruction occurs even when a tensile force is applied. Further, since the reinforcing layer 4 is made of a thermosetting resin and inorganic fibers, it has excellent workability.

Unlike the thermoplastic resin, the thermosetting resin 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 fire-resistant composite flooring 7 of this example is mainly composed of the gypsum board 3, the thermosetting resin and the reinforcing layer 4 made of inorganic fiber, it is lightweight, has excellent workability, and is inexpensive.

In this embodiment, the reinforcing layers 4 are formed on both sides of the gypsum board 3 as shown in FIG. 1, but may be formed on either the front side or the back side. Also,
The cut edge exposed by cutting the refractory composite flooring 7 may be coated with a coating layer for preventing gypsum powder from scattering. Further, the front side surface 71 of the refractory composite flooring 7 can be coated with a surface decorative layer, and the back side surface 72 can be provided with an electromagnetic wave shielding layer made of a conductive filler impregnated resin such as an aluminum filler.

Experimental Example 1 In this example, as shown in Table 1, fire-resistant composite flooring materials were produced using gypsum boards having different thicknesses, specific gravities and strengths, and their impact resistance was measured. The fire-resistant composite floor material according to the present invention was referred to as Examples 1 to 3, and the fire-resistant composite floor material according to the comparative example was referred to as Comparative Examples 1 to 3. Each gypsum board is a single layer. The reinforcing layer is composed of 100 parts by weight of glass fiber chopped strands as inorganic fibers and 90 parts by weight of phenol resin. Others were the same as the first embodiment.

In the measurement, the refractory composite floor material was cut into a size of 500 mm × 500 mm, and its four corners were supported by supporting legs having a distance between supporting points of 400 mm.
An impact load test was conducted in which a sand bag having a mass of 30 kg was dropped from a height of 500 mm according to the test method for 50 free access floor components.

The results are shown in Table 1. From the table, it can be seen that Examples 1 to 3 according to the present invention are all excellent in impact resistance.

[0049]

[Table 1]

[0050]

According to the present invention, it is possible to provide a fire-resistant composite floor material having high strength, light weight, excellent fire resistance, and excellent workability by using gypsum board for the floor material.

[Brief description of the drawings]

FIG. 1 is a schematic cross-sectional view of a fire-resistant composite floor material according to a first embodiment.

[Explanation of symbols]

 3. . . Gypsum board, 4. . . 4. reinforcement layer; . . Gypsum board, 7. . . Refractory composite flooring, 71. . . Front side, 72. . . 7. back side, . . Board paper,

Claims (9)

[Claims] 1. A fire-resistant composite flooring comprising a gypsum board or a gypsum board provided with a reinforcing layer made of a thermosetting resin and an inorganic fiber on at least one of a front side and a back side of the gypsum board or the gypsum. The thickness of the board is 9.5-
A fire-resistant composite flooring material having a size of 25.0 mm. 2. The fire-resistant composite flooring according to claim 1, wherein the specific gravity of the gypsum board or the gypsum board is 0.9 to 1.5. 3. The gypsum board according to claim 1, wherein the gypsum board has a bending strength of 80 to 350 kgf / cm ² .
Bending Young's modulus is 35,000-70,000kgf / c
m ² . 4. A fire-resistant composite flooring material comprising a gypsum board or a gypsum board provided with a reinforcing layer made of a thermosetting resin and an inorganic fiber on at least one of a front side and a back side of the gypsum board or the gypsum. The specific gravity of the plate is 0.9 ~
1.5. A refractory composite flooring material having a ratio of 1.5. 5. The fire-resistant composite flooring material according to claim 4, wherein said gypsum board or gypsum board has a thickness of 9.5 to 25.0 mm. 6. The gypsum board according to claim 4, wherein the gypsum board has a bending strength of 80 to 350 kgf / cm ² ,
Bending Young's modulus is 35,000-70,000kgf / c
m ² . 7. A fire-resistant composite flooring material comprising a gypsum board and a reinforcing layer made of a thermosetting resin and inorganic fibers adhered to at least one of a front side and a back side of the gypsum board, wherein the gypsum board has a flexural strength. Is 80 to 350 kgf / cm ² and the bending Young's modulus is 35,000 to 70,000 kgf.
/ Cm ^2, which is a fire-resistant composite flooring. 8. The fire-resistant composite flooring according to claim 7, wherein the gypsum board has a thickness of 9.5 to 25.0 mm. 9. The fire-resistant composite flooring material according to claim 7, wherein a specific gravity of the gypsum board is 0.9 to 1.5.