Fire-resistant resin composition

Abstract

To provide a fire-resistant resin composition that can render its residues hard even when filled with a high proportion of a thermal expansion material, and can sufficiently close a partition penetration part.SOLUTION: A fire-resistant resin composition contains a resin, a plasticizer, an additive, and a thermally-expandable laminar inorganic material and is used in the fireproof construction of a building. The resin contains at least one selected from the group consisting of polyvinyl acetal, polybutene, and a rubber component. The additive is at least one selected from the group consisting of a flame retardant, an endothermic agent, a lubricant, and an inorganic filler.SELECTED DRAWING: None

Description

Technical Field

[0001] The present invention relates to a fire-resistant resin composition, and more particularly, to a fire-resistant resin composition having expansibility capable of closing a partition penetration portion.

Background Art

[0002] In buildings such as apartment houses, office buildings, and schools, partition penetration portions may be provided in partition portions such as walls to allow long insertion bodies such as cables and pipes to pass through. When a fire breaks out in any compartment, the partition penetration portion is required to have a fire prevention structure (fire-resistant structure) to prevent the spread of fire to other compartments. The partition portion generally consists of two wall portions, and a hollow wall in which the space between the wall portions is a hollow portion is common.

[0003] As a method of making the partition penetration portion a fire-resistant structure, for example, a method of filling an amorphous filler such as a fire-resistant putty in the gap between the long insertion body and the through hole is known. When using an amorphous filler, a cylindrical member made of a refractory material may be disposed between the inside of the through hole of each wall portion and the insertion body (see, for example, Patent Documents 1 and 2).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, when using an amorphous filler for the fireproof treatment of the partition penetration part, there may be variations among workers, and sufficient fire resistance performance may not be obtained. Also, when installing refractory materials and their accessories, etc. inside the building body, it may not be clear how much (quantity, thickness, length, etc.) they are installed, or it may not be possible to determine whether they are installed as specified. Therefore, in order to confirm whether the refractory materials, etc. are installed as specified, it is necessary to destroy the partition penetration treatment structure and check the internal structure.

[0006] Also, in a partition penetration structure where long insertion bodies such as cables and pipes are inserted inside, when the insertion body is moved after applying the partition penetration treatment structure, the refractory materials, etc. installed inside may shift from their appropriate positions. Also, due to external forces such as earthquakes, the refractory materials, etc. may shift from their appropriate positions. Furthermore, if the refractory material does not expand uniformly but expands unevenly, it may shift or fall off from its appropriate position. Thus, due to the shift of the refractory materials, etc. from their appropriate positions, it becomes difficult to exhibit the fire resistance performance desired for the fireproof structure of the partition penetration part.

[0007] Based on the above problems, a method of installing a thermally expandable sheet having a high expansion ratio at the partition penetration part without using an amorphous filler inside the building body can be considered. The thermally expandable sheet can be obtained, for example, by highly filling a thermal expansion material, and can have a high expansion ratio. When a fire occurs, it can expand sufficiently by the flame, block the partition penetration part, and suppress the spread of fire. However, by highly filling the thermal expansion material, the residue of the sheet tends to become brittle and may be blown away by the flame or the like. Therefore, there may be cases where the partition penetration part cannot be sufficiently blocked and the spread of fire cannot be suppressed.

[0008] Therefore, an object of the present invention is to provide a fire-resistant resin composition that can appropriately block the partition penetration part and suppress the spread of fire when a fire occurs, and can harden the expansion residue to maintain the blockage of the partition penetration part.

Means for Solving the Problems

[0009] The present invention has been made to solve the above problems, and the gist of the present invention is as follows. [1] A fire-resistant resin composition containing a resin, a plasticizer, an additive, and a thermally expandable layered inorganic substance, and used for a fireproof structure of a building, wherein the resin contains at least one selected from the group consisting of polyvinyl acetal, polybutene, and a rubber component, and the additive is at least one selected from the group consisting of a flame retardant, an endothermic agent, a lubricant, and an inorganic filler. [2] The fire-resistant resin composition according to [1], wherein the rubber component is at least one selected from the group consisting of chloroprene rubber, natural rubber, butyl rubber, styrene-butadiene rubber, nitrile-butadiene rubber, ethylene-propylene rubber, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, and acrylic rubber. [3] The fire-resistant resin composition according to [1] or [2], wherein the resin further contains at least one selected from the group consisting of polyphenylene oxide and petroleum resin. [4] The fire-resistant resin composition according to any one of [1] to [3], wherein the polyvinyl acetal is polyvinyl butyral. [5] The fire-resistant resin composition according to any one of [1] to [4], wherein the content of the plasticizer is 0.5 to 100 parts by mass per 100 parts by mass of the resin. [6] The fire-resistant resin composition according to any one of [1] to [5], wherein the content of the thermally expandable layered inorganic substance is 10 to 50 parts by mass per 100 parts by mass of the fire-resistant resin composition. [7] The fire-resistant resin composition according to any one of [1] to [6], wherein the ratio (resin / powder) of the content of the resin to the powder is 0.2 to 3. [8] The fire-resistant resin composition according to any one of [1] to [7], wherein the thermally expandable layered inorganic substance is expandable graphite. [9] A refractory made of the fire-resistant resin composition according to any one of [1] to [8].

[10] The refractory according to [9], having an expansion ratio of 5 times or more at 300 °C and an expansion ratio of 20 times or more at 600 °C.

[11] The residue hardness at 300 °C is 4 kgf / cm 2 or more, and the residue hardness at 600 °C is 0.3 kgf / cm 2 or more. The refractory according to [9] or

[10] .

[12] The refractory according to any one of [9] to

[11] , having a residue retention rate of 80% or more at 300 °C and a residue retention rate of 50% or more at 600 °C.

[13] The refractory according to any one of [9] to

[12] , wherein the thermal expansion start temperature of the refractory resin composition is 100 to 300 °C.

[14] The refractory according to any one of [9] to

[13] , having a thickness of 0.1 to 10 mm.

[15] A refractory laminate comprising the refractory according to any one of [9] to

[14] , a base material integrated with the refractory, and an adhesive layer.

[16] A partition penetration treatment material containing the refractory according to any one of [9] to

[14] or the refractory laminate according to

[15] .

[17] A partition penetration treatment structure containing the partition penetration treatment material according to

[16] .

[18] A construction method of the partition penetration treatment structure according to

[17] . [Effect of the Invention]

[0010] According to the present invention, when a fire occurs, it is possible to provide a refractory resin composition that can block the partition penetration part, suppress the spread of fire, and harden the expansion residue to maintain the blockage of the partition penetration part. [Brief Description of the Drawings]

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Embodiments for Carrying Out the Invention

[0012] Hereinafter, the present invention will be described in detail. The fire-resistant resin composition of the present invention contains a resin, a plasticizer, a specific additive described later, and a thermally expandable layered inorganic substance.

[0013] (Resin) The fire-resistant resin composition of the present invention contains a resin containing at least one selected from the group consisting of polyvinyl acetal, polybutene, and a rubber component. By using these resins, a refractory material with good fire resistance and residue hardness can be obtained. Also, by using a rubber component, high fire resistance and residue hardness can be obtained, and by using polybutene or polyvinyl acetal, adhesiveness is easily obtained. Among these, it is preferable to contain a resin containing at least one selected from the group consisting of polybutene and a rubber component.

[0014] <Polyvinyl acetal> The polyvinyl acetal is not particularly limited as long as it is a polyvinyl acetal obtained by acetalizing polyvinyl alcohol with an aldehyde, but polyvinyl butyral (PVB) is preferable. By using polyvinyl butyral, it is possible to increase the mechanical strength even when the amount of resin relative to the fire-resistant additive is relatively small. Therefore, even if the thickness of the refractory material is reduced, a certain mechanical strength can be ensured. The hydroxyl group content of the above polyvinyl acetal is preferably 20 to 40 mol%. By setting the hydroxyl group content to 20 mol% or more, the polarity of the polyvinyl acetal increases, the binding force with the refractory additive becomes stronger, and the mechanical strength of the refractory is likely to be improved. Also, by setting the hydroxyl group content to 40 mol% or less, it is possible to prevent the refractory from becoming too hard. The above hydroxyl group content is more preferably 23 mol% or more, and even more preferably 26 mol% or more. Also, the above hydroxyl group content is more preferably 37 mol% or less, and even more preferably 35 mol% or less.

[0015] The degree of acetalization of the above polyvinyl acetal is preferably 40 to 80 mol%. By setting the degree of acetalization within the above range, the hydroxyl group content described above can be within a desired range, and the mechanical strength of the refractory is likely to be improved. The degree of acetalization is more preferably 55 mol% or more, and even more preferably 65 mol% or more, and also more preferably 76 mol% or less. Also, the acetyl group content of the above polyvinyl acetal is preferably 0.1 to 30 mol%. When the acetyl group content is within this range, it has excellent moisture resistance, excellent compatibility with plasticizers, exhibits high flexibility, and improves handleability. Also, by setting the acetyl group content within these ranges, the hydroxyl group content described above can be within a desired range, and the mechanical strength of the refractory is likely to be improved. From these viewpoints, the acetyl group content is more preferably 0.2 mol% or more, even more preferably 0.5 mol% or more, also more preferably 15 mol% or less, and even more preferably 7 mol% or less. Note that the degree of acetalization, hydroxyl group content, and acetyl group content can be measured and calculated by a method conforming to, for example, JIS K6728 "Test Methods for Polyvinyl Butyral".

[0016] The degree of polymerization of the polyvinyl acetal is preferably 200 to 3000. By setting the degree of polymerization within these ranges, the refractory additive can be appropriately dispersed in the refractory. The degree of polymerization is more preferably 250 or more, and even more preferably 300 or more. Lowering the degree of polymerization of polyvinyl acetal decreases the viscosity, making it easier to disperse refractory additives in the refractory material and improving the mechanical strength of the refractory material. From such a perspective, the degree of polymerization of the polyvinyl acetal resin is preferably 2000 or less, more preferably 1500 or less, and even more preferably 1000 or less. Note that the degree of polymerization of the polyvinyl acetal resin refers to the viscosity-average degree of polymerization measured based on the method described in JIS K6728.

[0017] The 10 mass% ethanol / toluene viscosity of the polyvinyl acetal resin is preferably 5 mPa·s or more, more preferably 10 mPa·s or more, and even more preferably 15 mPa·s or more. Also, the 10 mass% ethanol / toluene viscosity is preferably 500 mPa·s or less, more preferably 300 mPa·s or less, and even more preferably 200 mPa·s or less. By setting the 10 mass% ethanol / toluene viscosity of the polyvinyl acetal resin as described above, it becomes easier to disperse refractory additives in the refractory material and the mechanical strength of the refractory material is improved. Note that the 10 mass% ethanol / toluene viscosity is the value measured as follows. Take 150 ml of an ethanol / toluene (weight ratio 1:1) mixed solvent in an Erlenmeyer flask, add the weighed sample thereto to make the resin concentration 10 wt%, and shake and dissolve in a constant temperature room at 20°C. Keep the solution at 20°C and measure the viscosity using a BM-type viscometer to obtain the 10 mass% ethanol / toluene viscosity.

[0018] The above-mentioned aldehyde is not particularly limited, but generally, aldehydes having 1 to 10 carbon atoms are preferably used. The aldehydes having 1 to 10 carbon atoms are not particularly limited. For example, n-butyl aldehyde, isobutyl aldehyde, n-valeraldehyde, 2-ethylbutyl aldehyde, n-hexyl aldehyde, n-octyl aldehyde, n-nonyl aldehyde, n-decyl aldehyde, formaldehyde, acetaldehyde, benzaldehyde, etc. may be mentioned. Among them, n-butyl aldehyde, n-hexyl aldehyde, and n-valeraldehyde are preferred, and n-butyl aldehyde is more preferred. These aldehydes may be used alone or in combination of two or more.

[0019] The resin used in the present invention may consist only of polyvinyl acetal, or may be used in combination with other resins. The content of polyvinyl acetal is preferably 1 to 100 parts by mass, more preferably 5 to 80 parts by mass, and still more preferably 10 to 50 parts by mass with respect to 100 parts by mass of the resin.

[0020] <Rubber component> As the rubber component used in the present invention, it is preferably at least one selected from the group consisting of chloroprene rubber, natural rubber, butyl rubber, styrene-butadiene rubber, nitrile-butadiene rubber, ethylene-propylene rubber, ethylene-propylene-diene rubber and other ethylene-propylene rubbers, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, and acrylic rubber. By using these rubber components in the refractory resin composition, the fire resistance of the refractory made of the composition is improved. Among them, it is more preferable to contain rubber components containing chlorine atoms such as chloroprene rubber, chlorosulfonated polyethylene rubber, and epichlorohydrin rubber. Also, it is preferable that the rubber component contains at least butyl rubber. When butyl rubber is used as the rubber component, it becomes easier to impart adhesiveness to the refractory obtained from the composition. Further, from the viewpoint of improving adhesiveness, it is also preferable that butyl rubber is used in combination with polyvinyl acetal, polybutene, a petroleum resin described later, or a combination of two or more of these.

[0021] The content of the rubber component in the present invention is not particularly limited, but is preferably 10 to 100 parts by mass, more preferably 15 to 95 parts by mass, and still more preferably 20 to 93 parts by mass with respect to 100 parts by mass of the resin. Also, the content of the rubber component containing a chlorine atom is not particularly limited, but is preferably 0 to 80 parts by mass, more preferably 5 to 70 parts by mass, and still more preferably 10 to 65 parts by mass with respect to 100 parts by mass of the resin.

[0022] As the rubber component used in the present invention, the Mooney viscosity ML(1+4) at 100 °C is preferably 10 to 150, more preferably 20 to 140, and still more preferably 30 to 130. When the Mooney viscosity ML(1+4) is within the above range, the processability and moldability are good, and it is easy to produce the target sheet and molded body. Also, since it is uniformly filled, the effect of good refractory performance can be obtained. Further, when containing a rubber component containing a chlorine atom such as chloroprene rubber, epichlorohydrin rubber, chlorosulfonated polyethylene rubber, nitrile-butadiene rubber-PVC copolymer, the chlorine content of the rubber component containing a chlorine atom is preferably 5 to 50, more preferably 8 to 45, and still more preferably 10 to 40. By setting these to be not less than the lower limit values, the fire resistance of the refractory can be improved. Also, by setting these to be not more than the upper limit values, the generation of chlorine-derived toxic gases during a fire can be suppressed. Considering these points, it is preferable to contain butyl rubber, chloroprene rubber, and nitrile-butadiene rubber.

[0023] <Polybutene> When using polybutene in the present invention, it is not particularly limited, and examples include homopolymers of isobutene, copolymers of isobutene and n-butene, and polybutene made into an emulsion by emulsification. By using polybutene in the refractory resin composition, the adhesiveness of the refractory made of the composition is improved, and it can be easily attached to fittings and the like during construction without using a double-sided tape or the like. Among these, a copolymer of isobutene and n-butene is preferable. Moreover, the polybutene has a weight average molecular weight measured by a method conforming to ASTM D 2503 of, for example, 300 to 5000, preferably 300 to 2000.

[0024] The content of polybutene is not particularly limited, but is preferably 3 to 70 parts by mass, more preferably 5 to 65 parts by mass, and still more preferably 10 to 60 parts by mass with respect to 100 parts by mass of the resin.

[0025] The above-mentioned resin may be used alone or in combination of two or more. However, from the viewpoint of more effectively exhibiting the fire resistance and residue hardness, it is preferable to use two or more in combination.

[0026] In the present invention, when two or more resins are used in combination, examples of the resin combination include a combination of polyvinyl acetal and a rubber component, polyvinyl acetal and polybutene, polyvinyl acetal, polybutene and a rubber component, and a combination of polybutene and a rubber component. Among them, from the viewpoint of improving the residue hardness and residue retention rate of the refractory, it is more preferable to use polybutene and a rubber component in combination.

[0027] In the present invention, when two or more resins are used in combination, the content ratio of each resin is not particularly limited. For example, when polyvinyl acetal and a rubber component are used in combination, the content of polyvinyl acetal is preferably 50 to 300 parts by mass, more preferably 100 to 200 parts by mass, and still more preferably 120 to 180 parts by mass with respect to 100 parts by mass of the rubber component. When polyvinyl acetal and polybutene are used in combination, the content of polyvinyl acetal is preferably 30 to 150 parts by mass, more preferably 40 to 120 parts by mass, and still more preferably 50 to 100 parts by mass with respect to 100 parts by mass of the polybutene content. When polybutene and a rubber component are used in combination, the content of polybutene is preferably 5 to 300 parts by mass, more preferably 10 to 270 parts by mass, and still more preferably 15 to 240 parts by mass with respect to 100 parts by mass of the rubber component content.

[0028] In addition to the resins described above, the resin constituting the refractory resin composition of the present invention preferably contains at least one selected from the group consisting of polyphenylene oxide and petroleum resin. The polyphenylene oxide and the petroleum resin may contain one of them or both of them.

[0029] <Polyphenylene Oxide> The polyphenylene oxide may be an unmodified polyphenylene oxide such as poly(2,6-dimethyl-1,4-phenylene oxide), or a modified polyphenylene oxide. By using polyphenylene oxide, the residue hardness and the residue retention rate can be improved. When the resin contains polyphenylene oxide, the content of polyphenylene oxide is preferably 1 to 60 parts by mass, more preferably 3 to 50 parts by mass, and even more preferably 5 to 45 parts by mass per 100 parts by mass of the resin, from the viewpoint of adjusting the residue hardness and the residue retention rate of the refractory material to a desired range.

[0030] In the present invention, when using polyphenylene oxide, it is preferably used in combination with at least one resin selected from the group consisting of polybutene and rubber components, and more preferably used in combination with both polybutene and rubber components. When polyphenylene oxide is used in combination with a rubber component, it may be used in combination with a chlorine-containing rubber component or with other rubber components (chlorine-free rubber components). By using polyphenylene oxide, even without using a chlorine-containing rubber component, the residue hardness and the residue retention rate of the refractory material can be improved, and sufficient fire resistance can be ensured.

[0031] <Petroleum Resin> Examples of the petroleum resin include aliphatic hydrocarbon resin-based petroleum resin, aromatic hydrocarbon resin-based petroleum resin, alicyclic saturated hydrocarbon resin-based petroleum resin, copolymer-based petroleum resin, hydrogenated petroleum resin, petroleum resin emulsion, and the like. By using petroleum resin, the adhesiveness of the refractory material can be improved, and good workability can be obtained. When the resin contains a petroleum resin, from the viewpoint of improving the adhesiveness of the refractory and obtaining good workability, the content of the petroleum resin is preferably 2 to 30 parts by mass, more preferably 3 to 20 parts by mass, and even more preferably 4 to 10 parts by mass with respect to 100 parts by mass of the resin.

[0032] (Plasticizer) The refractory resin composition of the present invention contains a plasticizer. By containing a plasticizer, flexibility is imparted to the composition, whereby when manufacturing the composition, it becomes easier to uniformly mix the respective components of the composition. As a result, the residue hardness and residue retention rate of the refractory made of the composition can be adjusted to a desired range. In addition, good workability can be obtained, and it becomes easier to expand during a fire, thereby also improving the fire resistance. Specific examples of the plasticizer include, for example, phthalate plasticizers such as di-2-ethylhexyl phthalate (DOP), dibutyl phthalate (DBP), diheptyl phthalate (DHP), diisodecyl phthalate (DIDP); adipate esters such as di-2-ethylhexyl adipate (DOA), diisobutyl adipate (DIBA), dibutyl adipate (DBA); adipic acid ether ester plasticizers such as dibutoxyethyl adipate, di(butoxyethoxyethyl) adipate, di(methoxytetraethylene glycol) adipate, di(methoxypentaethylene glycol) adipate, (methoxytetraethylene glycol)(methoxypentaethylene glycol) adipate; fatty acid ester plasticizers such as adipic acid polyester; epoxidized ester plasticizers such as epoxidized soybean oil; polyether ester plasticizers; trimellitate ester plasticizers such as tri-2-ethylhexyl trimellitate (TOTM), triisononyl trimellitate (TINTM); phosphate ester plasticizers such as trimethyl phosphate (TMP), triethyl phosphate (TEP); and process oils such as mineral oil.

[0033] As the plasticizer used in the present invention, from the viewpoint of preventing crystallization of the resin and imparting flexibility, etc., plasticizers having an ester structure, namely phthalic acid ester plasticizers such as di-2-ethylhexyl phthalate (DOP), dibutyl phthalate (DBP), diheptyl phthalate (DHP), diisodecyl phthalate (DIDP), adipic acid ester plasticizers such as di-2-ethylhexyl adipate (DOA), diisobutyl adipate (DIBA), dibutyl adipate (DBA), and adipic acid dibutoxyethyl, adipic acid di(butoxyethoxyethyl), adipic acid di(methoxytetraethylene glycol), adipic acid di(methoxypentaethylene glycol), adipic acid (methoxytetraethylene glycol)(methoxypentaethylene glycol), etc., adipic acid ether ester plasticizers, fatty acid ester plasticizers such as adipic acid polyester, epoxidized ester plasticizers such as epoxidized soybean oil, polyether ester plasticizers, trimellitic acid ester plasticizers such as tri-2-ethylhexyl trimellitate (TOTM), triisononyl trimellitate (TINTM), and phosphate ester plasticizers such as trimethyl phosphate (TMP), triethyl phosphate (TEP), at least one selected from the group consisting thereof is preferable.

[0034] Among the plasticizers having an ester structure, at least one selected from the group consisting of plasticizers having an ether structure, namely polyether ester plasticizers, adipic acid dibutoxyethyl, adipic acid di(butoxyethoxyethyl), adipic acid di(methoxytetraethylene glycol), adipic acid di(methoxypentaethylene glycol), adipic acid (methoxytetraethylene glycol)(methoxypentaethylene glycol), etc., adipic acid ether ester plasticizers, is more preferable. In the present invention, the plasticizer can be used alone or in combination of two or more.

[0035] When the fire-resistant resin composition contains a plasticizer, the content of the plasticizer in the fire-resistant resin composition is in the range of, for example, 0.5 parts by mass or more and 100 parts by mass or less, preferably 1 part by mass or more and 80 parts by mass or less, more preferably 10 parts by mass or more and 70 parts by mass or less, and still more preferably 20 parts by mass or more and 50 parts by mass or less, based on 100 parts by mass of the resin component. When the plasticizer is at or above these lower limit values, flexibility is imparted and the moldability tends to be good. Also, by setting it at or below the upper limit value, an appropriate strength is imparted to the molded body. And by being within the above range, it becomes easy to adjust the residue hardness and residue retention rate of the refractory to a desired range.

[0036] (Thermally expandable layered inorganic substance) The thermally expandable layered inorganic substance is a conventionally known substance that expands upon heating, and examples include vermiculite, thermally expandable graphite, etc., and among them, thermally expandable graphite is preferable. As the thermally expandable layered inorganic substance, particulate or flaky ones may be used. Since the thermally expandable layered inorganic substance expands upon heating to form a large amount of voids, the refractory using the thermally expandable layered inorganic substance of the present invention suppresses the spread of fire and extinguishes the fire when ignited. Thermally expandable graphite is obtained by treating powders such as natural flaky graphite, pyrolytic graphite, and kish graphite with inorganic acids such as concentrated sulfuric acid, nitric acid, and selenic acid, and strong oxidizing agents such as concentrated nitric acid, perchloric acid, perchlorates, permanganates, dichromates, and hydrogen peroxide to form graphite intercalation compounds. The produced thermally expandable graphite is a crystalline compound that maintains the layered structure of carbon. As the thermally expandable graphite used in the present invention, those in which the thermally expandable graphite obtained by acid treatment is neutralized with ammonia, aliphatic lower amines, alkali metal compounds, alkaline earth metal compounds, etc. can also be used. Examples of the aliphatic lower amines include monomethylamine, dimethylamine, trimethylamine, ethylamine, propylamine, butylamine, etc. Examples of the alkali metal compounds and alkaline earth metal compounds include hydroxides, oxides, carbonates, sulfates, organic acid salts, etc. of potassium, sodium, calcium, barium, magnesium, etc.

[0037] The particle size of the expandable graphite is preferably 20 to 200 mesh. When the particle size of the expandable graphite is within the above range, it is easy to expand and create a large amount of voids, so the fire resistance is improved. Also, the dispersibility in the resin is improved. The average aspect ratio of the expandable graphite is preferably 2 or more, more preferably 5 or more, and still more preferably 10 or more. The upper limit of the average aspect ratio of the expandable graphite is not particularly limited, but from the viewpoint of preventing cracking of the expandable graphite, it is preferably 1,000 or less. When the average aspect ratio of the expandable graphite is 2 or more, it is easy to expand and create a large amount of voids, so the flame retardancy is improved. The average aspect ratio of the expandable graphite is the average value of the values obtained by measuring the maximum dimension (major axis) and the minimum dimension (minor axis) for each of 10 expandable graphites and dividing the maximum dimension (major axis) by the minimum dimension (minor axis). The major axis and minor axis of the expandable graphite can be measured using, for example, a field emission scanning electron microscope (FE-SEM).

[0038] Also, in the fire-resistant resin composition of the present invention, the content of the expandable layered inorganic substance is preferably 5 parts by mass or more, more preferably 10 parts by mass or more, still more preferably 20 parts by mass or more, and even more preferably 30 parts by mass or more with respect to 100 parts by mass of the fire-resistant resin composition. Also, the above content of the expandable layered inorganic substance is preferably 60 parts by mass or less, more preferably 50 parts by mass or less, and still more preferably 48 parts by mass or less. When it is above the above lower limit value, sufficient expandability can be obtained and it becomes possible to sufficiently block the partition penetration part. Also, in the present invention, even when the expandable layered inorganic substance is highly filled, the hardness of the expansion residue becomes high and it becomes relatively easy to maintain the fire resistance. On the other hand, when it is below the above upper limit value, the moldability becomes good, and the surface property, mechanical physical properties, flexibility, etc. of the seal member also become good. Also, by selecting the content of the expandable graphite within the above range, it becomes easy to adjust the expansion ratio within a desired range.

[0039] (Specific additive) The fire-resistant resin composition of the present invention contains, as specific additives, at least one selected from flame retardants, heat absorbers, lubricants, and inorganic fillers, in addition to the above-mentioned thermally expandable layered inorganic substances. These may be used individually or in combination of two or more. By containing specific additives, the fire-resistant resin composition can increase the residue hardness and residue retention rate of the fire-resistant resin composition.

[0040] <Flame retardant> Flame retardants, heat absorbers, and inorganic fillers are fire-resistant additives that improve the fire resistance of the fire-resistant resin composition. Examples of the flame retardant used in the present invention include phosphorus atom-containing compounds. Examples of phosphorus atom-containing compounds include red phosphorus, various phosphate esters such as triphenyl phosphate, tricresyl phosphate, trixylenyl phosphate, cresyl diphenyl phosphate, and xylenyl diphenyl phosphate, metal phosphates such as sodium phosphate, potassium phosphate, and magnesium phosphate, metal phosphites such as sodium phosphite, potassium phosphite, magnesium phosphite, and aluminum phosphite, and ammonium polyphosphate. By using these phosphorus-containing compounds, appropriate fire resistance and fire extinguishing performance can be imparted to the fire-resistant resin composition. The flame retardant may be used individually or in combination of two or more. Among these flame retardants, ammonium polyphosphate, aluminum phosphite, etc. are particularly preferable from the viewpoint of improving the fire resistance and fire extinguishing performance of the fire-resistant resin composition.

[0041] The flame retardant is preferably solid at normal temperature (23°C) and normal pressure (1 atm). The average particle size of the flame retardant is preferably 1 to 200 μm, more preferably 1 to 60 μm, even more preferably 3 to 40 μm, and still more preferably 5 to 20 μm. When the average particle size of the flame retardant is within the above range, the dispersibility of the flame retardant in the fire-resistant resin composition is improved, and the flame retardant can be uniformly dispersed in the resin or the compounding amount of the flame retardant with respect to the resin can be increased.

[0042] The content of the flame retardant in the present invention is not particularly limited, but is preferably 15 to 60 parts by mass, more preferably 20 to 55 parts by mass, and still more preferably 25 to 50 parts by mass with respect to 100 parts by mass of the resin.

[0043] <Endothermic agent> As the endothermic agent used in the refractory resin composition of the present invention, hydrated metal compounds are preferably mentioned. A hydrated metal compound is a compound that decomposes upon contact with a flame to generate water vapor and has an endothermic effect. Examples of the hydrated metal compound include metal hydroxides and hydrates of metal salts. Specifically, aluminum hydroxide, magnesium hydroxide, calcium hydroxide, calcium-magnesium-based hydroxides, hydrotalcite, boehmite, talc, dawsonite, hydrate of calcium sulfate, hydrate of magnesium sulfate, zinc borate [2ZnO·3B 2 O 5 ·3.5H 2 O] and the like can be mentioned. Among these, from the viewpoints of fire resistance, fire extinguishing performance, etc., at least one selected from aluminum hydroxide, magnesium hydroxide, calcium sulfate dihydrate, and magnesium sulfate heptahydrate is preferable, and aluminum hydroxide and magnesium hydroxide are particularly preferable.

[0044] As the endothermic agent, those having a thermal decomposition start temperature of 500°C or lower and an endothermic amount of 500 J / g or more are preferable. When either the thermal decomposition start temperature or the endothermic amount is within the above range, it is possible to quickly extinguish the fire during ignition. From the above viewpoints, the thermal decomposition start temperature of the endothermic agent is preferably 400°C or lower, more preferably 300°C or lower. Also, the thermal decomposition start temperature of the endothermic agent is usually 100°C or higher, preferably 150°C or higher, and more preferably 180°C or higher. By setting these lower limit values or higher, it is possible to prevent the endothermic agent from malfunctioning due to heating other than a fire. The thermal decomposition start temperature can be measured by a thermogravimetric differential thermal analyzer (TG-DTA), and specifically, it can be measured by the method described in the examples.

[0045] The heat absorption amount of the heat absorbent is preferably 600 J / g or more, more preferably 900 J / g or more. When the heat absorption amount of the heat absorbent is within the above range, the heat absorption property is improved, so the fire resistance and fire extinguishing performance become better. The heat absorption amount of the heat absorbent is usually 4000 J / g or less, preferably 3000 J / g or less. Note that the heat absorption amount can be measured using a thermogravimetric differential thermal analyzer (TG-DTA), and specifically, it can be measured by the method described in the examples.

[0046] Also, the heat absorbent preferably has an average particle diameter of 0.1 to 90 μm. By setting the average particle diameter within the above range, the heat absorbent is easily dispersed in the resin, it is easy to blend a large amount of the heat absorbent, and the fire resistance and fire extinguishing performance are also easily improved. From the above viewpoints, the average particle diameter of the heat absorbent is more preferably 0.5 to 60 μm, even more preferably 0.8 to 40 μm, and still more preferably 0.8 to 10 μm.

[0047] The content of the heat absorbent in the present invention is not particularly limited, but is preferably 5 to 40 parts by mass, more preferably 10 to 30 parts by mass, and even more preferably 12 to 20 parts by mass with respect to 100 parts by mass of the resin.

[0048] <Lubricant> A lubricant may be used in the fire-resistant resin composition of the present invention. By using the lubricant in the composition, the fluidity becomes good, and the thermally expandable layered inorganic substance and the fire-resistant additive are appropriately dispersed in the composition. Therefore, the thermal expansibility and the residue hardness of the refractory made of the composition are good, and the fire resistance of the refractory is improved. Examples of the lubricant used in the present invention include resin-based lubricants and phosphate ester-based lubricants. The lubricant is preferably used in combination with the above-described fire-resistant additive.

[0049] As the resin-based lubricant, known resin-based lubricants can be used, but acrylic oligomers are preferred. As the acrylic oligomer, an acrylate ester oligomer is preferred. Examples of the acrylate ester constituting the oligomer include methyl acrylate, ethyl acrylate, butyl acrylate, cyclohexyl acrylate, octyl acrylate and the like. Among these, a butyl acrylate-based oligomer is preferred. As the resin-based lubricant, commercially available products can also be used. For example, "ADEKA STAB FC-113" manufactured by ADEKA can be used.

[0050] Examples of the phosphate ester-based lubricant include long-chain aliphatic phosphate ester-based compounds, and long-chain monoalkyl phosphate esters, long-chain dialkyl phosphate esters and the like can be preferably used. The alkyl group constituting the long-chain monoalkyl phosphate ester and the long-chain dialkyl phosphate ester preferably has 12 to 18 carbon atoms. Examples of the alkyl group having 12 to 18 carbon atoms include a dodecyl group, a tridecyl group, an isotridecyl group, a tetradecyl group, a hexadecyl group, and an octadecyl group. As the long-chain aliphatic phosphate ester-based compound used in the present invention, at least one selected from the group consisting of monododecyl phosphate ester, didodecyl phosphate ester, monooctadecyl phosphate ester, and dioctadecyl phosphate ester is preferred, and monooctadecyl phosphate ester, dioctadecyl phosphate ester, or a mixture thereof is more preferred. As the lubricant used in the present invention, one kind may be used alone, or two or more kinds may be used in combination. For example, a resin-based lubricant and a phosphate ester-based lubricant may be used in combination. Among the above, it is more preferable to use an acrylic oligomer and a long-chain aliphatic phosphate ester-based compound in combination. The content of the lubricant in the fire-resistant resin composition of the present invention is preferably 0.1 to 15 parts by mass, more preferably 0.3 to 8 parts by mass, and still more preferably 0.5 to 4 parts by mass with respect to 100 parts by mass of the resin.

[0051] <Inorganic filler> Examples of the inorganic filler that can be used in the refractory resin composition of the present invention include inorganic fillers other than the above-described thermally expandable layered inorganic substances, flame retardants, heat absorbers, and lubricants, and are not particularly limited. For example, silica, diatomaceous earth, alumina, zinc oxide, titanium oxide, calcium oxide, magnesium oxide, iron oxide, tin oxide, antimony oxide, ferrites, basic magnesium carbonate, calcium carbonate, magnesium carbonate, zinc carbonate, barium carbonate, dawsonite, hydrotalcite, calcium sulfate, barium sulfate, gypsum fiber, calcium silicate, clay, mica, montmorillonite, bentonite, activated clay, sepiolite, imogolite, sericite, glass fiber, glass beads, silica balloon, aluminum nitride, aluminum phosphite, boron nitride, silicon nitride, carbon black, graphite, carbon fiber, carbon balloon, charcoal powder, various metal powders, potassium titanate, magnesium sulfate, lead zirconate titanate, aluminum borate, molybdenum sulfide, silicon carbide, stainless steel fiber, zinc borate, various magnetic powders, slag fiber, fly ash, dehydrated sludge, etc. can be mentioned. Among these, calcium carbonate and carbon black are preferable. These inorganic fillers may be used alone or in combination of two or more.

[0052] The average particle diameter of the inorganic filler is preferably 0.5 to 100 μm, more preferably 1 to 50 μm. When the content of the inorganic filler is small, a smaller particle diameter is preferable from the viewpoint of improving dispersibility. When the content is large, as high filling progresses, the viscosity of the refractory resin composition increases and the moldability decreases, so a larger particle diameter is preferable. The average particle diameter of the above-described flame retardant, heat absorber, and inorganic filler is the value of the median diameter (D50) measured by a laser diffraction / scattering type particle size distribution measuring device.

[0053] The content of the inorganic filler in the present invention is not particularly limited, but is preferably 5 to 80 parts by mass, more preferably 8 to 70 parts by mass, and even more preferably 10 to 65 parts by mass with respect to 100 parts by mass of the resin.

[0054] In the refractory resin composition of the present invention, the content of the specific additive is preferably 3 to 250 parts by mass, more preferably 5 to 200 parts by mass, still more preferably 10 to 150 parts by mass, and even more preferably 50 to 130 parts by mass with respect to 100 parts by mass of the resin. When the content of the specific additive is equal to or more than the lower limit value, flame retardancy can be obtained and the mechanical properties can be improved. On the other hand, when it is equal to or less than the upper limit value, the relative amount of the thermally expandable layered inorganic substance becomes sufficient, and when a fire occurs, it expands by the flame, closes the partition penetration part, and can suppress the spread of fire.

[0055] Also, when the blending amount of polyphenylene oxide is relatively increased, the amount of the specific additive can be relatively decreased. In that case, the content of the specific additive is preferably 3 to 50 parts by mass, more preferably 5 to 30 parts by mass with respect to 100 parts by mass of the resin, and the content of polyphenylene oxide is preferably 20 to 60 parts by mass, more preferably 30 to 50 parts by mass with respect to 100 parts by mass of the resin.

[0056] As described above, the specific additive mentioned above only needs to have at least one selected from a flame retardant, an endothermic agent, a lubricant, and an inorganic filler. Among these, as a combination of refractory additives, from the viewpoint of improving the fire resistance of the refractory, at least one selected from a flame retardant, an endothermic agent, and an inorganic filler is preferable, a combination of a flame retardant and an endothermic agent or a combination of a flame retardant and an inorganic filler is more preferable, and it is also preferable to use a combination of a flame retardant, an endothermic agent, and an inorganic filler. Further, a lubricant may be added to each of these combinations. Among them, a combination is preferable when ammonium polyphosphate (APP) is selected as the flame retardant and calcium carbonate is selected as the inorganic filler. It is considered to be due to the action of hardening the residue when ammonium polyphosphate and calcium carbonate react when heated by a fire or the like. Also, from the viewpoint of hardening the residue, it is also preferable to use aluminum phosphite as the refractory additive.

[0057] In the refractory resin composition of the present invention, the ratio of the content of the resin to the powder (resin / powder) is preferably 0.2 to 3, more preferably 0.5 to 2, and even more preferably 0.5 to 0.7. By setting the ratio of the content of the resin to the powder within the above range, it becomes easier to adjust the residue hardness and residue retention rate of the refractory material to a desired range. The powder is a solid at room temperature (23°C) and normal pressure (1 atm), and in the refractory resin composition, it does not dissolve or compatibilize with the resin and exists in the form of powder, particles, or fibers in the refractory resin composition. Specifically, among the components described above, the solid flame retardant, heat absorbent, inorganic filler, lubricant, and thermally expandable layered inorganic substance become the powder.

[0058] In the refractory resin composition of the present invention, additives generally used in thermally expandable resin compositions such as heat stabilizers, processing aids, antioxidants, antistatic agents, pigments, crosslinking agents, and crosslinking accelerators may be added as necessary within a range that does not impair its physical properties. Among these, it is preferable to use a processing aid.

[0059] [Refractory material] The refractory material of the present invention is composed of the refractory resin composition of the present invention, and is particularly preferably in the form of a sheet. The thickness of the refractory material is preferably 0.1 to 10 mm, more preferably 2 to 8 mm, and even more preferably 3 to 5 mm. When the thickness is equal to or greater than the lower limit value, sufficient refractory performance is ensured, and when it is equal to or less than the upper limit value, the flexibility of the refractory material is ensured.

[0060] The thermal expansion start temperature of the refractory material of the present invention is not particularly limited, but for example, it is preferably 100 to 300°C, more preferably 120 to 280°C, and even more preferably 130 to 250°C. By setting the lower limit value or higher, it is possible to prevent the thermally expandable material from expanding erroneously due to heating other than a fire. Also, by setting the upper limit value or lower, it becomes easier to surely expand the thermally expandable material by heating in a fire. Also, the method for measuring the thermal expansion start temperature of the refractory material of the present invention is as described in the examples below.

[0061] As the expansion ratio of the refractory of the present invention at 300°C, 5 times or more is preferable, 10 times or more is more preferable, and 15 times or more is even more preferable. Further, as the expansion ratio at 600°C, 20 times or more is preferable, 25 times or more is more preferable, and 30 times or more is even more preferable. When the expansion ratio of the refractory is at least the above lower limit value, the expansion performance during a fire becomes good, and the effect of closing the partition penetration part and preventing the spread of fire can be sufficiently exhibited. In addition, the expansion ratio of the refractory is not particularly limited, but from the viewpoint of ensuring a certain residue hardness and residue retention rate during a fire and preventing a gap from occurring between the refractory and the partition penetration part, at 300°C or lower, 50 times or less is preferable, 40 times or less is more preferable, 35 times or less is even more preferable, and even more preferably 20 times or less. Further, at 600°C or lower, 65 times or less is preferable, 60 times or less is more preferable, 50 times or less is even more preferable, and even more preferably 40 times or less.

[0062] As the residue hardness of the refractory of the present invention at 300°C, 3 kgf / cm 2 or more is preferable, 4 kgf / cm 2 or more is more preferable, 5 kgf / cm 2 or more is even more preferable. Further, as the residue hardness at 600°C, 0.1 kgf / cm 2 or more is preferable, 0.2 kgf / cm 2 or more is more preferable, 0.3 kgf / cm 2 or more is even more preferable. When the residue hardness is at least the above lower limit value, it is possible to prevent the refractory from being blown away by the flame during a fire, and it is possible to effectively prevent the spread of fire during a fire. In addition, the residue hardness of the refractory is not particularly limited, but at 300°C or lower, 50 kgf / cm 2 or less is preferable, 40 kgf / cm 2 or less is more preferable, 20 kgf / cm 2 or less is even more preferable. Further, at 600°C or lower, 10 kgf / cm 2 or less is preferable, 4 kgf / cm 2 or less is more preferable, 2 kgf / cm2 The following is more preferable.

[0063] As for the residue retention rate of the refractory material of the present invention at 300 °C, 60% or more is preferable, 70% or more is more preferable, and 80% or more is even more preferable. Also, as for the residue retention rate at 600 °C, 40% or more is preferable, 44% or more is more preferable, and 50% or more is even more preferable. When the residue retention rate is at least the above lower limit value, excellent fire resistance can be obtained, and the spread of fire during a fire can be effectively prevented. In addition, the residue retention rate of the refractory material is not particularly limited, but at 300 °C or lower, 95% or less is preferable, and 93% or less is more preferable. Also, at 600 °C or lower, 70% or less is preferable, and 65% or less is more preferable. Note that the expansion ratio, residue hardness, and residue retention rate of the refractory material can be measured by the methods described in the examples.

[0064] [Fire-resistant laminate] The refractory material of the present invention may be used as a single layer of refractory material, but two or more layers of refractory material (hereinafter also referred to as refractory material layers) may be laminated, or other layers other than the refractory material may be laminated and used as a multilayer body (fire-resistant laminate). Examples of the other layers used include a base material and an adhesive layer. The fire-resistant laminate may have both a base material and an adhesive layer, but it may have at least one of them.

[0065] [Base material] The base material used in the fire-resistant laminate supports the refractory material and, depending on its material, evenly transfers heat to the refractory material. Examples of the base material include metal foils such as aluminum foil and copper foil, composites of metal foils and glass cloth such as glass cloth and aluminum glass cloth (metal foil composites), paper, cloth, resin films, and the like. Among these, from the viewpoint of fire resistance, it is preferably composed of a non-combustible material, and metal foils and metal foil composites are more preferable. By using metal foils and metal foil composites, it becomes easier to evenly transfer heat to the refractory material, and when a fire occurs, the refractory material foams evenly, making it easier to improve fire resistance. Note that a non-combustible material is defined in the Building Standards Act and the Building Standards Act Enforcement Order.

[0066] The base material may be provided on one side of the refractory material, or may be provided on both sides so as to sandwich the refractory material. However, from the viewpoint of effectively controlling the expansion of the refractory material by the base material and expanding it in the direction of the partition penetration part so that the partition penetration part is surely blocked at the time of a fire, it is preferable to provide it on both sides of the refractory material.

[0067] The thickness of each base material is not particularly limited, but is, for example, 0.01 to 1 mm, preferably 0.05 to 0.5 mm. When the non-combustible material layer has a thickness below these upper limit values, flexibility is imparted to the sheet-like member. Also, when it has a thickness above the lower limit value, it becomes easier to ensure fire resistance performance.

[0068] <Adhesive layer> The adhesive layer used for the fire-resistant laminate is preferably formed by an adhesive. As the adhesive, for example, an acrylic adhesive, a urethane adhesive, a rubber adhesive, a silicone resin adhesive, etc. can be used. The adhesive layer may be non-combustible, semi-non-combustible, or flame-retardant, and a flame retardant or the like may be blended into the adhesive used. The thickness of the adhesive layer is, for example, 5 to 400 μm, preferably 10 to 150 μm. Also, the adhesive layer may be disposed on the outermost surface of the fire-resistant laminate so that the fire-resistant laminate can be adhered to other members.

[0069] As described above, a plurality of sheet-like refractory materials may be laminated. However, when laminating a plurality of sheet-like refractory materials, if they have adhesiveness, they may be laminated directly, or may be laminated via an adhesive layer composed of a known adhesive other than the adhesive layer or the adhesive layer.

[0070] When laminating a plurality of sheet-like refractory materials, it is preferable that they are layers with different expansion ratios from each other, and the expansion ratio may be controlled according to the usage form. When providing two or more layers of sheet-like refractory materials, at least one of them is preferably composed of the fire-resistant resin composition of the present invention and constitutes the refractory material layer of the layer with a high expansion rate. In addition, in the refractory laminate composed of a base material and a refractory layer, the base material may have two or more layers. Further, when the refractory agent layer has adhesiveness, it is preferably disposed on the outermost surface so as to be able to adhere to other members.

[0071] The refractory laminate preferably has a base material and a refractory layer. The refractory laminate may be composed of two layers of a base material and a refractory layer, or may be laminated with at least three layers alternately. Further, the refractory laminate is not limited to a three-layer structure, and the base material and the refractory layer may be alternately laminated with four layers, or more layers may be provided. Since the refractory layer obtained from the refractory resin composition of the present invention has a high expansion ratio and a hard residue, it may constitute some of the plurality of refractory layers, or may constitute all of the layers. Details of the refractory laminate will be described later.

[0072] Also, it is preferable that the refractory laminate has at least three layers alternately laminated with a base material and a refractory layer having thermal expansibility. Specifically, as shown in FIG. 1(a), the refractory laminate 3 may have three layers alternately laminated with the base materials 30A and 30B and the refractory layer 31A, or as shown in FIG. 1(b), the base material 30A and the refractory layers 31A and 31B may be alternately laminated with three layers. The sheet-like member 3 is not limited to a three-layer structure, and as shown in FIG. 1(c), the base materials 30A and 30B and the refractory layers 31A and 31B may be alternately laminated with four layers.

[0073] Also, when the base material and the refractory agent layer are alternately laminated, as long as the sheet-like member 3 has a base material / refractory layer / base material or a refractory layer / base material / refractory layer in this order, the base material and the refractory layer do not need to be provided alternately one by one, and the same kind of layers may be continuously laminated like a base material / base material / refractory layer / refractory layer. For example, as shown in FIG. 1(d), the base materials 30A and 30B may be continuously laminated, and the base materials 30B and 30C and the refractory layer 31A may be alternately laminated. Further, as shown in FIG. 1(e), the sheet-like member 3 is not limited to the number of laminated layers, and a plurality of base materials 30A, ··· 30Y, 30Z and a plurality of refractory layers 31A, ··· 31Y, 31Z may be alternately laminated in multiple layers.

[0074] As shown in Fig. 2(a), it is also preferable to dispose a refractory layer 31A having adhesiveness on the outermost surface of the refractory laminate 3. When an adhesive layer is provided, as shown in Fig. 2(b), it is also preferable to adopt a configuration in which a refractory layer 31A provided with an adhesive layer 33 is disposed on the outermost surface. In this case, as the resin, the content of chloroprene rubber, polyphenylene oxide, etc. is relatively increased, or the content of the thermally expandable layered inorganic substance is increased, so that it becomes easier to improve the fire resistance performance of the fire-resistant layer itself.

[0075] With the above configuration, even without using a fixing member as a separate member from the refractory laminate 3, the refractory laminate 3 can be easily fixed to other members such as a partition portion 11 (see Fig. 3) described later. Further, by imparting adhesiveness to the refractory layer itself, it is not necessary to provide an adhesive layer, so that the configuration of the refractory laminate 3 can be further simplified. In addition, when a refractory layer having adhesiveness or an adhesive layer is provided on the outermost surface of the refractory laminate 3, a release sheet may be attached to the outermost surface. The release sheet is preferably peeled off from the outermost surface during use.

[0076] Note that the refractory laminate shown in Fig. 2 is an example, and the configuration in the case of providing an adhesive layer on the outermost layer or providing a refractory layer having adhesiveness on the outermost layer is not limited to the configuration shown in Fig. 2, and a two-layer structure of a refractory layer / base material may be used, or a three-layer structure such as a refractory layer / base material / adhesive layer or a base material / refractory layer / adhesive layer may be used. Further, in the multilayer structure, the sheet-like member 3 may have the same layer configuration throughout, or may have a partially different structure. For example, the layer configuration of the base material and the refractory layer may be partially changed.

[0077] <Manufacturing method> The fire-resistant resin composition of the present invention can be manufactured, for example, as follows. First, a specific additive such as a predetermined amount of a fire-resistant additive, a thermally expandable layered inorganic substance, a resin, and other additives blended as necessary are mixed with a mixer such as a kneading roll to obtain a fire-resistant resin composition. The temperature during mixing is preferably 100 to 150°C. By setting the temperature during mixing to be equal to or higher than the lower limit value, it becomes easier to uniformly mix each component. Also, by setting the temperature during mixing to be equal to or lower than the upper limit value, it is possible to prevent the thermally expandable layered inorganic substance from expanding during mixing, and a high-quality refractory can be provided. Note that a solvent may be appropriately added to the fire-resistant resin composition and diluted.

[0078] The fire-resistant resin composition obtained as described above is preferably formed into a predetermined shape to be a refractory. Specifically, it is preferably formed into a sheet-shaped refractory by extrusion molding, press molding, etc. Also, the fire-resistant resin composition diluted with a solvent is preferably applied to a support such as a base material or a release sheet, and appropriately dried, etc., to form a refractory on one surface of the support. The refractory formed on the release sheet is preferably peeled off from the release sheet to be a sheet-shaped refractory composed of a single layer of refractory. Further, a fire-resistant laminate having a multilayer structure is preferably obtained by laminating on another layer after peeling off from the release sheet. Also, it may be laminated on another layer while being laminated on the release sheet or another support.

[0079] The fire-resistant resin composition of the present invention is used in the fire protection structure of a building, and is particularly preferably used in the fire protection structure of a partition penetration part for passing long insertion bodies such as cables and pipes in a partition part such as a wall. That is, in the partition penetration part, when a fire breaks out in any partition, it is preferably used as a refractory for preventing the spread of fire to other partitions. Also, the fire-resistant resin composition of the present invention can be suitably used as a partition penetration treatment material in a partition penetration treatment structure.

[0080] [Partition Penetration Treatment Structure] Hereinafter, a specific example in which the fire-resistant resin composition of the present invention is applied to a partition penetration treatment structure as a refractory will be described in detail while referring to the drawings. As shown in FIG. 3, the partition penetration treatment structure is a partition penetration treatment structure having a fire-resistant structure for a partition penetration portion 15 formed in a partition portion 11 of a building and through which a long insertion body 21 is inserted. In the partition penetration treatment structure, the refractory is used as a sheet-like member 3 and is used as at least a part of a partition penetration treatment material for forming the partition penetration treatment structure 10, which is constructed in the partition penetration portion 15. In this specification, as shown in FIG. 3, members (sheet-like member 3 and fixing members for fixing them, etc.) constructed in the partition penetration portion 15 to form the partition penetration treatment structure 10 may be collectively referred to as a partition penetration treatment material.

[0081] The partition portion 11 in the partition penetration treatment structure is a member that partitions between compartments (the first compartment A and the second compartment B) on the wall surface of a building, and has a partition penetration portion 15 that penetrates from one outer surface 11A side of the partition portion 11 to the other outer surface 11B side. The partition portion 11 shown in FIG. 3 is a hollow wall and is composed of two wall materials (partition materials) 12A and 12B arranged with an interval (hollow portion 13) therebetween. Therefore, the partition penetration portion 15 is composed of a through-hole 13A formed in one wall material 12A, a through-hole 13B formed in the other wall material 12B, and the hollow portion 13 therebetween. And the outer surface of one wall material 12A constitutes the outer surface 11A of the partition portion 11, and the outer surface of the other wall material 12B constitutes the outer surface 11B of the partition portion 11. The through-holes 13A and 13B may have, for example, a circular shape, an elliptical shape, or a shape approximating these. Note that the through-holes 13A and 13B constitute openings 13C and 13D of the partition penetration portion 15 provided in the partition portion 11 on the outer surfaces 11A and 11B, respectively.

[0082] Hereinafter, the configuration of the partition penetration treatment structure on one opening 13C side of the partition portion 11 will be described. However, in this embodiment, the configuration of the partition penetration treatment structure on the other opening 13D side is the same, so the description thereof will be omitted.

[0083] The partition penetration treatment structure 10 includes, as a partition penetration treatment material, a sheet-like member 3 and a cover member 5. As described above, the sheet-like member 3 is a refractory material in which a base material and a refractory layer are integrated. The sheet-like member 3 is a member provided with the above-described refractory material and may be composed of a single layer of refractory material. However, in FIG. 3, a structure of a refractory laminate is shown.

[0084] 〔Sheet-like member〕 As shown in FIG. 3, the refractory material (sheet-like member 3) has a slit 32 for inserting the insertion body 21 therein, and at least one of the slits 32 extends to the outer edge of the sheet-like member 3. The slit 32 is formed by a cut. The sheet-like member 3 can insert the insertion body 21 into the sheet-like member 3 through the slit 32 extending to the outer edge. Note that the slit 32 may be in a form having a hole for inserting the insertion body 21 therein and a slit 32 extending from the hole to the outer edge of the sheet-like member 3.

[0085] As shown in FIG. 4, the sheet-like member 3 into which the insertion body 21 is inserted by the slit 32 is disposed on the outer surface 11A so as to cover the gap 13E between the opening 13C and the insertion body 21 from the outside of the partition portion 11. Thereby, the gap 13E between the opening 13C and the insertion body 21 is blocked by the sheet-like member 3. The sheet-like member 3 is preferably disposed so as to contact both the outer surface 11A of the partition portion 11 and the outer periphery of the insertion body 21. By installing the sheet-like member 3 so as to contact the insertion body 21 and the partition portion 11, the opening 13C of the partition portion 11 can be blocked, and the fire resistance performance can be improved and maintained.

[0086] Although the details of the sheet-like member 3 (refractory material or refractory laminate) are as described above, by using the sheet-like member 3, a refractory structure is formed without disposing a filler such as refractory putty or rock wool inside the partition penetration portion 15, so that there is no variation caused by the operator. Furthermore, when a plurality of refractory layers are laminated on the sheet-like member 3, the refractory layer on the side of the expanded partition portion 11 is embedded inside the gap 13E, preventing the sheet-like member 3 from moving away from the partition portion 11 when it expands, and making it less likely for the above-mentioned displacement to occur. On the other hand, the refractory layer located at a position away from the partition portion 11 preferably expands evenly, and the expansion residue can appropriately prevent the spread of fire.

[0087] When there are a plurality of refractory layers on the sheet-like member 3, it is preferable that the expansion ratio of the refractory layer farthest from the outer surface 11A of the partition portion 11 is higher than the expansion ratio of the refractory layer closest to the outer surface 11A of the partition portion 11. That is, in the sheet-like member 3 in FIGS. 1(b) and (c), when the right side of the figure is the partition portion 11 side, it is preferable that the expansion ratio of the refractory layer 31B is higher than the expansion ratio of the refractory layer 31A. And at least the refractory layer 31B is preferably made of the refractory resin composition of the present invention. Since the refractory resin composition of the present invention can have a high expansion ratio, it is suitable as the material for the refractory layer 31B. In this way, when the expansion ratio of the refractory layer on the partition portion 11 side is low, the strength of the expansion residue is maintained high, and the sheet-like member 3 is appropriately supported by the refractory layer embedded inside the gap 13E, making it even less likely for displacement to occur. Also, the refractory layer at a position away from the partition portion 11 expands sufficiently by heating, making it easier to exhibit higher fire resistance performance.

[0088] When there are three or more refractory layers, in order to expand the refractory layers farther from the outer surface 11A of the partition portion 11 more favorably and substantially uniformly, it is preferable to increase the expansion ratio of the refractory layers farther from the outer surface 11A of the partition portion 11.

[0089] As shown in FIG. 2(a), when the sheet-like member 3 has a refractory layer 31A with adhesiveness disposed on the outermost surface, it may be adhered to the outer surface 11A of the partition portion 11 by the refractory layer with adhesiveness. Also, as shown in FIG. 2(b), when adopting a configuration in which a refractory layer 31A provided with an adhesive layer 33 is disposed on the outermost surface, it may be adhered to the outer surface 11A of the partition portion 11 by the adhesive layer. Further, the sheet-like member 3 may be fixed to the outer surface 11A of the partition portion 11 by a fixing member which is a separate member from the sheet-like member 3 such as a tacker or a screw. Of course, the sheet-like member 3 may be fixed to the partition portion 11 by a combination of two or more of these.

[0090] 〔Cover member〕 The cover member 5 is provided so as to be connected to the sheet-like member 3, and is a member that covers the sheet-like member 3 provided on the partition portion 11. For example, as shown in FIG. 3, four cover members 5 are used so as to be connected to the four edges of the sheet-like member 3, and are four extending portions extending outward from the sheet-like member 3, and as shown in FIG. 4, cover the sheet-like member 3 provided on the partition portion 11. As means for providing the cover member 5 so as to be connected to at least a part of the sheet-like member 3, for example, known fixing means such as an adhesive, an adhesive agent and an adhesive tape, and a fixing member such as a tacker or a screw can be mentioned. Here, the adhesive, the adhesive agent and the adhesive tape are preferably any of a non-combustible material, a semi-non-combustible material or a flame-retardant material, and a flame retardant or the like may be blended in the adhesive, the adhesive agent or the like. The cover member 5 is sheet-like and deformable, so that it can easily cover the sheet-like member 3.

[0091] As shown in FIG. 4, the portion of the cover member 5 that covers the opening 13C of the partition penetrating portion 15 surrounds the insertion body 21 so as to be in contact therewith, and is fixed to the insertion body 21 by a string-like member 22 wound from the outside. The string-like member 22 may be any member that can be bent, and is preferably a wire member including a wire. The wire member may be a single metal wire, a resin-coated wire in which a metal wire such as a torsion spring (registered trademark) is coated with resin, or a member in which a wire and a fiber are intertwined such as a molding. When a wire member is used, the cover member 5 can be fixed to the insertion body 21 simply by twisting or screwing.

[0092] The cover member 5 may cover a part of the sheet-like member 3 and make a part of the sheet-like member 3 invisible from the outside. Specifically, it is preferable to cover the portion through which the insertion body 21 of the sheet-like member 3 is inserted, whereby the design property of the partition penetration portion 15 can be improved, and the fire resistance of the partition penetration portion 15 can be enhanced. On the other hand, the cover member 5 may cover a part of the sheet-like member 3 so as to be visible from the outside. Specifically, as shown in FIG. 4, the cover member 5 may make the end face 3C of the sheet-like member 3 visible from the outside. By making the end face 3C of the sheet-like member 3 visible from the outside with the cover member 5 installed, it is possible to easily perform a visual inspection to confirm that the sheet-like member 3 is installed in the partition penetration portion 15.

[0093] The cover member 5 is preferably installed in contact with the sheet-like member 3 and the insertion body 21. By installing the cover member 5 in contact with the sheet-like member 3 and the insertion body 21, the opening 13C of the partition portion 11 can be closed by the sheet-like member 3 and the cover member 5, and the fire resistance can be improved.

[0094] The cover member 5 is installed so as to form a gap 40 between the cover member 5 and the sheet-like member 3. The presence of the gap 40 between the sheet-like member 3 and the cover member 5 allows the cover member 5 to be fixed with a margin for the axial movement of the insertion body 21. By fixing the cover member 5 to the insertion body 21 with a margin, even when the insertion body 21 disposed inside the sheet-like member 3 and the cover member 5 is axially moved after the installation of the sheet-like member 3 and the cover member 5, the margin of the cover member 5 buffers the situation where the sheet-like member 3 and the cover member 5 move together with the insertion body 21. By buffering the situation where the sheet-like member 3 and the cover member 5 move together with the insertion body 21, it is possible to suppress the sheet-like member 3 and the cover member 5 from shifting from the partition penetration portion 15. That is, with such a configuration, the sheet-like member 3 and the cover member 5 can be continuously maintained and arranged at appropriate positions in the partition penetration portion 15, and the fire resistance of the partition penetration portion 15 can be maintained. There can be various forms of the configuration in which there is a gap 40 between the sheet-like member 3 and the cover member 5, and the cover member 5 is fixed with a margin with respect to the axial movement of the inserted body 21. For example, a configuration using a material having flexibility and stretchability such that at least a part of the cover member 5 can be bent or curved, and a configuration in which at least a part of the cover member 5 is fixed so as to have sag with respect to the inserted body 21 can be mentioned.

[0095] The cover member 5 may be composed of a single layer of a fire-resistant material, may be composed of a single layer of a non-combustible material, or may have both a refractory layer and a non-combustible material layer. However, it is preferable to have a non-combustible material layer, and it is more preferable to be composed of a non-combustible material layer. Further, it may have a layer other than the refractory layer and the non-combustible material layer, and examples of such a layer include a material layer composed of a material other than a non-combustible material, an adhesive layer, and the like. Examples of the cover member 5 preferably include a metal foil such as an aluminum foil, a glass cloth, and a metal foil composite such as a composite of a metal foil and a glass cloth such as an aluminum glass cloth. These constitute a non-combustible material layer. Among these, an aluminum glass cloth is more preferable from the viewpoint of fire resistance. The thickness of the non-combustible material layer is not particularly limited, but is, for example, 0.01 to 1 mm, preferably 0.05 to 0.5 mm. By having a thickness below these upper limit values, flexibility is imparted to the cover member 5. Therefore, the cover member 5 can be wound around the outer periphery of the inserted body 21 while being in close contact therewith, even if it has a non-combustible material layer, for example. Also, by having a thickness above the lower limit value, it becomes easier to ensure fire resistance performance.

[0096] As described above, the cover member 5 is preferably a sheet that can be deformed so as to cover the sheet-like member 3, but it is preferably thinner than the sheet-like member 3 so that flexibility is imparted and deformation is easy. The thickness of the cover member 5 is not particularly limited, but is, for example, 0.01 to 1 mm, preferably 0.05 to 0.5 mm.

[0097] The refractory layer used for the cover member 5 is preferably a thermally expandable member that expands upon heating. The thermally expandable member prevents the spread of fire by expanding during a fire. The thermally expandable member is preferably formed of the above-described thermally expandable resin composition. Further, the refractory layer may have adhesiveness. Note that the thickness of the refractory layer is not particularly limited, but is, for example, 0.01 to 1 mm, preferably 0.05 to 0.5 mm. By having a thickness below these upper limit values, flexibility is imparted to the cover member 5. Therefore, even if the cover member 5 has a refractory layer, it can be wound around the outer periphery of the inserted body 21. Also, by having a thickness above the lower limit value, it becomes easier to ensure fire resistance performance.

[0098] The cover member 5 may have a refractory layer having adhesiveness or an adhesive layer. The refractory layer having adhesiveness and the adhesive layer may form the outermost surface of the cover member 5. With the above configuration, the cover member 5 can be fixed to the sheet-like member 3 or the inserted body 21 without using a fixing member as a separate member from the cover member 5. Also, by giving the refractory layer itself adhesiveness, it is not necessary to provide an adhesive layer, so the configuration of the cover member 5 can be further simplified. Note that when the cover member 5 is provided with a refractory layer having adhesiveness or an adhesive layer on its outermost surface, a release sheet may be attached to the outermost surface. The release sheet is preferably peeled off from the outermost surface during use.

[0099] The construction method of the partition penetration treatment structure 10 includes a step of installing the above-described sheet-like member 3 so as to block at least a part of the gap 13E between the opening 13C of the partition penetration part 15 provided in the partition part 11 and the inserted body 21. Then, the sheet-like member 3 can be constructed by covering the sheet-like member 3 with the cover member 5 installed on the sheet-like member 3 and fixing a part of the cover member 5 to the inserted body 21. Therefore, the construction is easy.

[0100] The sheet-like member 3 and the cover member 5 used in construction may be separate. In the case where they are separate, after installing the sheet-like member 3 on the partition portion 11, the cover member 5 is adhered to the sheet-like member 3 for installation, and the installed cover member 5 covers the sheet-like member 3 to enable construction. Also, the sheet-like member 3 and the cover member 5 used in construction may be an integral body in which the sheet-like member 3 and the cover member 5 are adhered in advance.

[0101] According to the configuration of the present embodiment described above, the gap 13E inside the opening 13C of the partition penetration portion 15 is blocked by the sheet-like member 3 and the cover member 5, and at least the sheet-like member 3 among these has a refractory material. Therefore, appropriate fire resistance can be imparted to the partition penetration portion treatment structure 10. Also, in the present embodiment, since the fire-resistant structure is formed by the sheet-like member 3 and the cover member 5 without arranging filling materials such as fire-resistant putty and rock wool inside the partition penetration portion 15, there is no variation caused by the operator.

[0102] Furthermore, in the present embodiment, at least a part of at least the sheet-like member 3 and the cover member 5 is exposed and visible from the outside. Also, when a fixing member for fixing the sheet-like member 3 or the cover member 5 is provided, the fixing member may be arranged at a position visible from the outside. And inside the partition penetration portion 15, no member other than the insertion body 21 is provided. Therefore, it can be easily inspected by visual observation or photography that the partition penetration treatment material has been constructed as specified. Also, it is less likely to occur such as forgetting the construction.

[0103] The adhesive layer is preferably formed of an adhesive. As the adhesive, for example, an acrylic-based adhesive, a urethane-based adhesive, a rubber-based adhesive, a silicone resin-based adhesive, etc. can be used. The adhesive layer may be non-combustible, semi-non-combustible, or flame-retardant, and a flame retardant or the like may be blended with the adhesive used. The thickness of the adhesive layer is, for example, 5 to 400 μm, preferably 10 to 150 μm. By configuring the cover member 5 to have an adhesive layer on one surface 5A, the cover member 5 can be fixed to the insertion body 21 without using a fixing member as a separate member from the cover member 5. In addition, when an adhesive layer is provided on one surface 5A of the cover member 5, a release sheet may be attached to the one surface 5A. The release sheet may be peeled off from the one surface 5A during use.

[0104] The cover member 5 is composed of an elastic foam having flexibility capable of following the outer periphery of the insertion body 21. Specific examples of the elastic foam include olefin resin foam and urethane resin foam. The thickness of the elastic foam is not particularly limited, but for example, it is 0.1 to 10 mm, preferably 0.15 to 5 mm. By having a thickness below these upper limit values, flexibility is imparted to the cover member 5. Therefore, the cover member 5 can be wound around while being in close contact with the outer periphery of the insertion body 21. Also, by having a thickness above the lower limit value, the arrangement of the cover member 5 becomes easy.

[0105] According to the configuration of the present embodiment described above, the gap 13E inside the opening 13C of the partition penetration portion 15 is blocked by the sheet-like member 3 and the cover member 5, and at least the sheet-like member 3 among these has a refractory material. Therefore, appropriate refractory performance can be imparted to the partition penetration portion treatment structure 10. Also, as described above, the partition penetration treatment structure 10 prepares the sheet-like member 3 and the cover member 5, and first, the sheet-like member 3 is installed so as to block the gap 13E between the opening 13C of the partition penetration portion 15 and the insertion body 21. Next, the cover member 5 is wound around the insertion body 21 one or more times, and the sheet-like member 3 can be fixed so as to cover at least a part thereof by the cover member 5. Therefore, the construction is easy. Also, in the present embodiment, since the refractory structure is formed by the sheet-like member 3 and the cover member 5 without arranging a filler such as refractory putty or rock wool inside the partition penetration portion 15, there is no variation caused by the operator.

[0106] In the above description, the partition portion 11 is a hollow wall with a hollow portion 13 inside, but it is not limited to a hollow wall and may be a wall without a hollow provided, for example, a wall made of a single wall material. Further, the partition portion 11 is not limited to the wall of a building and may be the ceiling or floor of a building. Even in the case of the ceiling or floor, the partition portion may have a structure with a hollow portion between two partition materials, or may have a structure without a hollow portion and may be composed of, for example, a single partition material.

[0107] The cover member 5 is not limited to the above aspect. For example, in the partition penetration processing structure 10 shown in FIG. 3, the cover member 5 is shown as four extending portions extending outward from the sheet-like member 3, but it may be a single sheet-like member that is slightly larger than the sheet-like member 3. Further, in the partition penetration processing structure 10 shown in FIG. 4, an aspect is shown in which the cover member 5 is adhered only to a part of the surface 3A of the sheet-like member 3. However, when using a single sheet-like cover member 5 that is slightly larger than the sheet-like member 3, the cover member 5 can be adhered to the entire surface 3A of the sheet-like member 3. That is, it may have a structure in which the sheet-like member 3 is laminated on one surface of the cover member 5. In such a structure, it is preferable that the cover member 5 has a non-combustible material layer. By making the sheet-like member 3 and the cover member 5 a combination of a non-combustible material layer and a refractory material layer, the fire resistance can be improved. Further, an adhesive layer may be provided on the surface of the cover member 5 to which the sheet-like member 3 is adhered, and the adhesive layer enables easy adhesion to the sheet-like member 3. Further, the sheet-like member 3 may have a structure in which a base material, which is one layer of the sheet-like member 3, extends outward from other layers. According to such a structure, the extending portion of the base material can be used as the cover member 5 as it is. Further, in the partition penetration processing structure 10 shown in FIGS. 3 and 4, an aspect is shown in which the sheet-like member 3 and the cover member 5 are provided respectively, but the cover member 5 may be omitted. In addition, in the partition penetration processing structure, the sheet-like member is arranged to cover the opening of the partition portion, but it is not limited to such a mode. For example, it may be bent into a sleeve shape and inserted into the partition penetration portion 15 for use.

Example

[0108] The present invention will be described more specifically with reference to the following examples, but the present invention is not limited thereto. The components used in the examples and comparative examples are shown below.

[0109] (Resin) ·PVB (manufactured by Sekisui Chemical Co., Ltd., product name "BH-3", hydroxyl group content 35 mol%, acetalization degree 64 mol%, acetyl group content 1 mol%) ·Polybutene (manufactured by ENEOS Corporation, product name "Nisseki Polybutene LV-100", number average molecular weight 500) ·Chloroprene rubber (manufactured by Tosoh Corporation, product name "SKYPRENE B-12", Mooney viscosity at 100 °C 35) ·Natural rubber (manufactured by Sokutech Co., Ltd., product name "HA latex", Mooney viscosity at 100 °C 121) ·Butyl rubber (manufactured by JSR Corporation, product name "JSR BUTYL 365", Mooney viscosity at 125 °C 33) ·Styrene-butadiene rubber (manufactured by Asahi Kasei Corporation, product name "Tufdene 2003", Mooney viscosity at 100 °C 33) ·Nitrile-butadiene rubber (manufactured by JSR Corporation, product name "N520", Mooney viscosity at 100 °C 51) ·Ethylene-propylene rubber (manufactured by Sumitomo Chemical Co., Ltd., product name "Esprene 532", Mooney viscosity at 100 °C 110) ·Chlorosulfonated polyethylene (manufactured by Tosoh Corporation, product name "TOSO-CSM (registered trademark) TS-430", Mooney viscosity at 100 °C 58) ·Epichlorohydrin rubber (manufactured by Daiso Co., Ltd., product name "Epichlomer H", Mooney viscosity at 100 °C 50) ·Acrylic rubber (manufactured by Nippon Zeon Co., Ltd., product name "Nipol AR51", Mooney viscosity at 100 °C 55) · Polyphenylene oxide (manufactured by Asahi Kasei Corporation, product name "Xyron S202") · Petroleum resin (manufactured by Idemitsu Kosan Co., Ltd., product name "Imarve")

[0110] (Thermally expandable layered inorganic substance) · Thermally expandable graphite 1 (manufactured by ADT Co., Ltd., product name "ADT-351", thermal expansion start temperature: 180 °C) · Thermally expandable graphite 2 (manufactured by Air Water Inc., product name "SS-3N", thermal expansion start temperature: 200 °C) · Thermally expandable graphite 3 (manufactured by Fuji Graphite Industry Co., Ltd., product name "EXP-50S 150", thermal expansion start temperature: 150 °C)

[0111] (Specific additive) <Flame retardant> · Aluminum phosphite (manufactured by Taihei Chemical Industry Co., Ltd., product name "APA100") · Ammonium polyphosphate (manufactured by Taihei Chemical Industry Co., Ltd., product name "APP") <Endothermic agent> · Aluminum hydroxide (manufactured by Nippon Light Metal Co., Ltd., product name "BF013", average particle diameter 1 μm, thermal decomposition start temperature 200 °C, endothermic quantity 1000 J / g) · Magnesium hydroxide (manufactured by Kyowa Chemical Industry Co., Ltd., product name "Kisuma 10", average particle diameter 0.9 μm, thermal decomposition start temperature 280 °C, endothermic quantity 1350 J / g) <Lubricant> · Butyl acrylate-based oligomer (manufactured by ADEKA Corporation, product name "Adekastab FC-113") · Mixture of monooctadecyl phosphate and dioctadecyl phosphate (manufactured by ADEKA Corporation, product name "Adekastab AX-71") <Inorganic filler> · Calcium carbonate (manufactured by Shiraishi Calcium Co., Ltd., product name "BF300") · Carbon black (manufactured by Mitsubishi Chemical Corporation, product name "Diamond Black H")

[0112] (Plasticizer) · Diisodecyl phthalate (manufactured by Tokyo Chemical Industry Co., Ltd., trade name "DIDP") · Adipic acid ether ester (manufactured by ADEKA, product name "RS-107") · Polyether ester (manufactured by ADEKA, product name "RS-700")

[0113] The measurement methods and evaluation methods for each physical property are as follows. (Thermal expansion start temperature) A refractory material with a size of 2 cm square was placed on a hot plate set at 300 °C, and the temperature when it reached twice its initial thickness was defined as the thermal expansion start temperature.

[0114] (Expansion ratio) Test pieces (length 100 mm, width 100 mm, thickness 2.0 mm) of refractory materials composed of the refractory resin compositions obtained in each example and comparative example were prepared. The test pieces were supplied to an electric furnace and heated at 300 °C or 600 °C for 30 minutes. Then, the thickness of the test pieces was measured, and (thickness of the test piece after heating) / (thickness of the test piece before heating) was calculated as the expansion ratio.

[0115] (Residual hardness) The test piece after heating was supplied to a compression testing machine (manufactured by Kato Tech, "Finger Filling Tester"), and compressed at a speed of 0.1 cm / second with a indenter of 0.25 cm 2 to measure the breaking point stress.

[0116] (Residual rate) The weights of the test pieces after heating, for which the expansion ratios were measured at 300 °C and 600 °C, were measured. The test pieces were heated in a horizontal furnace for 1 hour along the heating curve of ISO834. The weights of the test pieces after heating were measured. The remaining rate (%) of the test piece weight after the heating test with respect to before the heating test was calculated and used as a measure of the durability of the residue.

[0117] (Fire resistance test) An opening with a diameter of 160 mm was made in the concrete body, and a VU pipe made of PVC100 (outer diameter 114 mm, thickness 3.1 mm, JIS standard K6741) was piped through it, extending 300 mm below the floor and 500 mm above the floor. The refractory materials obtained in each example and comparative example were bent into a sleeve shape and installed in the opening. The position of the pipe was adjusted so that each clearance between the sleeve and the pipe was 10 mm or more, and it was heated in a horizontal furnace for 2 hours along the heating curve of ISO834. When the temperature of the through-pipe 25 mm above the floor was less than the initial temperature + 180°C and there was no flame coming out after penetration, it was evaluated as qualified (PASS), and when the initial temperature was + 180°C or higher or the floor pipe penetrated and a flame came out, it was evaluated as unqualified (FAIL).

[0118] [Examples 1 - 6, Comparative Examples 1 - 4] With the formulations shown in Table 1 below, resin, thermally expandable layered inorganic substance, flame retardant, heat absorbent, lubricant, inorganic filler, plasticizer, and petroleum resin were put into a roll and kneaded at 130°C for 5 minutes to obtain a fire-resistant resin composition. The obtained fire-resistant resin composition was press-molded at 130°C for 3 minutes to obtain a thermally expandable sheet with a thickness of 1.5 mm (1.3 mm for Example 23). The evaluation results are shown in Table 1.

[0119]

Table 1

[0120] As shown in each of the above examples, the refractory material using the fire-resistant resin composition of the present invention had a sufficient expansion ratio, and the residue hardness and residue retention rate were also good. Therefore, even in the fire resistance test, there was no penetration and no flame came out. On the other hand, the refractory materials produced in the comparative examples had a low residue hardness and residue retention rate, or did not expand even at high temperatures, and all of them had penetration and flame-out in the results of the fire resistance test.

Explanation of symbols

[0121] 3 Sheet-like member 5 Cover member 10 Compartment penetration treatment structure 11 Partition part 12A, 12B Wall materials 13 Hollow part 13A, 13B Through holes 13C, 13D Openings 13E Gap 15 Compartment through part 21 Inserted body 22 String-like member 30A, ··· 30Y, 30Z Base materials 31A, ··· 31Y, 31Z Refractory material layers 32 Slit 33 Adhesive layer 40 Void

Claims

1. A fire-resistant resin composition for use in a fire-resistant structure of a building, comprising a resin, a plasticizer, an additive, and a thermally expandable layered inorganic material, The resin includes at least one selected from the group consisting of polyvinyl acetal, polybutene, and a rubber component, The fire-resistant resin composition, wherein the additive is at least one selected from the group consisting of a flame retardant, a heat absorbing agent, a lubricant, and an inorganic filler.

2. 2. The fire-resistant resin composition according to claim 1, wherein the rubber component is at least one selected from the group consisting of chloroprene rubber, natural rubber, butyl rubber, styrene-butadiene rubber, nitrile-butadiene rubber, ethylene propylene rubber, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, and acrylic rubber.

3. The fire-resistant resin composition according to claim 1 or 2, wherein the resin further comprises at least one selected from the group consisting of polyphenylene oxide and petroleum resin.

4. The fire-resistant resin composition according to any one of claims 1 to 3, wherein the polyvinyl acetal is polyvinyl butyral.

5. The fire-resistant resin composition according to any one of claims 1 to 4, wherein the content of the plasticizer is 0.5 to 100 parts by mass per 100 parts by mass of the resin.

6. The fire-resistant resin composition according to any one of claims 1 to 5, wherein the content of the thermally expandable layered inorganic material is 10 to 50 parts by mass per 100 parts by mass of the fire-resistant resin composition.

7. The fire-resistant resin composition according to any one of claims 1 to 6, wherein the ratio of the resin content to the powder content (resin / powder) is 0.2 to 3.

8. The fire-resistant resin composition according to any one of claims 1 to 7, wherein the thermally expandable layered inorganic material is thermally expandable graphite.

9. A fire-resistant material comprising the fire-resistant resin composition according to any one of claims 1 to 8.

10. The fireproof material according to claim 9, having an expansion ratio of 5 times or more at 300°C and an expansion ratio of 20 times or more at 600°C.

11. Residual hardness at 300°C is 4 kgf / cm ２ or more, and the residual hardness at 600°C is 0.3 kgf / cm ２ The fireproof material according to claim 9 or 10.

12. The fireproof material according to any one of claims 9 to 11, having a residue maintenance rate of 80% or more at 300°C and 50% or more at 600°C.

13. The fire-resistant material according to any one of claims 9 to 12, wherein the fire-resistant resin composition has a thermal expansion starting temperature of 100 to 300 ° C.

14. The fireproof material according to any one of claims 9 to 13, having a thickness of 0.1 to 10 mm.

15. A fire-resistant laminate comprising the fire-resistant material according to any one of claims 9 to 14, and a substrate and an adhesive layer integrated with the fire-resistant material.

16. A compartment penetration treatment material comprising the fire-resistant material according to any one of claims 9 to 14 or the fire-resistant laminate according to claim 15.

17. A compartment penetration treatment structure comprising the compartment penetration treatment material according to claim 16.

18. A method for constructing the compartment penetration structure according to claim 17.

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