JP7574109B2 - Laminate and covering structure - Google Patents

Description

The present invention relates to a novel laminate and covering structure.

Traditionally, in architectural structures, it has been required to make the main structures such as pillars and beams heat-resistant in order to protect the building from fire. One method of providing heat resistance is to cover the base material of the main structures with a material that foams when heated (thermally foamable coating material). Thermally foamable coating materials are thin and lightweight under normal conditions, but when the temperature rises due to a fire or other cause, they foam and carbonize to form an insulating layer, providing heat-resistant protection.

Various proposals have been made regarding coated structures using such thermally foamable coating materials. One example is described in Patent Document 1, which describes a method of obtaining a coated structure by coating the periphery of a long wooden substrate having a rectangular cross section with a thermally foamable coating material, applying adhesive to each of the outer surfaces, and then joining non-combustible sheet pieces.

JP 2011-38317 A

However, in the above patent document, the process for obtaining the coated structure is complicated, and there is room for improvement in terms of heat resistance and protection.

The present invention has been made in consideration of the above-mentioned problems, and aims to provide a laminate and a covering structure that are excellent in workability, heat resistance, and other properties.

As a result of intensive research into solving the above problems, the inventor came up with the idea of a laminate having a specific shape in which at least a heat absorbing layer and a thermal foaming layer are laminated, and a covering structure having the laminate, which led to the completion of the present invention.

That is, the present invention has the following features.
1. A coating structure in which a substrate is surrounded by a laminate,
The laminate is a thermally foamable laminate, and includes at least a heat absorbing layer and a thermally foamable layer.
The thermally foamed layer contains a resin component, a flame retardant, a foaming agent, a carbonizing agent, and a filler,
The thermally foamed layer has a thickness of 0.1 to 10 mm.
The covering structure is characterized in that the heat absorption layer is arranged in a row at intervals on the back side of the thermal foaming layer.

The present invention provides a coated structure with excellent workability, heat resistance, and other properties.

FIG. 1 is a cross-sectional view showing an example of a laminate of the present invention. FIG. 1 is a perspective view showing an example of a laminate of the present invention. 1 is a cross-sectional view showing an example of a covering structure of the present invention. 1 is a cross-sectional view showing an example of a covering structure of the present invention. FIG. 1 is a cross-sectional view showing an example of a laminate of the present invention.

1: Laminate 2, 21 to 24: Heat absorbing layer 3: Thermal foaming layer 4: Adhesive layer 5: Decorative layer 6: Substrate

The following describes how to implement the present invention.

The laminate of the present invention is a laminate of at least a heat absorbing layer and a thermal foaming layer, and the heat absorbing layers are arranged side by side at intervals on the back side of the thermal foaming layer. In the present invention, such a specific laminate is used to surround the periphery of the substrate, and a covering structure is efficiently obtained, which has excellent workability. Furthermore, the combined action of the heat absorbing layer and the thermal foaming layer that constitute the laminate can provide excellent heat-resistant protection.

[Laminate]
The laminate of the present invention comprises at least a heat absorbing layer and a thermally foamable layer laminated together.

In the present invention, the heat absorption layer may be one that exhibits a heat absorption effect when the temperature rises. The heat absorption layer is preferably a layer having bound water and/or free water, and such a heat absorption layer can absorb heat by dehydrating (evaporating, etc.) the bound water and/or free water when the temperature rises. Here, bound water is water that is bound to the components that make up the heat absorption layer, and examples of such water include hydration water, crystal water, and adsorbed water. On the other hand, free water is water other than bound water that is contained in the heat absorption layer without being bound to the components that make up the heat absorption layer.

Materials constituting the heat absorbing layer include, for example, hardened products made from raw materials such as cement and gypsum (e.g., mortar, concrete, gypsum board, etc.), hardened products made from raw materials such as calcium silicate (e.g., calcium silicate board, etc.), and boards, sheets, hardened products containing water-absorbent polymers, hydrogels, etc. These can be used alone or in combination of two or more types.

In the present invention, an example of a suitable material for forming the heat absorption layer is gypsum board. Gypsum board is usually composed mainly of calcium sulfate dihydrate, so it contains a lot of bound water and exhibits heat absorption within a temperature range of 100 to 200°C. Therefore, it can exhibit a stable heat absorption effect when the temperature rises due to fire, heat, etc. In addition to general gypsum board, non-combustible laminated gypsum board (gypsum board using non-combustible base paper as the cover), reinforced gypsum board (gypsum board with gypsum mixed with inorganic fibers such as glass fiber as the core material), glass fiber non-woven fabric gypsum board (gypsum board with gypsum mixed with glass fiber as the core material and glass fiber non-woven fabric inserted on the front and back sides) can be used as the gypsum board.

The thickness of the heat absorbing layer is preferably 1 to 30 mm, more preferably 3 to 28 mm, and even more preferably 5 to 25 mm, from the viewpoints of heat insulation, heat resistance, strength, light weight, etc. In the present invention, "a to b" is synonymous with "a or more and b or less."

The thermal foam layer can be one that foams due to the action of the raw materials that make up the thermal foam layer when the ambient temperature rises due to a fire or other cause and the temperature of the thermal foam layer reaches a predetermined foaming temperature, forming a carbonized insulating layer. The thermal foam layer can be formed, for example, from a thermal foaming sheet.

The foaming temperature of the thermal foam layer is preferably 150°C or higher, more preferably 180°C or higher, and even more preferably 200 to 400°C, in consideration of temperature rise due to flames, heat, etc.

The thermal foam layer is preferably made of a mixture of components including a resin component, a flame retardant, a foaming agent, a carbonizing agent, and a filler. Among these, examples of the resin component include thermoplastic resins such as acrylic resin, acrylic styrene resin, vinyl acetate resin, and ethylene vinyl acetate resin. Examples of the flame retardant include ammonium polyphosphate, and examples of the foaming agent include melamine, dicyandiamide, and azodicarbonamide. Examples of the carbonizing agent include pentaerythritol and dipentaerythritol, and examples of the filler include titanium dioxide, calcium carbonate, and inorganic fibers. Each of these components can be used alone or in combination of two or more types.

The mixing ratio (weight ratio) of each component that makes up the thermal foam layer is preferably 200 to 600 parts by weight of flame retardant, 40 to 150 parts by weight of foaming agent, 40 to 150 parts by weight of carbonizing agent, and 50 to 160 parts by weight of filler, calculated as solid content, per 100 parts by weight of resin component, from the viewpoint of heat resistance protection, etc.

The thermally foamable sheet used in the thermally foamable layer can be a mixture containing the above components and, if necessary, various additives, molded into a sheet.

Additives that can be used in the mixture that forms the thermally foamed layer may be any additive that does not significantly impair the effects of the present invention, and examples of such additives include pigments, fibers, wetting agents, plasticizers, lubricants, preservatives, antifungal agents, anti-algae agents, antibacterial agents, thickeners, dispersants, defoamers, crosslinking agents, UV absorbers, light stabilizers, antioxidants, diluting solvents, etc.

The thickness of the thermally foamed layer may be set appropriately depending on the application, etc., but from the standpoint of heat resistance, protection, light weight, etc., it is preferably 0.1 to 10 mm, more preferably 0.3 to 8 mm, and even more preferably 0.5 to 6 mm.

The thermally foamed layer may be composed only of a molded product of a mixture containing the above-mentioned components and additives, or may have a fibrous sheet or the like laminated on the front or back surface of the thermally foamed layer. As such a fibrous sheet, for example, a known sheet containing organic fibers and/or inorganic fibers can be used.

In the present invention, for example, each layer can be bonded together using an adhesive or the like. As the adhesive, for example, a water-dispersed, water-soluble, or solvent-based adhesive made mainly of acrylic resin, silicon resin, epoxy resin, vinyl resin, phenolic resin, polyester resin, urethane resin, paraffin, or the like can be used. If necessary, the adhesive can be blended with additives such as flame retardants, foaming agents, carbonizing agents, and fillers that are blended in the above-mentioned thermally foamable layer. In the present invention, the adhesive also includes pressure-sensitive adhesives.

In the present invention, by laminating the heat absorbing layer and the thermal foaming layer via an adhesive layer, when the thermal foaming layer foams to form a carbonized insulation layer, the shape of the carbonized insulation layer can be maintained and the layer can be prevented from falling off, and effects such as heat resistance protection can be stably obtained.

In the laminate of the present invention, a plurality of heat absorbing layers are arranged side by side with gaps between them on the back side of the thermal foaming layer. FIG. 1 shows an example (cross-sectional view) of the laminate of the present invention. FIG. 2 is a perspective view of the laminate of FIG. 1. In the laminate of FIGS. 1 and 2, four heat absorbing layers 21-24 are arranged side by side with gaps between them on the back side of the thermal foaming layer 3. The heat absorbing layers 21-24 are each a quadrilateral (square or rectangular) plate material when viewed from the front. The thermal foaming layer 3 is a quadrilateral (rectangular) sheet when viewed from the front. The thermal foaming layer 3 and the heat absorbing layers 21-24 are bonded together via an adhesive layer 4.

The distance between the heat absorbing layers can be set appropriately depending on, for example, the size of the substrate and the method of coating the substrate.

The laminate in Figures 1 and 2 has four heat absorbing layers arranged side by side, but in the present invention, it is sufficient that at least two or more heat absorbing layers are arranged side by side.

In the laminate of Figures 1 and 2, the thermal foam layer 3 extends in one direction beyond the right end of the heat absorption layer 24. The thermal foam layer extending beyond the end of the heat absorption layer in this manner can cover the side of the lower heat absorption layer, or the side or surface of the adjacent laminate. This makes it possible to fully obtain effects such as heat resistance protection. It is desirable that the length of the thermal foam layer extending beyond the end of the heat absorption layer is equal to or greater than the thickness of the lower heat absorption layer, or equal to or greater than the thickness of the adjacent laminate. The thermal foam layer extending beyond the end of the heat absorption layer can also be appropriately cut when forming the covering structure.

In the laminate of the present invention, a heat reflective layer can be further laminated. The laminated heat reflective layer provides a heat shielding effect and can improve heat resistance protection. The heat reflective layer can be provided, for example, on the back side of each heat absorbing layer, the back side of the thermal foam layer, or the front side of the thermal foam layer.

As the heat reflective layer, for example, a metal plate, sheet, tape, etc. with high heat reflectivity can be used. Examples of metals constituting the heat reflective layer include aluminum, copper, silver, etc., and among these, aluminum is preferred. Specific examples of the heat reflective layer include aluminum foil, aluminum tape, aluminum cloth, aluminum foil/glass nonwoven fabric laminated sheet, aluminum foil/mesh laminated sheet, aluminum foil/glass cloth composite sheet, aluminum foil/synthetic resin laminated sheet, etc. For example, when using aluminum tape, a tape with an adhesive layer formed on one side of the aluminum layer can be used. These can be used alone or in combination of two or more types.

The thickness of the heat reflective layer is preferably 0.01 to 1 mm, more preferably 0.02 to 0.5 mm, and even more preferably 0.01 to 1.0 mm, from the viewpoints of heat reflectivity, heat resistance, light weight, and the like.
It is between 0.3 and 0.3 mm.

[Covering structure]
In the present invention, a covered structure can be obtained by covering the periphery of a substrate with the above-mentioned laminate.

Examples of substrates include pillars, beams, etc., which constitute structures such as buildings and civil engineering structures. Examples of such substrates include those made of materials such as cement-based materials, plastics, wood materials, and metals. The shape of these substrates is preferably long, and examples of their cross-sectional shapes include circles and polygons (rectangles, etc.).

In the present invention, the laminate is installed on the substrate so that the heat absorption layer side of the laminate faces the substrate and the thermal foaming layer side faces outward. The laminate can be installed on the substrate using, for example, fasteners such as nails, screws, rivets, pins, bolts, and staples, or gypsum-based or cement-based adhesives. This makes it possible to efficiently obtain a covering structure in which at least the heat absorption layer and the thermal foaming layer are laminated in order on the substrate, which is advantageous in terms of workability. By laminating the layers in the above order, the effect of suppressing temperature rise due to heat such as fire is enhanced, excellent effects in heat resistance protection, etc. are exhibited, and a decrease in the strength of the substrate can be suppressed. Furthermore, the carbonized insulation layer can be prevented from falling off, and effects such as heat resistance protection can be stably obtained.

The seams between laminates (places where laminates come into contact with each other) can be treated appropriately. Examples of methods for treating such seams include covering (straddling) the seams with a thermally foamable coating material or a thermally foamable sheet, filling the seams with a thermally foamable putty, and installing a fibrous reinforcing material so as to straddle the seams. Two or more of these treatment methods can also be combined. The thermally foamed layer or fibrous reinforcing material straddling the seams can be flattened by, for example, heating, pressing, or other treatment.

In the longitudinal direction of the substrate, the laminates can be placed adjacent to each other so that they are butt-to-butt. The seams between the laminates can be treated as necessary. The seam treatment methods described above can be used.

In the coated structure of the present invention, a decorative layer can be provided on the outside of the thermally foamed layer, if necessary. Any decorative layer can be used as long as it does not inhibit the foaming properties of the thermally foamed layer. The decorative layer can have a variety of appearances, such as transparent or opaque, colorless or colored, non-glossy or glossy, monochromatic or multicolored, and flat or uneven. In the present invention, the aesthetics, water resistance, weather resistance, etc. of the coated structure can be improved by providing a decorative layer.

The decorative layer can be provided in advance, for example, when the laminate is manufactured, or can be provided after the covering structure is formed. The decorative layer can be formed by a known method, such as a method of applying various coating materials or a method of attaching a film, sheet, or the like. A plurality of materials can also be laminated as the decorative layer.

The coated structure of the present invention can be applied to applications requiring heat-resistant protection in various fields such as architecture and civil engineering. When used as a building material, it can be applied to columns, beams, etc., for example. The coated structure of the present invention can exhibit heat-resistant protection (fire resistance) that meets the specified conditions in the test specified in JIS A1304:2017, for example. Such performance can be appropriately adjusted by selecting, for example, the type, stacking mode, thickness, etc. of each layer.

[Example 1]
FIG. 3 shows an example (cross-sectional view) of the covering structure of the present invention. In the covering structure of FIG. 3, a long rectangular substrate is covered using the laminate of FIGS. 1 and 2. Specifically, in the covering structure of FIG. 3, the laminate 1 is provided so that the heat absorption layers 21-24 are aligned along the outer sides of the four sides of the substrate 6 (rectangular substrate) in cross-sectional view. In the laminate 1, the heat absorption layers 21-24 have the same thickness. The size of the heat absorption layers 21-24 is equal to the length of one side of the rectangular substrate. The size referred to here is the length along the side of the substrate in cross-sectional view.

At the corners of the base material 6 (upper right corner, lower right corner, and lower left corner), the thermal foam layer 3 is bent, so that the heat absorption layers 21 to 24 are placed along the outside of the four sides. At each corner, a triangular space is provided in cross section. At the upper left corner of the base material 6, the laminate 1 in FIG. 1 goes around once, and the left and right ends of the laminate 1 are in contact. The seams between such laminates can be appropriately treated using the methods described above, etc.

In the covering structure of FIG. 3, the entire periphery of the square substrate is covered with a laminate of a heat absorbing layer and a thermal foaming layer. When the covering structure of FIG. 3 is exposed to high temperatures due to a fire or the like, the thermal foaming layer 3 foams and forms a carbonized insulating layer, and the heat absorbing layer 2 exhibits a heat absorbing effect, thereby suppressing the temperature rise of the substrate 6 and maintaining its strength.

In FIG. 3, a triangular space is provided at each corner in cross section, but this space can also be filled with a corner material (wet or dry). The corner material can be made of the same material as the heat absorption layer. Also, at each corner, a thermal foam layer can be installed along the side of the heat absorption layer without providing the above-mentioned space.

[Example 2]
Another example (cross-sectional view) of a covering structure using the laminates of Figures 1 and 2 is shown in Figure 4. Specifically, in the covering structure of Figure 4, the laminates of Figures 1 and 2 are placed along the outsides of the four sides of a substrate 6 (rectangular substrate) in a cross-sectional view. In the laminate 1 of Figure 4, the heat absorption layers 21 to 24 have the same thickness, and the size of the heat absorption layers 21 to 24 is equal to the sum of the length of one side of the rectangular substrate and the thickness of the adjacent heat absorption layers.

At the corners of the substrate 6 (rectangular substrate), the back surface of one heat absorption layer is in contact with the side surface of the other heat absorption layer. Specifically, at the upper right corner, the side surface of heat absorption layer 21 is in contact with the back surface of heat absorption layer 22. At the lower right corner, the side surface of heat absorption layer 22 is in contact with the back surface of heat absorption layer 23. At the lower left corner, the side surface of heat absorption layer 23 is in contact with the back surface of heat absorption layer 24. At the upper left corner, the side surface of heat absorption layer 24 is in contact with the back surface of heat absorption layer 21.

At the upper left corner of the substrate 6, the laminate 1 in FIG. 1 goes around once, and the left end and right end of the laminate 1 meet. Such a laminate seam can be appropriately treated by the above-mentioned method, etc.

When the covering structure in Figure 4 is exposed to high temperatures due to a fire or the like, the thermal foam layer 3 foams and forms a carbonized insulating layer, and the heat absorption layer 2 exhibits a heat absorption effect, thereby suppressing the temperature rise of the substrate 6 and maintaining its strength.

[Example 3]
FIG. 5 shows another example (cross-sectional view) of the laminate of the present invention. In the laminate of FIG. 5, the heat absorption layer 2, the thermal foaming layer 3, and the decorative layer 5 are laminated in this order. In the laminate of FIG. 5, four heat absorption layers 21 to 24 are arranged side by side at intervals on the back side of the heat foaming layer 3. The heat absorption layers 21 to 24 are each a quadrangular (square or rectangular) plate material in a front view. The heat foaming layer 3 is a quadrangular (rectangular) sheet in a front view, and the decorative layer 5 is a quadrangular (rectangular) decorative sheet in a front view. In the laminate of FIG. 5, the heat foaming layer 3 and the heat absorption layers 21 to 24 are bonded together via the adhesive layer 4. The decorative layer 5 can be laminated on the surface of the heat foaming layer 3 via an adhesive layer or the like. In the laminate of FIG. 5, the heat foaming layer 3 and the decorative layer 5 extend in one direction beyond the right end of the heat absorption layer 24.

For example, a decorative sheet having a design such as a wood grain or sandstone pattern can be used as the decorative layer 5. By using such a decorative sheet, the aesthetic appearance can be improved.

The laminate of FIG. 5 can be used to form a covering structure, for example, in the manner of FIG. 3, FIG. 4, etc. Where the laminate goes around the substrate, a seam in the decorative layer is generated, but such a seam can be appropriately treated, for example, with an adhesive, coating material, putty, or the like of a similar color to the decorative layer.

When the covering structure formed using the laminate of Figure 5 is exposed to high temperatures due to a fire or the like, the thermal foam layer 3 foams and forms a carbonized insulating layer, and the heat absorption layer 2 exhibits a heat absorption effect, thereby suppressing the temperature rise of the substrate 6 and maintaining its strength.

Claims (1)

A coating structure in which a substrate is surrounded by a laminate,
The laminate is a thermally foamable laminate, and includes at least a heat absorbing layer and a thermally foamable layer.
The thermally foamed layer contains a resin component, a flame retardant, a foaming agent, a carbonizing agent, and a filler,
The thermally foamed layer has a thickness of 0.1 to 10 mm.
The covering structure is characterized in that the heat absorption layer is arranged in a row at intervals on the back side of the thermal foaming layer.

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