JPH11240105A - Fire-resistant composite floor material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fire-resistant composite floor material having high strength, excellent not only in lightweight properties and fire resistance but also in processability and capable of preventing the scattering of a gypsum powder by using a gypsum board as a floor material. SOLUTION: A fire-resistant composite floor material is obtained by bonding a reinforcing layer consisting of a thermosetting resin and an inorg. fiber to at least one of the upper and rear surfaces of a gypsum board 3 and forming a coating layer 1 for preventing the scattering of a gypsum powder on the cut end surface 30 of the gypsum board 3. The coating layer 1 is formed, for example, by using an inorg. material such as water glass or the like or an org. material such as a rubbery emulsion.

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 means an FA floor (free access 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. As the floor material of such FA floors, a metal plate such as steel, aluminum or the like, a resin plate such as polyvinyl chloride, ABS resin or polypropylene, a concrete plate, a metal plate on a calcium silicate plate are used. There are wood-based ones such as affixed ones and particle boards.

[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. Therefore, the applicant has filed Japanese Patent Application No. 9-279922 in order to form a reinforcing layer on the surface of a gypsum board so that the gypsum board can be used as a floor material.

[0005] However, when trying to put such flooring into practical use, an unsolved problem was found that gypsum powder scattered from the cut end of the gypsum board and soiled the surrounding area.
Further improvements needed to be made.

In order to solve such an unsolved problem, the present invention uses gypsum board as a flooring material, and has high strength, light weight, excellent fire resistance, excellent workability, and can prevent scattering of gypsum powder. It is intended to provide a fire-resistant composite flooring.

[0007]

According to the present invention, there is provided a gypsum board 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 thereof, and a gypsum board is provided with a gypsum board. A fire-resistant composite flooring comprising a coating layer for preventing powder scattering.

In the present invention, a coating layer for preventing gypsum powder from scattering is formed on the tip of the gypsum board. For this reason, there is no problem that the gypsum powder scatters from the lip of the wood at the time of use and contaminates the surroundings. Also, the handling of the fire-resistant composite flooring is improved.

[0009] Gypsum board is a porous inorganic core material, and is low in cost and excellent in compressive strength.
When a force is applied, a tensile force is generated on the side opposite to the side on which the force is applied, and destruction starts from the point where the force is generated.

Therefore, in the present invention, the strength against the tensile force of the gypsum board is improved by bonding a reinforcing layer to the front side or the back side of the gypsum board. That is,
The reinforcing layer is made of a thermosetting resin and inorganic fibers and has excellent workability. In addition, a high-strength reinforcing layer is formed on the surface of the gypsum board to prevent breakage even when a tensile force is applied. Therefore, it is preferable that the reinforcing layer is formed at least on the back side of the gypsum board (the side opposite to the indoor side). The reinforcing layer may be formed on only one side of the gypsum board or on both sides thereof.

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. Furthermore, since the refractory composite flooring of the present invention is composed of gypsum board, thermosetting resin, and inorganic fibers, it is lightweight, has excellent workability, and is low in cost.

Next, the details of the present invention will be described. The coating layer is, for example, an inorganic material. As the inorganic material, for example, sodium silicate solution, silica sol, alumina sol, or the like is preferably used. Thereby, the scattering of the gypsum powder can be effectively prevented. Silica sol,
The alumina sol is obtained by dispersing SiO ₂ or Al ₂ O ₃ particles having a size of 10 to 100 nm in water, and preferably has a concentration of 20 to 40% by weight. Thereby, the reinforcing layer can be formed uniformly.

[0013] The coating layer may be an organic material. In this case, it is preferable to use, for example, various resin emulsions such as a rubber emulsion and an acrylic emulsion as the organic material. This gives
The scattering of the gypsum powder can be effectively prevented. The rubber emulsion is preferably a nitrile-butadiene rubber solution or an ethylene-butadiene solution. The concentration of each emulsion solution is preferably 30 to 60% by weight.
Thereby, a coating layer can be formed uniformly.

It is preferable that the coating layer forms an impregnated layer impregnated on the surface of the wood edge. Thereby, the scattering of the gypsum powder can be effectively prevented.

[0015] The thickness of the coating layer is 0.01 to 4.5 m in both cases of the impregnated layer and the non-impregnated layer.
m is preferable. As a result, it is possible to effectively prevent the gypsum powder from scattering from the tip of the gypsum board. on the other hand,
If it is less than 0.01 mm, the gypsum powder may be scattered. In addition, if it exceeds 4.5 mm, the effect corresponding thereto cannot be achieved. It is preferable that the coating layer covers the entire opening of the gypsum board. This gives
It is possible to almost completely prevent the gypsum powder from scattering from the wood surface.

The reinforcing layer comprises 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 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. As for the inorganic fiber, the discontinuous fiber may be formed in a mat shape.
The continuous continuous fiber may be cut into 3 to 7 cm to form a mat (chopped strand mat), or the continuous continuous fiber may be spirally laminated to form a mat, or the continuous continuous fiber may be woven. .

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. The ratio of the thickness of the reinforcement layer to the thickness of the gypsum board (thickness of the reinforcement layer / thickness of the gypsum board)
It is preferably 0.01 to 0.63. As a result, without increasing the thickness of the refractory composite flooring too much,
Rigidity and impact resistance can be 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.

A gypsum board is a board made of gypsum. Gypsum boards are generally made by sticking board base paper on the surface, but also include those without board base paper.

The total thickness of the gypsum board is 9.5 to 30.
It is preferably 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. 30.
If it exceeds 0 mm, the refractory composite flooring may be heavy.

In particular, the total thickness of the gypsum board is 19 to 2
It is preferably 5 mm. Thereby, more excellent rigidity, impact resistance and workability can be obtained. Further, a plurality of gypsum boards may be laminated and adjusted to the above thickness.

The total thickness of the gypsum board refers to a thickness of one layer when only one layer of gypsum board is provided on the refractory composite flooring, and a plurality of layers when a plurality of layers are laminated. When the board base paper described later is adhered, the total thickness refers to the thickness including the thickness of the board base paper.

The total specific gravity of the gypsum board is 0.9-0.9.
It is preferably 1.5. Thereby, it is relatively lightweight, and can exhibit excellent rigidity and impact resistance. On the other hand, 0.
If it is less than 9, it may become brittle. Also 1.
If it exceeds 5, weight reduction may be hindered. The specific gravity is a value based on 4 ° C. water.

The total specific gravity of the gypsum board refers to the specific gravity of one layer when the fire-resistant composite flooring is provided with only one layer of gypsum board, and the specific gravity of a plurality of layers when multiple layers are laminated. The overall specific gravity of the layer means the specific gravity including the thickness of the board base paper when the board base paper described later is adhered.

It is preferable that the reinforcing layer is adhered to at least one of the front surface and the back surface of the gypsum board by an adhesive. Thereby, the reinforcing layer is firmly adhered to the gypsum board.

Preferably, the adhesive comprises one or more selected from the group consisting of phenolic resins, epoxy resins, resorcinol resins and melamine resins. Since these adhesives have little bending after bonding, the bending of the entire refractory composite flooring can be suppressed. As the adhesive, urethane resin, vinyl acetate resin, or the like can be used in addition to the above.

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, and the reinforcing layer is adhered on the board base paper. The board base paper refers to, for example, paper mainly made of waste paper, pulp, or the like. It is preferable that a water-producing agent or the like is added to the board base paper. Thereby, the gypsum board can be provided with water resistance. Further, it is preferable to use thick paper having a thickness of about 0.3 to 0.5 mm as the board base paper.

It is preferable that a plurality of layers of the gypsum board are laminated and bonded, and the reinforcing layer is bonded to at least one of the outermost surfaces. Thereby, the impact resistance and rigidity of the fire-resistant composite flooring are further increased. Further, it is preferable that the gypsum board has a plurality of layers laminated via the board base paper. Thereby, the strength of the refractory composite flooring is improved. The ratio of the thickness of each gypsum board is 1/2 to 1 /
It is preferably 1. If the thickness is significantly different, it may be difficult to improve the impact resistance of the refractory composite flooring.

It is preferable that each gypsum board is bonded with an adhesive. It is preferable to use the same adhesive as the adhesive for bonding between the gypsum board and the reinforcing layer. That is, the adhesive is preferably made of one or more 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. This can prevent the entire fire-resistant composite floor material from bending.

In the method for producing the fire-resistant composite flooring material of the present invention, first, a reinforcing layer is bonded to at least one of the front and back surfaces of the gypsum board. For this bonding method,
For example, a method in which inorganic fibers impregnated with an inorganic or organic binder are preliminarily formed into a plate-like shape, and a thermosetting resin composition is impregnated, dried, and cured, and then applied to a gypsum board via an adhesive. There is. Alternatively, a method in which a resin composition is impregnated into a mat of inorganic fibers, dried, heated, and the thermosetting resin is cured to form a molded article, and the molded article is adhered to 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, heated and pressed, and the thermosetting resin is cured to form the molded article. Alternatively, a method may be used in which a thermosetting resin is applied to a gypsum board, a mat of inorganic fibers is placed on the gypsum board, and hot pressing is 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, laminated on a gypsum board, and heated and pressed can 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 made to flow out of a nozzle, and is fiberized by a blowing method or a centrifugal method. The cotton is collected by spraying the resin solution. When glass fiber, rock wool, or ceramic fiber is used, a silane coupling agent is preferably coated.

Next, the gypsum board to which the reinforcing layer has been adhered is cut into a desired size, and a coating layer is formed on the cut edge of the gypsum board. As a method for forming the coating layer, for example, a method in which the above-mentioned various materials for forming the coating layer are made into a solution and the solution is applied to the tip of a gypsum board and dried, or a gypsum board is immersed in the solution and dried. There are ways to do that. Also,
The drying temperature is preferably from room temperature to 100 ° C. Thereby, it is possible to efficiently dry the coating layer without deteriorating the material.

[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 FIGS. Refractory composite flooring 7 of this example
As shown in FIG. 1, on the back surface 31 of the gypsum board 3,
The reinforcing layer 4 made of a thermosetting resin and inorganic fibers is bonded. The coating layer 1 for preventing the gypsum powder from scattering is formed on the tip 30 of the gypsum board 3.

The coating layer 1 formed on the cut edge 30 is a water glass impregnated layer having a thickness of 2.5 mm. The coating layer 1 is formed by impregnating a part of or the whole of the coating layer on the surface of the wooden surface. The coating layer 1 is a gypsum board 3
The entirety of the front surface 30 of the wood is covered.

The gypsum board 3 is composed of one layer and has a total thickness of 12.5 mm. The overall specific gravity of the gypsum board 3 is 1.3. Board base paper 8 is adhered to the front and back sides of the gypsum board 3. As the board base paper 8, a thick paper having a thickness of about 0.3 to 0.5 mm obtained by using a waste paper, pulp, or the like as a main raw material and adding a water generating agent or the like is used.

The reinforcing layer 4 comprises 80 parts by weight of a thermosetting resin and 100 parts by weight of inorganic fibers. The thermosetting resin is a phenol resin. As the inorganic fiber, a glass fiber chopped strand mat (weight 900 g /
m ² ). The thickness of the reinforcing layer 4 is 1.2 mm. The reinforcing layer 4 is adhered to the gypsum board 3 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 gypsum board 3 (specific gravity 1.3, thickness 12.5 mm) having board base paper 8 stuck on both sides was prepared. (2) Next, a phenol resin solution (adhesive) containing a curing agent was applied to the surface of the gypsum board 3 at a rate of 720 g / m ² (solid content), and a commercially available glass fiber chopped strand mat (weight 900 g / m ² , thickness 1.2 m
m) and pressed at a temperature of 80 ° C. for 20 minutes. Thus, the gypsum board 3 coated with the reinforcing layer 4 was obtained.

(3) Next, the gypsum board 3 was cut with a normal woodworking band saw to have a size of several tens of cm square. Next, a water glass solution was applied to the cut edge 30 exposed by cutting, and dried at 80 ° C. to form a coating layer 1. Thus, the fire-resistant composite flooring 7 of this example was obtained.

The obtained fire-resistant composite flooring material is used, for example, as a fire-resistant composite flooring material for FA floors by attaching legs to the back side and combining a plurality of these.

Next, the operation and effect of this embodiment will be described. In the present example, a coating layer 1 for preventing gypsum powder from scattering is formed on the tip 30 of the gypsum board 3. for that reason,
In use, there is no problem that gypsum powder is scattered from the wooden surface 30 and stains the surroundings. In addition, the handleability of the refractory composite flooring 7 is also improved.

The gypsum board 3 is inexpensive and has excellent compressive strength, but has insufficient 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 reinforcing layer 4 is made of a thermosetting resin and inorganic fibers, and has excellent workability. In addition, since the high-strength reinforcing layers 4 are formed on both sides of the gypsum board 3, breakage does not occur even when a tensile force is applied.

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. Further, since the refractory composite flooring 7 of this embodiment is composed of the gypsum board 3, the reinforcing layer 4 made of thermosetting resin and inorganic fiber, and the coating layer 1, it is lightweight, has excellent workability and is inexpensive.

In the refractory composite flooring of this embodiment, the reinforcing layer 4 is formed on the back side of the gypsum board 3 as shown in FIG. 1, but it may be formed on the front side. Also, it may be formed on both sides. Also in these cases, it is possible to prevent the destruction of the refractory composite flooring when a tensile force is applied. In addition, the thickness of the gypsum board of the refractory composite floor material of this example is 9.5 mm, but is not limited thereto.
2.5 mm and 15.0 mm can be used. In this embodiment, one layer of gypsum board is used, but two or more layers may be used.

[0046]

As described above, according to the present invention, it is lightweight and inexpensive, and has excellent workability, fire resistance and strength.
It is possible to provide an inexpensive fire-resistant composite flooring material that has impact resistance at both normal temperature and high temperature, is excellent as a flooring material, and can prevent gypsum powder from scattering.

[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.

FIG. 2 is a perspective view of the refractory composite flooring of the first embodiment.

[Explanation of symbols]

 1. . . 2. a coating layer; . . Gypsum board, 30. . . Kiguchi surface, 31. . . 3. back side, . . 6. reinforcement layer, . . 7. fire-resistant composite flooring, . . Board paper,

Claims (4)

[Claims] 1. A gypsum board having a reinforcing layer made of a thermosetting resin and an inorganic fiber adhered to at least one of a front side and a back side of the gypsum board.
A fire-resistant composite flooring comprising a coating layer for preventing gypsum powder from scattering. 2. The fire-resistant composite flooring according to claim 1, wherein the coating layer is made of an inorganic material. 3. The fire-resistant composite flooring according to claim 1, wherein the coating layer is made of an organic material. 4. The method according to claim 1, wherein:
A fire-resistant composite flooring material, characterized in that the coating layer forms an impregnated layer impregnated on the surface of the wood edge.