Partition wall

Abstract

To provide a lightweight, fire-resistant partition wall that ensures good workability.SOLUTION: A partition wall 10 comprises a substrate 11 that contains a cardboard layer and a non-combustible layer 20 that is provided on at least a part of the surface of the substrate 11.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to partition walls used in buildings and the like.

Background Art

[0002] Currently, due to the aging and decrease of construction workers, the demand for easy construction is increasing. Also, from the perspective of environmental impact, the demand for reducing carbon dioxide emissions is increasing. In response to these two demands, for the former, lightweight building materials and workability that can be processed without tools are required, and for the latter, reduction of carbon dioxide emissions during manufacturing and demolition and heat insulation are required. In recent years, the utilization of cardboard has attracted attention as a building material that meets the above demands.

[0003] For example, in Patent Document 1, a building member excellent in sound insulation, heat insulation, and waterproofness is disclosed, which has a base material including a cardboard layer and a coating layer provided on at least a part of the surface of the base material and containing a synthetic resin.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] By the way, among building materials, gypsum board is currently widely used for partition walls, but in buildings, a large number of construction sheets are required and the weight is also large, so there is a problem of poor workability. Therefore, the use of cardboard for partition walls has been considered.

[0006] However, the conventional building member with a cardboard layer as the base material as shown in Patent Document 1 has insufficient fire resistance and it is difficult to meet the required performance even when used as a partition wall.

[0007] Therefore, an object of the present invention is to provide a partition wall having fire resistance while ensuring light weight and good workability.

Means for Solving the Problems

[0008] As a result of intensive studies, the present invention has found that the above problems can be solved by using, as a partition wall, a structure in which a non-combustible layer is provided on the surface of a base material including a cardboard layer, and has completed the following present invention. That is, the present invention provides the following [1] to [5]. [1] A partition wall comprising a base material including a cardboard layer and a non-combustible layer provided on at least a part of the surface of the base material. [2] The partition wall according to [1] above, wherein the base material is laminated with at least two or more types of corrugated cardboard layers. [3] The partition wall according to [1] or [2] above, wherein the non-combustible layer and the cardboard layer are adhered by a fire-resistant adhesive. [4] The partition wall according to any one of [1] to [3] above, wherein the base material includes a plurality of cardboard layers, and the plurality of cardboard layers are adhered by a fire-resistant adhesive. [5] The partition wall according to any one of [1] to [4] above, wherein the non-combustible layer is non-combustible paper.

Effects of the Invention

[0009] According to the present invention, it is possible to provide a partition wall having fire resistance while ensuring light weight and good workability.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Mode for Carrying Out the Invention

[0011] Hereinafter, the present invention will be described in more detail with reference to embodiments. FIG. 1 shows a schematic cross-sectional view of a partition wall according to an embodiment of the present invention. A partition wall 10 according to an embodiment of the present invention includes a base material 11 including a cardboard layer, and a non-combustible layer 20 provided on the surface of the base material 11. The partition wall 10 may be used as an inner wall for partitioning the interior space of a building inside the building.

[0012] Since the base material 11 of the partition wall 10 includes a cardboard layer, it is lightweight and easy to process, and excellent workability can be ensured. Further, since the non-combustible layer 20 is provided on the surface, fire resistance can be imparted to the partition wall 10. Furthermore, in the partition wall 10, since the base material 11 has a cardboard layer, an air layer is formed by a core 14 described later, and the heat insulation property is good. In addition, since the partition wall 10 has a cardboard layer, recycling and the like become easy, and it also contributes to the reduction of carbon dioxide emissions.

[0013] In the present embodiment, as shown in FIG. 1, the non-combustible layer 20 is preferably adhered to the surface of the base material 11 with an adhesive 21, particularly a fire-resistant adhesive. However, the adhesive 21 may be omitted, and the non-combustible layer 20 may be directly laminated on the base material 11. Note that FIG. 1 shows an example in which the base material 11 is composed of a two-layer cardboard layer called double flute, but the configuration of the base material 11 can be in various forms as described later and is not limited to the configuration of FIG. 1.

[0014] Hereinafter, each member constituting the partition wall will be described in detail. <Base Material> Specific examples of the base material are shown in FIGS. 2 and 3. The base material includes at least one corrugated cardboard layer, and each corrugated cardboard layer includes a core 14 and liners 15, 15 provided on both sides of the core 14. The core 14 is composed of corrugated flutes, and the tops of the corrugated flutes are adhered to the liners 15, 15 on both sides respectively. The adhesion between the liner 15 and the core 14 is preferably performed by an adhesive (not shown). The core 14 and the liner 15 are preferably composed of paper materials used for general corrugated cardboard.

[0015] As shown in FIG. 2(A), the base material 11 may be composed of a single corrugated cardboard layer called single flute. In this specification, the number of cores 14 provided in the thickness direction of the base material 11 is the number of layers of the corrugated cardboard layer. When the base material is composed of a single corrugated cardboard layer, as shown in FIG. 2(A), it is preferably a so-called double-sided corrugated cardboard including a core 14 and liners 15, 15 provided on both sides of the core.

[0016] As shown in FIG. 2(B), the base material 11 may be composed of two corrugated cardboard layers called double flute. Also, when there are a plurality of corrugated cardboard layers, as shown in FIG. 2(C), it may be composed of three corrugated cardboard layers, or although not shown, it may also be composed of four or more corrugated cardboard layers. By having two or more corrugated cardboard layers, the base material 11 has high mechanical strength and can be suitably used for the partition wall 10. Also, from the viewpoint of enhancing mechanical strength, it is more preferable for the base material 11 to have three or more corrugated cardboard layers. The corrugated cardboard layer of the base material 11 is not particularly limited, but from the viewpoint of preventing the thickness from becoming larger than necessary as a partition wall, for example, it may be about 10 layers or less, preferably 7 layers or less, and more preferably 5 layers or less.

[0017] In each core 14 constituting the corrugated flute, the number of steps is not particularly limited, but it may be about 20 to 110 per 30 cm, preferably 30 to 100, and more preferably 32 to 55. Also, in each core 14, the height of the step may be about 1 to 6 mm, preferably 1.5 to 5.5 mm, and more preferably 2.5 to 5.5 mm. The core 14 having the above number of steps and step height can be manufactured generally, and it is easy to improve the mechanical strength of the partition wall 10.

[0018] Each core 14 is not particularly limited, but it is preferably composed of A flute, B flute, C flute, or E flute defined in JIS Z 1516:2003. Note that for A flute, the number of steps per 30 cm is 34 ± 2, and the step height is generally about 5 mm. For B flute, the number of steps per 30 cm is 50 ± 2, and the step height is generally about 3 mm. For C flute, the number of steps per 30 cm is 40 ± 2, and the step height is generally about 4 mm. For E flute, the number of steps per 30 cm is 93 ± 5, and the step height is generally about 1.8 mm.

[0019] When the base material has two or more corrugated cardboard layers, as shown in FIGS. 2(B), (C) and FIGS. 3(A), (B), it is preferable that at least two or more types of corrugated cardboard layers of flute are laminated. Here, the flutes may be different in type due to different numbers of steps, but typically the step height also differs according to the number of steps. In the present invention, by using corrugated cardboard layers with different types of flutes as the base material, it is easy to obtain a partition wall having high mechanical strength.

[0020] When the base material 11 is composed of two or more types of corrugated cardboard layers, it is more preferable to have two or more types of corrugated cardboard layers with different types of flutes defined in JIS Z 1516:2003. When it is composed of two layers of corrugated cardboard layers, the base material is preferably any of, for example, AB flute, AC flute, AE flute, BC flute, BE flute, or CE flute. In addition, when the base material is composed of three or more corrugated layers, three or more types of flutes such as ABC flute, AABE flute, etc. may be provided, or two types of flutes such as ACA flute, AAB flute, AAC flute, etc. may be provided. That is, when the base material is composed of two or more types of corrugated layers and three or more corrugated layers are provided, some of them may be of the same type of flute as each other. Note that FIGS. 2(B), (C) and FIGS. 3(A), (B) are examples in which two different types of corrugated layers are laminated, and FIGS. 2(C) and 3(B) are examples in which corrugated layers of the same type are further provided.

[0021] When the base material 11 is composed of two corrugated layers, as shown in FIG. 2(B), it may have three liners 15 and a core 14 disposed between the liners 15, 15 respectively. Similarly, when the base material 11 is composed of three corrugated layers, as shown in FIG. 2(C), it may have four liners 15 and a core 14 disposed between each of the liners 15, 15 respectively. That is, in the structures shown in FIGS. 2(B), (C), adjacent cores 14 may be adhered to one same liner 15 therebetween. Even when it is composed of four or more corrugated layers, it may have a similar configuration.

[0022] When the base material 11 has two or more corrugated layers, as shown in FIGS. 3(A), (B), two liners 15, 15 may be provided between adjacent cores 14, 14, and in that case, adjacent cores 14, 14 may be adhered to separate liners 15. In the case of the configuration shown in FIGS. 3(A), (B), the corrugated layer composed of the core 14 and a pair of liners 15, 15 on both sides thereof may be adhered to the liner 15 constituting another corrugated layer via the adhesive 16. With such a configuration, the base material 11 can be obtained by adhering a general-purpose corrugated board with the adhesive 16. Therefore, it becomes easy to manufacture the partition wall 10 with high mechanical strength by an easy manufacturing method. In addition, in the configuration shown in FIG. 3, there were two liners 15 between adjacent cores 14 and 14. However, the number of liners between adjacent cores 14 and 14 may be two as shown in FIGS. 3(A) and (B) for one of them, and one as shown in FIGS. 2(B) and (C) for the other. Also, the number of liners between adjacent cores 14 and 14 is not limited to one or two, and may be three or more.

[0023] When the base material 11 has two or more corrugated cardboard layers, it is preferable to use a refractory adhesive as the adhesive for bonding between the corrugated cardboard layers. Here, the adhesive for bonding between the corrugated cardboard layers may be the adhesive 16 for bonding between the liners 15 and 15 in the configurations shown in FIGS. 3(A) and (B). On the other hand, in the configurations shown in FIGS. 2(B) and (C), the adhesive for bonding between the corrugated cardboard layers may be an adhesive (not shown) that bonds at least one of the adjacent cores 14 and 14 and the liner 15 disposed between these adjacent cores 14 and 14. By using a refractory adhesive as the adhesive for bonding between the corrugated cardboard layers, a partition wall with high fire resistance can be manufactured. Also, for example, by laminating a plurality of sheets in the thickness direction using a refractory adhesive for at least one of a commonly used single flute corrugated cardboard (double-sided corrugated cardboard or single-sided corrugated cardboard) or a double flute corrugated cardboard, a base material 11 with high fire resistance and mechanical strength can be easily manufactured. Also, when the number of corrugated cardboard layers is three or more, it is preferable that all the corrugated cardboard layers are bonded by a refractory adhesive. However, some of the corrugated cardboard layers may be bonded by a refractory adhesive, and some of the corrugated cardboard layers may be bonded by an adhesive other than the refractory adhesive.

[0024] The refractory adhesive is not particularly limited as long as it can adhere to paper materials and has fire resistance, but inorganic adhesives are preferred. Examples of inorganic adhesives include water glass-based adhesives that use water glass as an adhesive component. The water glass-based adhesive may be composed of water glass composed of water and silicates such as sodium silicate, but may also contain appropriately inorganic fillers and other additives in addition to water glass. By using a water glass-based adhesive as the refractory adhesive, while improving the fire resistance, it becomes easier to adhere liners made of paper materials to each other or to adhere a liner to a core.

[0025] The thickness of the base material 11 is not particularly limited, but for example, it may be about 5 to 30 mm, preferably 9 to 25 mm, and more preferably 12 to 25 mm. By the thickness of the base material 11 being equal to or greater than the above lower limit value, appropriate mechanical strength can be imparted to the partition wall 10. Also, by making it equal to or less than the above upper limit value, the partition wall 10 can be appropriately used in a building without narrowing the living space of the building or the like. Note that the thickness of the base material 11 is the total thickness of the base material 11.

[0026] <Non-combustible layer> The non-combustible layer 20 is preferably composed of non-combustible paper. As the non-combustible paper, for example, inorganic paper can be used, such as inorganic paper mainly composed of magnesium silicate, paper containing aluminum hydroxide, sheets made of rock wool, etc., and sheets containing phosphoric acid-based and boric acid-based flame retardants. Also, as long as the non-combustible layer 20 is a sheet-like non-combustible material, materials other than non-combustible paper can also be used, for example, metal foils, sheets made of aluminum, iron, SUS, ceramics, etc.

[0027] As the non-combustible paper constituting the non-combustible layer and sheet-like non-combustible materials other than non-combustible paper, it is preferable to use materials recognized as non-combustible materials based on Article 2, Paragraph 9 of the Building Standards Act.

[0028] In the present invention, the non-combustible layer 20 may be provided only on one surface of the base material 11, but it is preferably provided on both surfaces of the base material 11. The surface of the base material 11 on which the non-combustible layer 20 is provided is a plane perpendicular to the thickness direction of the partition wall 10 and constitutes the main surface of the base material 11. And the surface of the partition wall 10 provided with the non-combustible layer 20 may preferably constitute either the front surface or the back surface of the partition wall 10, which will be described later. The partition wall 10 has good fire resistance by providing the non-combustible layer 20 on one surface of the base material 11. Further, when the non-combustible layer 20 is provided on both surfaces of the partition wall 10, it becomes difficult to burn from either surface during a fire, and the fire resistance is further improved.

[0029] The non-combustible layer 20 may be provided over the entire surface or partially on each surface of the base material 11, but it is preferably provided over the entire surface from the viewpoint of improving fire resistance. Further, when provided partially, it is preferable that the non-combustible layer 20 is provided on most of each surface. Specifically, for example, the non-combustible layer 20 may be provided on an area of 50% or more, preferably 80% or more, more preferably 90% or more of each surface area.

[0030] The thickness of the non-combustible layer 20 is not particularly limited, but it may be about 0.02 to 2.0 mm, preferably 0.1 to 1.0 mm. By setting the thickness to be equal to or greater than the above lower limit value, appropriate fire resistance can be imparted to the partition wall 10. Also, by setting it to be equal to or less than the above upper limit value, it is possible to prevent the thickness of the partition wall 10 from becoming unnecessarily large or the non-combustible layer 20 from peeling off from the base material 11 due to its own weight. Here, the thickness of the non-combustible layer 20 means the thickness of each non-combustible layer 20 provided on each surface of the base material.

[0031] The non-combustible layer 20 is preferably formed by bonding a sheet-like non-combustible material such as non-combustible paper to the base material 11 with an adhesive 21, particularly a fire-resistant adhesive. By bonding the non-combustible layer 20 to the base material 11 with a fire-resistant adhesive, a partition wall 10 with high fire resistance can be manufactured by an easy manufacturing method.

[0032] Incidentally, since specific examples of the refractory adhesive are as described above, the description thereof is omitted. However, a water glass-based adhesive is also preferable as the refractory adhesive used as the adhesive 21. By using a water glass-based adhesive, it becomes possible to bond a non-combustible paper and a cardboard layer composed of paper materials such as a liner with high adhesive strength, and a partition wall 10 with higher mechanical strength can be obtained.

[0033] <Method for manufacturing partition wall> The method for manufacturing the partition wall is not particularly limited, but it can be manufactured by forming a cardboard layer by a known manufacturing method and laminating a non-combustible layer on the surface of the cardboard layer. The method for laminating the non-combustible layer is not particularly limited, but it is preferable to apply an adhesive, preferably a refractory adhesive, to either the surface of the cardboard layer or a sheet-like non-combustible material, and bond the sheet-like non-combustible material to the surface of the cardboard layer via the adhesive. When making the cardboard layer into multiple layers, an adhesive, preferably a refractory adhesive, is applied to at least one of the surfaces (for example, the surface of the liner or the surface of the core) of a single flute cardboard made of double-sided cardboard or single-sided cardboard, or a double flute cardboard, and the plurality of cardboard layers are bonded together via the adhesive to make the cardboard layer into multiple layers. Depending on the type of adhesive, the cardboard layer bonded with the adhesive and the sheet-like non-combustible material, or the cardboard layers themselves, may be subjected to post-treatment to solidify or cure the adhesive. For example, when the adhesive is a water glass-based adhesive, after bonding the cardboard layer and the sheet-like non-combustible material, or the cardboard layers themselves with the adhesive, heating or the like may be performed to cure the water glass.

[0034] <Partition wall structure> FIG. 4 shows the partition wall structure of a building to which the partition wall of the present invention is applied. As shown in Fig. 4, the partition wall structure 30 includes the above-described partition wall 10 and a support member 31 that supports the partition wall 10. The support member 31 is provided, for example, on the foundation 41 of a building. The support member 31 is not particularly limited, but it is preferably assembled into a frame shape by a vertical frame member 33 extending in the vertical direction and a horizontal frame member 34 extending in the horizontal direction. The vertical frame member 33 and the horizontal frame member 34 may be made of wood or may be constituted by a metal such as a steel frame.

[0035] The partition wall 10 may be fixed to the support member 31 by a known fixing member. Specifically, as shown in Fig. 4, the partition wall 10 may be fixed to the support member 31 by screws 35 such as nails and screws, or may be fixed by a stay (not shown). The screws 35 and the stay (not shown) may penetrate from the front surface to the back surface of the partition wall 10 and reach the frame member 32 and be fixed to the frame member 32. Further, the partition wall 10 may be fixed by a double-sided adhesive tape or the like disposed between the back surface of the partition wall 10 and the support frame 31. The double-sided adhesive tape may be an adhesive tape having a tape base material and adhesive layers on both sides of the tape base material, or may be a so-called base material-less double-sided adhesive tape without a base material. Furthermore, the partition wall 10 may be fixed to the support member 31 by combining two or more of screws, stays, and adhesive tapes.

[0036] The partition wall 10 has a cardboard layer as the base material 11, and its front and back surfaces are constituted by a non-combustible layer 20 such as non-combustible paper, or when the non-combustible layer is not provided, it is constituted by the cardboard layer. Therefore, the partition wall 10 is lightweight and can be easily attached to the support frame 31 by a fixing member for fixing a conventional partition wall such as screws, stays, and double-sided adhesive tapes to the support frame, resulting in good workability. Also, since the partition wall 10 is provided with the non-combustible layer 20 on its back surface or surface, the fire resistance of the partition wall structure 30 is improved.

Explanation of Reference Numerals

[0037] 10 Partition wall 11 Base material 14 Core 15 Liner 16, 21 Adhesive 20 Non-combustible layer 30 Partition wall structure 31 Support material

Claims

1. A partition wall comprising a base material including a corrugated cardboard layer and a non-combustible layer provided on at least a part of the surface of the base material.

2. The partition wall according to claim 1, wherein the base material is laminated with at least two or more types of corrugated cardboard layers.

3. The partition wall according to claim 1, wherein the non-combustible layer and the corrugated cardboard layer are adhered by a fire-resistant adhesive.

4. The partition wall according to claim 1, wherein the base material includes a plurality of corrugated cardboard layers, and the plurality of corrugated cardboard layers are adhered by a fire-resistant adhesive.

5. The partition wall according to any one of claims 1 to 4, wherein the non-combustible layer is non-combustible paper.

Images