Fire resistant structural material and building

Abstract

To provide a fire resistant structural material that can improve fire resistance, and a building.SOLUTION: A fire resistant structural material 10 comprises: an outer shell material 11 formed into a long cylindrical shape using a metal material; and a core material 12 inserted into the interior of the outer shell material 11. The core material 12 comprises: a non-combustible portion 13 in which at least one type of combustion inhibitor among a phosphorus-based combustion inhibitor, a boron-based combustion inhibitor and a halogen-based combustion inhibitor, and a silicate compound are impregnated and which is formed with a wood material hardened with the silicate compound; and an insulating portion 14 including an inorganic fiber aggregate 21 and a heat resistant composition 22 contained within the inorganic fiber aggregate 21.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a fire-resistant structural material with enhanced fire-resistant performance, and a building provided with columns and beams made of the fire-resistant structural material.

Background Art

[0002] Regarding structural materials for constructing buildings such as houses and buildings, those described in Patent Document 1 have been proposed. Patent Document 1 describes a fire-resistant composite member configured by integrating a steel material having a substantially H-shaped cross-sectional portion with a plurality of through holes and concrete. In the steel material, the yield strength at 600°C of the material is 155 N / mm for 400 N standard steel 2 or more, and 215 N / mm for 490 N standard steel 2 or more of fire-resistant steel is used.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] Buildings are supported by structural materials such as columns and beams. In the event of a fire, the building may collapse due to the loss of strength of the structural materials. In order to prevent such collapse of buildings during a fire, attempts have been made to improve the fire-resistant performance by using fire-resistant steel for the steel materials used in the structural materials or by integrating the steel materials and concrete as disclosed in Patent Document 1. However, the temperature during a fire can reach over 500°C about 5 minutes after ignition and 1100 - 1200°C about 7 - 8 minutes after ignition. However, the fire resistance performance of fire-resistant steel is about 500 - 600°C, and that of concrete is about 400°C, falling far short of 1000°C. Therefore, with the use of conventional fire-resistant steel, sufficient fire resistance performance cannot be obtained, and in particular, fire resistance performance such as 2-hour fire resistance or 3-hour fire resistance cannot be achieved.

[0005] The present invention solves the above-mentioned problems of the prior art, and an object thereof is to provide a fire-resistant structural material and a building capable of improving fire resistance performance.

Means for Solving the Problems

[0006] As means for solving the above problems, the present invention is as follows. 〔1〕The fire-resistant structural material of the present invention is a fire-resistant structural material comprising an outer shell material formed in a long cylindrical shape using a metal material, and a core material inserted inside the outer shell material, wherein the core material comprises a non-combustible part formed from a wood material impregnated with at least one combustion inhibitor selected from phosphorus-based combustion inhibitors, boron-based combustion inhibitors, and halogen-based combustion inhibitors and a silicate compound, and the silicate compound is cured, and a heat-insulating part including an inorganic fiber aggregate and a heat-resistant composition contained in the inorganic fiber aggregate, and is characterized by this. 〔2〕The core material may further comprise a rigid part formed from a steel pipe or a section steel, wherein the non-combustible part is arranged inside the rigid part, and the heat-insulating part may be arranged between the rigid part and the outer shell material. 〔3〕The non-combustible part may be formed in a columnar shape from one or more of the wood materials and filled inside the rigid part. 〔4〕The heat-insulating part may cover the rigid part from the outside. 〔5〕In the heat-insulating part, the inorganic fiber aggregate may include one or more glass fibers selected from E glass, S glass, T glass, and silica glass. 〔6〕The building of the present invention essentially comprises columns and / or beams formed using the fire-resistant structural material described in 〔1〕or 〔2〕.

Advantages of the Invention

[0007] According to the fire-resistant structural material and the building of the present invention, the core material having a non-combustible part and a heat-insulating part can maintain its strength even when exposed to high temperatures during a fire by suppressing heat transfer due to the fire in the heat-insulating part and suppressing combustion due to the fire in the non-combustible part, thereby improving the fire resistance performance.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Embodiments for Carrying Out the Invention

[0009] Hereinafter, the present invention will be described with reference to the drawings. The matters shown here are illustrative and for exemplarily explaining the embodiments of the present invention, and are described for the purpose of providing an explanation that can most effectively and easily understand the principle and conceptual features of the present invention. In this regard, it is necessary for a fundamental understanding of the present invention and does not intend to show the structural details of the present invention to a greater extent than necessary, and is to clarify to those skilled in the art how some forms of the present invention are actually embodied by the description combined with the drawings.

[0010] 〔1〕Fire-resistant structural material The fire-resistant structural material 10 of the present invention includes an outer shell material 11 formed in a long cylindrical shape using a metal material, and a core material 12 inserted inside the outer shell material 11 (see FIGS. 1 and 2). The fire-resistant structural material 10 is a structural material used in the construction of buildings and is a structural material provided with fire-resistant performance. A structural material refers to something used in the framework of buildings with structures such as wooden structures, steel frame structures, reinforced concrete structures, and steel frame reinforced concrete structures, and refers to something that bears and supports forces such as loads applied to the building. Specifically, examples of structural materials include vertical members provided to extend in a substantially vertical direction (vertical direction) such as columns, intermediate columns, continuous columns, and cross braces, and horizontal members provided to extend in a horizontal direction (horizontal direction) such as beams, girders, foundations, joists, roofs, and wall plates.

[0011] The outer shell material 11 is provided for protecting the core material 12 and imparting design properties to the fire-resistant structural material 10. The outer shell material 11 is formed in a long cylindrical shape using a metal material, and covers and protects the core material 12 inserted inside it from the outside. The outer shell material 11 can be decorated and painted by spraying a spraying material such as mortar or urethane on the outer surface, painting the outer surface with paint, pasting cloth or wallpaper on the outer surface, providing panel materials or board materials on the outer surface, etc., thereby imparting design properties to the fire-resistant structural material 10.

[0012] Note that for the panel materials, board materials, etc. provided on the outer surface of the outer shell material 11, structural plywood defined by Japanese Agricultural and Forestry Standards (JAS), or board materials and panel materials having strength equivalent to that of the structural plywood can be used. In this case, the strength of the fire-resistant structural material 10 can be increased. Alternatively, so-called "fire-resistant panels" such as gypsum boards, calcium silicate boards, cement boards, and ALC panels (lightweight cellular concrete panels) can be used for the panel materials, board materials, etc. provided on the outer surface of the outer shell material 11. In this case, the fire-resistant performance of the fire-resistant structural material 10 can be further improved. Among these fire-resistant panels, gypsum boards and calcium silicate boards are preferable from the viewpoint of being lightweight. In addition, for the panel material, board material, etc. provided on the outer surface of the outer shell material 11, for example, a laminated board formed by laminating a plurality of wood plates, or a laminated board formed by laminating a plurality of fire-resistant panels, or a laminated board formed by laminating a wood plate and a fire-resistant panel can also be used.

[0013] The material of the outer shell material 11 is not particularly limited as long as it is a metal material, and examples thereof include iron, copper, fire-resistant steel, nickel alloy, chromium alloy, nickel-chromium alloy, stainless steel, etc. When fire-resistant steel is used as the material of the outer shell material 11 among these, the fire-resistant performance of the fire-resistant structural material 10 can be further improved. The shape of the outer shell material 11 is not particularly limited as long as it is a cylindrical shape through which the core material 12 can be inserted, and examples of the cross-sectional shape include a polygonal ring shape such as a square ring shape, a triangular ring shape, a hexagonal ring shape, a circular ring shape, an elliptical ring shape, etc. The shape of the outer shell material 11 shown in FIGS. 1 and 2 is a cylindrical shape with a square ring-shaped cross section.

[0014] The core material 12 is provided for imparting the strength and rigidity required for the fire-resistant structural material 10 as the building framework, and imparting fire-resistant performance to the fire-resistant structural material 10. The core material 12 is inserted inside the outer shell material 11 and constitutes the core of the fire-resistant structural material 10. When the fire-resistant structural material 10 supports forces such as the load applied to the building, it becomes the main part that bears the force. For example, as shown in FIGS. 1 and 2, it is preferable that the outer diameter of the core material 12 is substantially the same as the inner diameter of the outer shell material 11. In this case, a configuration can be adopted in which the core material 12 is filled inside the outer shell material 11 without gaps, and the core material 12 and the outer shell material 11 are substantially integrated to bear the forces such as the load applied to the building, thereby improving the strength and rigidity of the fire-resistant structural material 10.

[0015] The core material 12 includes a non-combustible part 13 and a heat-insulating part 14. By providing these non-combustible part 13 and heat-insulating part 14 in the core material 12, the fire-resistant structural material 10 can exhibit excellent fire-resistant performance. That is, the non-combustible part 13 suppresses the combustion of the core material 12 without burning even during a fire, and by maintaining the shape, strength, etc. of the core material 12, it can prevent the fire-resistant structural material 10 from burning out, breaking, collapsing, etc. during a fire. The heat insulation part 14 prevents heat transfer from the outside to the inside of the core material 12 without cracking or the like even during a fire, and suppresses the core material 12 from reaching a high temperature (combustion temperature), thereby preventing the fire-resistant structural material 10 from burning out, breaking, collapsing, etc. during a fire.

[0016] The core material 12 can further include a rigid part 15 formed of a steel pipe and / or a section steel. The rigid part 15 is provided to improve the strength and rigidity of the core material 12. The material of the rigid part 15 is usually a steel material such as stainless steel, but iron, copper, fire-resistant steel, nickel alloy, chromium alloy, nickel-chromium alloy, etc. can also be used. In particular, when using fire-resistant steel, nickel alloy, chromium alloy, nickel-chromium alloy, etc. for the material of the rigid part 15, the fire-resistant performance of the fire-resistant structural material 10 can be further improved.

[0017] The steel pipe forming the rigid part 15 is not particularly limited in shape, and examples of the cross-sectional shape include polygonal annular shapes such as square annular, triangular annular, hexagonal annular, circular annular, elliptical annular, etc. The section steel forming the rigid part 15 is not particularly limited in shape, and examples of the cross-sectional shape include H-shaped, I-shaped, Z-shaped (crank-shaped), T-shaped, L-shaped (gable-shaped), C-shaped (grooved-shaped), etc. For the rigid part 15, only the rigid part 15 formed of a steel pipe (see Fig. 1), or only the rigid part formed of a section steel (not shown) can be used, or the rigid part 15A formed of a steel pipe and the rigid part 15B formed of a section steel can be used in combination (see Fig. 2).

[0018] When the core material 12 includes the rigid part 15, it is preferable that the non-combustible part 13 is arranged inside the rigid part 15, and the heat insulation part 14 is arranged between the rigid part 15 and the outer shell material 11. When the non-combustible part 13 is arranged inside the rigid part 15, it is preferable that the non-combustible part 13 is formed in a columnar shape from one or more wood materials and is filled inside the rigid part 15. In this case, the non-combustible part 13 can constitute the core part of the core material 12 which is the core part of the fire-resistant structural material 10. In the fire-resistant structural material 10 that bears forces such as the load applied to the building, by making the core part of the core material 12 a so-called "non-combustible", the strength and rigidity of the fire-resistant structural material 10 (core material 12) can be maintained over a long period of time during a fire. Also, the non-combustible part 13 can be configured to be filled inside the rigid part 15 without gaps, and by making the non-combustible part 13 and the rigid part 15 substantially integral, the strength and rigidity of the core material 12 can be improved.

[0019] When the non-combustible part 13 is formed in a columnar shape from one wood material, in order to fill it inside the rigid part 15 without gaps, processing such as cutting and shaving the wood material according to the size of the rigid part 15 is required. On the other hand, when the non-combustible part 13 is formed in a columnar shape from a plurality of wood materials, wood materials of various sizes can be combined to match the size of the rigid part 15, and the processing of the wood material can be omitted, so the workability can be improved.

[0020] When the heat insulation part 14 is arranged between the rigid part 15 and the outer shell material 11, it is preferable that the heat insulation part 14 is configured to cover the rigid part 15 from the outside. In this case, since the rigid part 15 is covered by the heat insulation part 14, it is possible to suppress the transmission of the high heat during a fire to the rigid part 15 and suppress the softening of the rigid part 15, and the strength and rigidity of the fire-resistant structural material 10 (core material 12) can be maintained over a long period of time during a fire. Also, by adjusting the thickness of the heat insulation part 14 that covers the rigid part 15, the core material 12 can be configured to be filled inside the outer shell material 11 without gaps, and by making the core material 12 and the outer shell material 11 substantially integral, the strength and rigidity of the fire-resistant structural material 10 can be improved. Note that the heat insulation part 14 can be configured to cover the rigid part 15 from the outside by forming it in a sheet shape and winding it around the outer surface of the rigid part 15, or forming it in a plate shape, box shape, cylindrical shape, etc. and adhering it to the rigid part 15.

[0021] (1) Non-combustible part The above-mentioned non-combustible part 13 is formed from a wood material impregnated with at least one combustion inhibitor among phosphorus-based combustion inhibitors, boron-based combustion inhibitors, and halogen-based combustion inhibitors and a silicate compound, and the silicate compound is cured (gelled). That is, the wood material used for the non-combustible part 13 has been subjected to a flame retardant treatment using a combustion inhibitor and a silicate compound. Even when this flame retardant-treated wood material is exposed to a high temperature during a fire, it will not burn and be lost, but can maintain its shape, strength, etc. by carbonizing. That is, the non-combustible part 13 formed from the flame retardant-treated wood material can maintain its shape, strength, etc. by carbonizing even when exposed to a high temperature during a fire. In this way, even when exposed to a high temperature during a fire, since the non-combustible part 13 carbonizes and maintains its shape, strength, etc., the fire-resistant structural material 10 (core material 12) can maintain its strength and rigidity for a long time, and in particular, can have the performance of meeting the requirement of 2-hour fire resistance in the Building Standards Law, and more preferably can have the performance of meeting the requirement of 3-hour fire resistance.

[0022] (1-1) Flame retardant treatment The flame retardant treatment is a treatment for making materials derived from wood, such as wood and wood-based panels, flame retardant. Therefore, "wood" and "wood-based panels" are not particularly limited as long as they are materials derived from wood, and all natural woods, processed woods, or glued laminated timber, plywood, medium density fiberboard (MDF), hard fiberboard (hard board), soft fiberboard (insulation board), particle board, etc. can be used. The form of the wood and wood-based panels is also not particularly limited, and examples include square timbers, bars, columns, and boards. The tree species from which the material is derived (tree species) is not particularly limited. However, when using natural wood or processed wood, the higher the density (ρ), the better the retention of shape, strength, etc. during carbonization in case of fire. From this perspective, the density (ρ) is preferably 260 kg / m 3 or more. Specifically, as tree species, cedar (ρ; about 270 - 330 kg / m 3 ), aspen (ρ; about 630 - 640 kg / m 3 ), beech (ρ; about 650 - 670 kg / m 3 ), or hinoki (asnalo), cypress, sawara, etc. of the cypress family (ρ; about 370 - 460 kg / m 3 ), oak, kunugi, konara, kashiwa, naragashiwa, abemaki, etc. of the oak family (ρ; 800 kg / m 3 or more), ash, Japanese hornbeam, etc. of the ash family (ρ; 1000 kg / m 3 or more), etc. can be mentioned.

[0023] The wood, wood-based panels, etc. to be subjected to the flame retardant treatment can be used as they are, or those that have been sufficiently dried before treatment can be used. In particular, the dried ones can improve the strength by removing shrinkage, warping, etc. The degree of drying is not particularly limited. Usually, the moisture content of wood and wood-based panels is about 15% by mass at the equilibrium moisture content for outdoor storage, 8 - 15% by mass for indoor storage, and about 12% by mass on average. However, the wood and wood-based panels before treatment can be dried, for example, to a moisture content of 0 - 5% by mass. The drying method is not particularly limited, and examples include high-frequency heating, superheated steam heating, hot plate heating, etc.

[0024] The flame retardant treatment comprises the following steps. First impregnation step; a step of impregnating wood, wood-based panels, etc. with a silicate compound and a gelling agent. Hardening step; a step of hardening (gelatinizing) the silicate compound with the gelling agent. Second impregnation step; a step of impregnating wood, wood-based panels, etc. with at least one combustion inhibitor selected from a phosphorus-based combustion inhibitor, a boron-based combustion inhibitor, and a halogen-based combustion inhibitor. The first impregnation step and the second impregnation step can be carried out separately in two steps, but can also be carried out in one step together.

[0025] The order of each step included in the flame retardant treatment is not particularly limited as long as the curing step is carried out after the first impregnation step. As specific orders of each step, the following orders A to D can be mentioned. Order A: First impregnation step, curing step, second impregnation step Order B: First impregnation step, second impregnation step, curing step Order C: First impregnation step and second impregnation step, curing step Order D: Second impregnation step, first impregnation step, curing step

[0026] Among the above-mentioned orders A to D, order A is preferable because after impregnating wood or the like with a silicate compound and curing (gelatinizing) it, a combustion inhibitor can be impregnated. That is, the cured (gelatinized) silicate compound has excellent adsorptivity, and the combustion inhibitor is adsorbed by the cured (gelatinized) silicate compound and firmly fixed inside wood or the like. Therefore, elution of the combustion inhibitor to the surface of wood or the like can be prevented, and water resistance can be improved. Also, in the case of order A, since the silicate compound has been previously impregnated and cured (gelatinized) inside wood or the like, the amount of the combustion inhibitor to be impregnated later can be reduced.

[0027] In the flame retardant treatment, in the case of the above-mentioned order A, a silicate compound and a gelling agent can be impregnated into wood or the like, and after the silicate compound is cured (gelatinized), a combustion inhibitor can be impregnated into wood or the like. In this case, wood or the like can be dried before impregnating with the silicate compound and the gelling agent and before impregnating with the combustion inhibitor, respectively. In particular, when wood or the like is dried after the silicate compound is cured (gelatinized) and before the combustion inhibitor is impregnated into wood or the like, voids are generated due to shrinkage of the cured (gelatinized) silicate compound inside wood or the like, so that the permeability of the liquid agent used for impregnating the combustion inhibitor can be improved.

[0028] (1-2) Liquid agent The flame retardant treatment is a treatment for making wood, wood-based panels, etc. flame retardant by impregnating them with a silicate compound and at least one flame retardant selected from phosphorus-based flame retardants, boron-based flame retardants, and halogen-based flame retardants, and then curing the silicate compound. In this flame retardant treatment, a liquid agent for impregnating wood, wood-based panels, etc. with a silicate compound, a flame retardant, etc. is used. The liquid agent contains a silicate compound, a flame retardant, and a gelling agent for curing the silicate compound. As the silicate compound, a silicate-based compound that can be gelled (cured) by a gelling agent can be used. Specifically, examples of the silicate compound include silica contained in colloidal silica and alkali silicate. As the flame retardant, at least one of a phosphorus-based flame retardant, a boron-based flame retardant, and a halogen-based flame retardant can be used.

[0029] (1-3) Silicate compound Colloidal silica as a silicate compound is represented by the general formula: Me2O·nSiO2 [Me is Na, R3N or R4N (R is a hydrogen atom or an organic group such as choline, monomethyltriethanolammonium, etc.), and n is 50 to 300.]. Colloidal silica is a colloid in which silica is dispersed in a medium. This silica, unlike alkali silicate, has a high molar ratio of SiO2 of 50 to 300. Also, the particle size of the silica is usually 5 nm or more, and the upper limit is 50 μm or less, preferably 20 μm or less. In colloidal silica, the concentration of silica is not particularly limited, and in terms of SiO2 concentration, it is preferably 20 to 50% by mass, more preferably 20 to 40% by mass. Also, colloidal silica includes those in an aqueous dispersion system (hereinafter also referred to as "aqueous colloidal silica") and those in an organic medium dispersion system (hereinafter also referred to as "organocolloidal silica"), and either one alone can be used, or both can be used in combination.

[0030] When using aqueous colloidal silica, a low-viscosity product with a silica particle size preferably of 20 μm or less, more preferably 15 μm or less can be used. Also, when using aqueous colloidal silica, the SiO2 concentration is preferably 20 to 50% by mass, more preferably 20 to 40% by mass, and even more preferably 20 to 35% by mass. Aqueous colloidal silica is preferable because when Me in the above general formula is R4N (ammonium silicate), it has advantages such as low viscosity even when the SiO2 concentration is relatively high compared to other colloids and strong binding force.

[0031] When using organo colloidal silica, a low-viscosity product with a silica particle size preferably of 20 μm or less, more preferably 15 μm or less can be used. Also, when using organo colloidal silica, the SiO2 concentration is preferably 20 to 40% by mass, more preferably 20 to 30% by mass. Organo colloidal silica can be a colloid with low viscosity and high SiO2 concentration when the medium is methanol, isopropanol, or a xylene-butanol mixed medium, etc., and is preferable.

[0032] Aqueous colloidal silica and organo colloidal silica preferably have a low viscosity of preferably 1 to 50 cps / 25 °C, more preferably 1 to 30 cps / 25 °C. By having a low viscosity, the permeability into wood and the like can be made good. The silica dispersed in the colloidal silica preferably has a small particle size, for example, with a particle size of 20 μm or less. When the particle size is 20 μm or less, it is about the same as the cell wall pores of wood and the like, and the silicate compound can be impregnated into the interior of the cell wall of wood and the like.

[0033] When an alkali silicate that is liable to discolor is included, it is preferable to use colloidal silica in combination. Thereby, discoloration due to an alkali metal can be significantly suppressed. When an alkali silicate and colloidal silica are used in combination, when the total amount of the silicate compound is 100% by mass, the alkali silicate (proportion in solid content) is preferably 50% by mass or less, particularly preferably 30% by mass or less, and still more preferably 10% by mass or less.

[0034] As the alkali silicate as the silicate compound, it is a salt of a silicate compound represented by the general formula; Me2O·nSiO2 (Me is Na, K, Li, R3N, or R4N (R is an organic group such as choline or monomethyltriethanolammonium, or a hydrogen atom), and n is a number from 0.5 to 10). Specifically, examples of the alkali silicate include sodium silicate, potassium silicate, lithium silicate, tertiary amine silicate, quaternary ammonium silicate, and the like. Among these, it is preferably at least one of sodium silicate, lithium silicate, and potassium silicate, and more preferably at least one of sodium silicate and lithium silicate. Moreover, when sodium silicate and lithium silicate are used in combination, it is particularly preferable because it has a low viscosity and excellent permeability to wood. Furthermore, from the viewpoint of suppressing discoloration of the modified wood, lithium silicate, tertiary amine silicate, and quaternary ammonium silicate are preferable. These alkali silicates may be used alone or in combination of two or more.

[0035] The content of the alkali silicate is not particularly limited, and when the total amount of the liquid agent is 100% by mass, it can be preferably 10 to 50% by mass, more preferably 15 to 30% by mass. In this case, while having a sufficiently high concentration, it has an appropriate viscosity and excellent permeability to wood. Also, in this case, the viscosity can be reduced and the permeability can be further improved by heating to such an extent that gelation does not occur. That is, more silicate compounds can be impregnated into wood or the like in one treatment. Furthermore, in order to impregnate more silicate compounds into wood or the like, pressurization and depressurization can be repeated.

[0036] When using sodium silicate as the alkali silicate and water as the medium, it is preferable to use lithium silicate in combination. In particular, since it contains more silicon relative to the alkali metal element and can efficiently impregnate wood with silicon, as the alkali silicate, it is preferable to use sodium silicate of JIS No. 3 or JIS No. 4. However, if attempting to prepare a liquid agent with the above-mentioned concentration of alkali silicate using only these sodium silicates, the viscosity will increase. In this case, by using lithium silicate, which has a low viscosity when water is the medium, in combination, the viscosity can be reduced. The viscosity of the liquid agent in this case can be, for example, 5 - 250 cps / 25°C, particularly 10 - 150 cps / 25°C.

[0037] (1 - 4) Gelation agent The gelation agent only needs to be able to gel, that is, cure, the silicate compound, and can be appropriately selected and used according to the type of silicate compound. This gelation agent can be solid or liquid. Examples of the gelation agent include acidic reaction agents and metal salt reaction agents.

[0038] Examples of the acidic reaction agent include sulfuric acid, phosphoric acid, boric acid, oxalic acid, acetic acid, carbonic acid, formic acid and its salts, compounds that exhibit acidity, boric acid and its salts, compounds that exhibit acidity, phosphate salts or boric acid salts that exhibit acidity by thermal decomposition, etc. can be used. Specific examples include sodium phosphate, sodium dihydrogen phosphate, ammonium dihydrogen phosphate, calcium hydrogen phosphate, alkyl group - stabilized aluminum polyphosphate, etc.

[0039] As the metal salt reaction agent, salts of metals such as alkali metals and alkaline earth metals can be used. Specific examples include sodium chloride, calcium chloride, magnesium chloride, magnesium sulfate, aluminum sulfate, etc.

[0040] When the silicate compound is silica (when using colloidal silica), the hydrogen ion index (pH) of the liquid agent is adjusted to avoid the most unstable pH range of 4.0 to 7.0, and to be in either the acidic or alkaline stable range that can extend the pot life. After adjusting the pH, the liquid agent is impregnated into the wood, and then the gelling agent is decomposed, or the gelling agent can be impregnated in the next step to cause gelation. When using an alkali silicate, for example, water glass, avoid the most unstable neutral pH range of 6.5 to 8.5, impregnate the wood as an acidic silica sol dispersion in the acidic range that can extend the pot life, then decompose the gelling agent contained in the liquid agent, adjust the pH to the unstable neutral range to cause gelation, or the gelling agent can be impregnated in the next step to cause gelation. Furthermore, when using an alkali silicate, as the gelling agent, other gelling agents excluding the metal salt reactant, for example, an acidic reactant, are used.

[0041] (1-5) Combustion inhibitor The combustion inhibitor is for suppressing the combustion of wood, and at least one of a phosphorus-based combustion inhibitor, a boron-based combustion inhibitor, and a halogen-based combustion inhibitor can be used. Also, as the combustion inhibitor, for example, a compound that can be in the form of a solution or a dispersion, that is, a compound that can be liquefied, can be used. It is preferable to use a phosphorus-based combustion inhibitor and a boron-based combustion inhibitor in combination. Compared with the case of using the phosphorus-based combustion inhibitor and the boron-based combustion inhibitor alone, higher heat resistance and flame retardancy can be exhibited. This can be understood from the fact that when the wood impregnated with the combustion inhibitor is subjected to differential thermal analysis, the residual weight during heating is more when used in combination than when used alone.

[0042] (1-6) Phosphorus-based combustion inhibitor Phosphorus-based combustion inhibitors contain compounds having a phosphorus element and can usually exhibit a combustion-inhibiting effect by the dehydration carbonization action of the compounds having a phosphorus element. The dehydration carbonization action is an action of dehydrating cellulose constituting wood and separating it into water and carbon when heated. In addition to the compounds having a phosphorus element, the phosphorus-based combustion inhibitors can also contain other compounds other than the compounds having a phosphorus element.

[0043] Specific examples of the phosphorus-based combustion inhibitors include phosphoric acid, phosphates, and the like. Examples of phosphoric acid include metaphosphoric acid and polyphosphoric acid. Examples of phosphates include ammonium phosphate, guanidine phosphate, guanylurea phosphate, melamine phosphate, ammonium sodium hydrogen phosphate, ammonium hydrogen phosphate, sodium phosphate, sodium hydrogen phosphate, and the like. These phosphoric acids, phosphates, etc. can be used alone or in combination of two or more. For the phosphorus-based combustion inhibitors, any of synthetic products, natural products, processed natural products, and their mixtures can be used.

[0044] The phosphorus-based combustion inhibitors can more effectively exhibit the combustion-inhibiting effect by being used in combination with other compounds, particularly nitrogen-based combustion-inhibiting aids. The nitrogen-based combustion-inhibiting aids are composed of compounds having a nitrogen element. Examples of the nitrogen-based combustion-inhibiting aids include various compounds having a nitrogen element such as ammonium nitrate, urea, guanidine, dicyandiamide, and ammonium chloride. These can be used alone or in combination of two or more. For the nitrogen-based combustion-inhibiting aids, any of synthetic products, natural products, processed natural products, and their mixtures can be used.

[0045] (1-7) Boron-based combustion inhibitors The boron-based combustion inhibitor contains a compound containing boron element. Usually, the compound containing boron element is dehydrated and decomposed by heating, and then melted to form a glassy state to cover the wood surface, thereby suppressing combustion. Specific examples of the boron-based combustion inhibitor include boric acid, borate, etc. Examples of borate include sodium borate (borax). These boric acid, borate, etc. can be used alone, or two or more of them can be used in combination. For the boron-based combustion inhibitor, any of synthetic products, natural products, processed natural products, and their mixtures can be used. In addition, the boron-based combustion inhibitor can contain other compounds other than the compound having boron in addition to the compound having boron.

[0046] (1-8) Halogen-based combustion inhibitor The halogen-based combustion inhibitor contains a compound having a halogen element. Usually, during the thermal decomposition of wood, the compound having a halogen element combines with the decomposition components to form a non-combustible component or a flame-retardant component, thereby suppressing combustion. The halogen element is not particularly limited, but among them, bromine and chlorine are preferred. Specific examples of the halogen-based combustion inhibitor include various halides, for example, ammonium chloride, ammonium bromide, calcium chloride, zinc chloride, antimony chloride, chlorinated paraffin, etc. For the halogen-based combustion inhibitor, any of synthetic products, natural products, processed natural products, and their mixtures can be used. In addition, the halogen-based combustion inhibitor can contain other compounds other than the compound having a halogen element in addition to the compound having a halogen element.

[0047] (1-9) Medium, etc. The liquid agent is any one of a liquid in which a silicate compound, a combustion inhibitor, a gelling agent, etc. are dissolved in a medium, a liquid dispersed in a medium, and a mixture of these. This liquid agent can be in a single dosage form in which all of the silicate compound, combustion inhibitor, and gelling agent are dissolved or dispersed in the same medium, or can be in a two-dosage form in which one or two selected from the silicate compound, combustion inhibitor, and gelling agent are dissolved or dispersed in different media, or can be in a three-dosage form in which the silicate compound, combustion inhibitor, and gelling agent are dissolved or dispersed in different media respectively. The method for preparing the liquid agent is not particularly limited as long as the silicate compound, combustion inhibitor, and gelling agent can be dissolved or dispersed in the medium respectively. Specifically, the liquid agent can be prepared by mixing three agents: a dispersion of a silicate compound such as colloidal silica or a solution of a silicate compound such as an alkali silicate, a dispersion or solution of a combustion inhibitor, and a gelling agent. Whether the liquid agent is in the single-dosage form, two-dosage form, or three-dosage form is not particularly limited. For example, it can be appropriately selected according to, for example, which order among the above-mentioned orders A to D each step of the flame retardant treatment is carried out. As a specific example, when each step of the flame retardant treatment is carried out in order A, the liquid agent can be in a two-dosage form having Agent A containing a silicate compound and a gelling agent and Agent B containing a combustion inhibitor. When each step of the flame retardant treatment is carried out in order C, the liquid agent can be in a single-dosage form containing a silicate compound, a combustion inhibitor, and a gelling agent.

[0048] The medium used for the liquid agent is not particularly limited, and water, an organic medium, or a mixed medium of water and an organic medium may be used. The medium is preferably an aqueous medium, and water or a mixed medium of water and a highly hydrophilic organic medium is preferred. In the case of a mixed medium, as the organic medium to be used, an alcohol having 1 or 2 carbon atoms, particularly methanol having 1 carbon atom, is preferred. In this case, the permeability can be further improved. The content of the alcohol having 1 or 2 carbon atoms in the mixed medium is not particularly limited, but when the total amount of the medium is 100% by mass, it is preferably 50% by mass or less, more preferably 10 to 40% by mass.

[0049] The pot life of the liquid agent only needs to be longer than the time required to impregnate wood or the like with the silicate compound and the combustion inhibitor, and is not particularly limited. This pot life is usually 2 to 50 days, preferably 10 days or more, and more preferably 50 days or more. If this pot life is 10 days or more, there are advantages such as excellent operability, sufficient time to impregnate the liquid agent into the wood, and the ability to use it continuously many times. Also, this pot life can be controlled by adjusting the pH. After penetrating and impregnating wood or the like, water is removed in the drying process, concentrated and gelled (cured), the gelling agent is thermally decomposed to adjust the pH to the neutral range for gelling (curing), or the gelling agent can be impregnated in the next step for gelling (curing).

[0050] The specific pot life is as follows. 〔1〕When using colloidal silica containing 30% by mass of silica and aluminum alkyl-stabilized polyphosphate, and making a liquid agent containing 70 parts by mass of colloidal silica, 30 parts by mass of aluminum alkyl-stabilized polyphosphate and 10 parts by mass of water, it is stable for 6 months or more at room temperature (for example, 20 to 30 °C). When making a liquid agent containing 50 parts by mass of colloidal silica and 50 parts by mass of aluminum alkyl-stabilized polyphosphate, it is stable for 5 to 6 days.

[0051] 〔2〕When using colloidal silica containing 30% by mass of silica and oxalic acid dihydrate, and making a liquid agent containing 100 parts by mass of colloidal silica and 4 parts by mass of oxalic acid dihydrate, gelation starts on the 4th day at room temperature, and when the temperature of the sol is raised at 2 °C / min, gelation starts at 84 °C. 〔3〕When using colloidal silica containing 30% by mass of silica and potassium silicate 1K, and making a liquid agent containing 100 parts by mass of colloidal silica and 10 parts by mass of potassium silicate 1K, gelation starts on the 17th day at room temperature. When making a liquid agent containing 100 parts by mass of colloidal silica and 25 parts by mass of potassium silicate 1K, gelation starts on the 3rd day.

[0052] [4] When using colloidal silica containing 30% by mass of silica and potassium disilicate, a liquid agent containing 80 parts by volume of colloidal silica and 20 parts by volume of potassium disilicate starts to gel on the second day at room temperature. When it is a liquid agent containing 50 parts by volume of colloidal silica and 50 parts by volume of potassium disilicate, it starts to gel in 16 hours. The pot life is a bit short but it is practicable. [5] When using colloidal silica containing 30% by mass of silica and ammonium formate, a liquid agent containing 100 parts by mass of colloidal silica and 0.5 parts by mass of ammonium formate starts to gel on the third day at room temperature. [6] When using colloidal silica containing 30% by mass of silica and ammonium acetate, a liquid agent containing 100 parts by mass of colloidal silica and 0.5 parts by mass of ammonium acetate starts to gel on the sixth day at room temperature, and when the sol is heated at 100 °C for 5 minutes, it starts to gel.

[0053] Furthermore, when the silicate compound is colloidal silica, in the range of pH 8.0 - 11.0, especially 8.5 - 10.0, the pot life is short, unstable and extremely difficult to use. Therefore, it is preferable to adjust the pH with a basic compound - based gelling agent and control the pot life for use. Also, when the silicate compound is an alkali silicate, in the range of pH 3.5 - 10.0, especially 4.5 - 9.5, the pot life is short, unstable and extremely difficult to use. Therefore, it is preferable to convert it to an acidic sol (pH 1.0 - 2.5) with high stability and long pot life by using sulfuric acid, phosphoric acid, etc. and having a low viscosity, impregnate wood, etc., and then adjust the pH to 6.0 - 8.0 for gelling.

[0054] (1 - 10) Impregnation method and impregnation conditions The method of impregnating a liquid agent into wood, etc. is not particularly limited. For example, there are pressure impregnation in which nitrogen gas, etc. is used to impregnate while applying pressure, and normal pressure impregnation in which impregnation is carried out without applying pressure. Among these, pressure impregnation is preferable because more silicate compounds, combustion inhibitors and gelling agents can be impregnated into the tissue of wood, etc. (inside conduits, cell walls, etc.) by applying pressure. During impregnation, the liquid agent may be applied to the surface of wood, wood-based panels, etc. However, it is preferable to provide hole-shaped or slit-shaped recesses on the surface of wood, wood-based panels, etc. For example, when impregnating a wood material made of a square timber as the wood material used for forming the non-combustible part 13 with a liquid agent, as shown in FIGS. 3(a) and 3(b), a plurality of hole-shaped recesses 111A are provided on the surface of the wood material 111, and the liquid agent is injected or press-fitted into these recesses 111A to impregnate with a silicate compound, a combustion inhibitor, and a gelling agent.

[0055] The method for forming the recess 111A is not particularly limited. For example, holes may be formed by laser light, by a woodworking machine such as a drill, or by other methods, or two or more of these methods may be used in combination. Note that the type of laser light is not particularly limited, but a carbon dioxide laser is preferable. The wavelength, output, etc. of the laser light are also not limited, and it is preferable to set them according to the type of wood, etc., the shape and depth of the recess, etc. When using laser light, compared with other methods, for example, when using a woodworking machine, recesses with higher dimensional accuracy can be formed more easily.

[0056] The recess 111A is a hole formed in the wood material 111, and this hole may penetrate the wood material or may be a bottomed one that does not penetrate. That is, the depth of the recess (hole) is not particularly limited, and it is preferably set in consideration of the fact that the liquid agent is impregnated in the range of 30 to 50 mm around the recess. The shape of the recess 111A is not particularly limited. For example, a cylindrical hole with a substantially circular opening shape and a linear cross-sectional shape, and a conical hole with a substantially circular opening shape and a cross-sectional shape that tapers inward as shown in FIGS. 3(a) and 3(b) can be mentioned. In addition, for the opening shape, polygons such as a quadrilateral can be mentioned, and for the cross-sectional shape, a polygonal line shape, a curved line shape, etc. can be mentioned.

[0057] The extending direction of the recess 111A is not particularly limited, and for example, a direction intersecting the wood grain and a direction substantially parallel to the wood grain can be mentioned. The size of the recess 111A is not particularly limited. For example, the opening diameter of the recess 111A can be set to 0.5 mm to 1 mm. The recess 111A can diffuse and impregnate the liquid agent in a range of 30 to 50 mm around the periphery of one recess.

[0058] The formation position, number of formations, formation density, etc. of the recess 111A are not particularly limited. These formation position, number of formations, formation density, etc. can be set according to the properties and uses of the wood material, etc. For example, if a recess is formed at an inconspicuous location such as the back surface, end surface, or peripheral surface of the wood material, etc., deformation and strength reduction of the wood material, etc. can be suppressed, and deterioration of the appearance can be prevented. Regarding the formation position, number of formations, formation density, etc. of the recess 111A, it can be appropriately set according to the hardness of the wood material, etc., the density of the wood grain (annual rings), the grain pattern, the straight grain, etc.

[0059] When the recess 111A is provided, the liquid agent is not only impregnated into the surface layer portion of the wood material, etc., but also impregnated into the interior of the wood material, etc. through the recess 111A. Therefore, more silicate compounds, combustion inhibitors, and gelling agents can be impregnated into the wood material, etc. That is, the formation of the recess 111A contributes to improving the permeability of the liquid agent to the wood material, etc. For this reason, even when it is difficult to penetrate and impregnate the liquid agent deep into the interior by applying pressure or heat, such as in the case of a long wood material like the wood material 111, or a large-sized one such as a large area, or a hard one with clogged wood grain, etc., the formation of the recess allows the liquid agent to be easily penetrated and impregnated (for example, at low pressure and in a short time).

[0060] The impregnation conditions are not particularly limited, but it is preferable to impregnate in consideration of the pot life of the liquid agent. Regarding the presence or absence of heating of the liquid agent and / or the wood, wood-based board, etc. during impregnation, it is not particularly limited. However, when heated, the penetration rate can be increased, and particularly, a sufficient penetration rate can be achieved even at normal pressure or low pressure. However, when heating a liquid agent with a particularly short available time, it is necessary to be fully cautious because the silicate compound may harden (gel) during impregnation.

[0061] When applying pressure, the pressure application method is not particularly limited. For example, a gas may be injected into the reaction vessel for pressurization, or pressurization may be achieved by heating, or a combination of these methods may be used. The pressurization conditions are not particularly limited either, but it is preferably set appropriately according to, for example, the type of wood, moisture content, degree of vacuum, state and type of wood grain, dimensions and shape of the wood, etc. Generally, the pressure is preferably 10 MPa or less, particularly 8 MPa or less, and more preferably 6 MPa or less (usually 0.2 MPa or more). This can sufficiently prevent warping, deformation, cracking, etc. without being affected by the type and shape of the wood.

[0062] Particularly, for wood or wood materials without distinguishable annual rings, regardless of whether they are soft or hard, pressurization can be carried out up to 10 MPa. For softwood or wood materials with distinguishable annual rings, it is preferably 3 MPa or less (usually 0.5 MPa or more). For hardwood or wood materials with distinguishable annual rings, it is preferably 5 MPa or less (usually 1.5 MPa or more). The softwood or wood material refers to wood or wood material with a density of less than 0.56 kg / m 3 measured according to JIS Z2101 at a temperature of 25°C and a moisture content of 7 mass% or less. Examples of softwood include coniferous wood such as cedar, cypress, and lauan.

[0063] The liquid agent can also be heated for impregnation. When heating, the liquid agent may be heated, the entire container of the liquid agent may be heated, or a combination of these heating methods may be used. The liquid agent can be heated, for example, using a heating container separate from the container for impregnating the liquid agent. Also, the liquid agent can be circulated between the containers. The temperature of the heated liquid agent is not particularly limited, but it is preferably less than 180°C, particularly 40 to 150°C, and more preferably 60 to 120°C. If the liquid temperature is within this range, the penetration rate can be sufficiently improved, and damage to the wood and deterioration of the liquid can be prevented. Further, by raising the liquid temperature in this way, the penetration rate can be improved 2 to 5 times compared to when impregnating at room temperature (for example, 20 to 30°C), and the time required for the step of impregnating with the silicate compound (the first step) can be significantly shortened.

[0064] (1-11) Impregnation amount of silicate compound The impregnation amount of the silicate compound into wood or the like is not particularly limited, but in order to obtain a sufficient flame retardant effect, based on 100 parts by mass of the mass of the wood before impregnation, in terms of the content of SiO2, it can preferably be 40 to 200 parts by mass, more preferably 50 to 150 parts by mass, and still more preferably 60 to 120 parts by mass.

[0065] (1-12) Mixing amount of gelling agent The mixing amount of the gelling agent in the liquid agent varies depending on the type of the gelling agent and is not particularly limited, but it can be set to a blending amount that can sufficiently gel the silicate compound. For example, in the case of ammonium formate, ammonium acetate, etc., it can be 0.2 to 1.0 part by mass (assuming 100 parts by mass of the silicate compound. The same applies hereinafter), particularly about 0.3 to 0.7 part by mass, and in the case of aluminum alkyl group stabilized polyphosphate, oxalic acid, 1K (2K) potassium silicate, etc., it can be 1 to 40 parts by mass, particularly 2 to 30 parts by mass. Thus, although the mixing amount of the gelling agent needs to be set depending on the type, it is preferably 0.2 to 40 parts by mass, particularly 0.3 to 30 parts by mass, and still more preferably 0.5 to 25 parts by mass. In addition, since there is a preferable mixing range depending on each combination of the silicate compound and the gelling agent, it is preferable to set the mixing amount to obtain a sufficient pot life. Further, the mixing amount of the gelling agent represents the mass ratio of the acidic reactant to 100 parts by mass of the silicate compound in a liquid agent containing only the acidic reactant (not containing the metal salt reactant). In addition, in a liquid agent containing only a metal salt reactant (not containing an acidic reactant), the mass ratio of the metal salt reactant to 100 parts by mass of the silicate compound is represented. Furthermore, in a liquid agent containing an acidic reactant and a metal salt reactant, the total mass ratio of the acidic reactant and the metal salt reactant to 100 parts by mass of the silicate compound is represented.

[0066] (1 - 13) Impregnation amount of combustion inhibitor The impregnation amount of the combustion inhibitor into wood or the like is not particularly limited. However, from the viewpoint of obtaining a suitable combustion inhibition effect, usually, for the lower limit of the impregnation amount in 1 m 3 of the volume of wood or the like, it can be 100 Kg / m in terms of solid content. 3 or more. The impregnation amount of the combustion inhibitor can preferably be 150 Kg / m 3 or more, more preferably 200 Kg / m 3 or more, and still more preferably 300 Kg / m 3 or more. Also, the upper limit of the impregnation amount of the combustion inhibitor is not particularly limited, but usually, it can be 700 Kg / m 3 or less. Note that as the combustion inhibitor, at least one of a phosphorus - based combustion inhibitor, a boron - based combustion inhibitor, and a halogen - based combustion inhibitor is used. However, the above - mentioned impregnation amount is the total amount of what is impregnated as the combustion inhibitor. That is, when two or more of a phosphorus - based combustion inhibitor, a boron - based combustion inhibitor, and a halogen - based combustion inhibitor are used as the combustion inhibitor, it is the total amount of them.

[0067] Specifically, from the viewpoint of obtaining a sufficient combustion inhibition effect, the lower limit of the impregnation amount of the phosphorus - based combustion inhibitor is, in terms of solid content, preferably 100 Kg / m 3 or more, more preferably 120 Kg / m 3 or more, still more preferably 200 Kg / m 3 or more, and particularly preferably 300 Kg / m 3 or more. The upper limit of the impregnation amount of the phosphorus - based combustion inhibitor is not particularly limited and can usually be 500 Kg / m 3 or less in terms of solid content. From the perspective of obtaining a sufficient combustion suppression effect, the impregnation amount of the boron-based combustion suppressant, in terms of solid content, is preferably 100 Kg / m 3 or more, more preferably 120 Kg / m 3 or more, still more preferably 200 Kg / m 3 or more. The upper limit of the impregnation amount of the boron-based combustion suppressant is not particularly limited, and in terms of solid content, it can usually be 400 Kg / m 3 or less. From the perspective of obtaining a sufficient combustion suppression effect, the impregnation amount of the halogen-based combustion suppressant, in terms of solid content, is preferably 50 Kg / m 3 or more, more preferably 100 Kg / m 3 or more, still more preferably 120 Kg / m 3 or more. The upper limit of the impregnation amount of the boron-based combustion suppressant is not particularly limited, and in terms of solid content, it can usually be 300 Kg / m 3 or less.

[0068] (2) Heat insulation part The above heat insulation part 14 includes an inorganic fiber aggregate 21 and a heat-resistant composition 22 contained in the inorganic fiber aggregate 21 (see FIGS. 1 and 2). That is, a heat-resistant insulation material containing an inorganic fiber aggregate 21 and a heat-resistant composition 22 is used as the material of the heat insulation part 14. The heat insulation part 14 includes an inorganic fiber aggregate 21 composed of a plurality of inorganic fibers derived from the heat-resistant insulation material, and a heat-resistant composition 22 contained in the inorganic fiber aggregate 21. The heat insulation part 14 containing the inorganic fiber aggregate 21 and the heat-resistant composition 22 derived from the heat-resistant insulation material is difficult to melt and burn even in a high-temperature region during a fire, so it can exhibit excellent heat-resistant performance.

[0069] In other words, the heat insulation part 14 is made of a heat-resistant insulation material having excellent heat-resistant performance, and the heat-resistant insulation material is a so-called fiber-reinforced heat-resistant ceramic containing an inorganic fiber aggregate 21 and a heat-resistant composition 22. That is, the heat-resistant and heat-insulating material is a ceramic material having heat resistance with improved strength by fiber reinforcement through the composite of an inorganic fiber aggregate 21 which is a fiber and a heat-resistant composition 22 which is a ceramic, and has very high toughness, rigidity, and heat resistance. The heat-insulating part 14 made of a heat-resistant and heat-insulating material (fiber-reinforced heat-resistant ceramics) can prevent cracking in a high-temperature range such as during a fire. In addition, the heat-insulating part 14 made of a heat-resistant and heat-insulating material (fiber-reinforced heat-resistant ceramics) is usually a material that can be nailed or screwed, similar to steel materials, wooden materials, fire-resistant panel materials, etc. used in buildings, and is also suitable as a building material.

[0070] Specifically, the heat-insulating part 14 made of a heat-resistant and heat-insulating material (fiber-reinforced heat-resistant ceramics) preferably has a heat-resistant performance of not melting in a temperature range of 1000 °C or higher. In other words, the heat-insulating part 14 does not melt even in a temperature range of 1000 °C or higher, and therefore preferably has a fire-resistant performance of not burning in a temperature range of 1000 °C or higher. In addition, in the heat-insulating part 14, the fire-resistant performance of not burning in a temperature range of 1000 °C or higher can also be said to be preferably a performance that satisfies the requirement of 2-hour fire resistance in the Building Standards Law, and more preferably a performance that satisfies the requirement of 3-hour fire resistance.

[0071] The density (bulk specific gravity) of the heat-insulating part 14 made of a heat-resistant and heat-insulating material (fiber-reinforced heat-resistant ceramics) is not particularly limited, but is preferably 62.5 Kg / m 3 or more and 700 Kg / m 3 or less, more preferably 187.5 Kg / m 3 or more and 660 Kg / m 3 or less, and even more preferably 312.5 Kg / m 3 or more and 600 Kg / m 3 or less. In this case, the balance between the strength, weight reduction, and heat insulation performance in the heat-insulating part 14 can be made suitable. The heat-insulating part 14 can have a skin layer on the surface layer part. This skin layer is formed in a film shape by the heat-resistant composition 22 and substantially does not contain the inorganic fiber aggregate 21.

[0072] The heat insulation part 14 made of a heat-resistant and heat-insulating material (fiber-reinforced heat-resistant ceramics) is formed in a porous shape having a plurality of air bubbles 23 inside. Therefore, the weight of the core material 12 (fire-resistant structural material 10) provided with the heat insulation part 14 can be reduced. Furthermore, the heat insulation part 14 can exhibit good heat insulation performance by holding air in the internal air bubbles 23. The heat insulation performance by this heat insulation part 14 affects the heat transfer to the non-combustible part 13 and the rigid part 15 of the core material 12 during a fire. That is, the heat insulation part 14 suppresses or prevents the heat during a fire from being transmitted to the non-combustible part 13 and the rigid part 15 of the core material 12 by its heat insulation performance, delays the carbonization of the non-combustible part 13 and the softening of the rigid part 15, and improves the fire resistance performance of the fire-resistant structural material 10.

[0073] In the above-mentioned heat insulation part 14, the heat-resistant composition (ceramics) contained in the heat-resistant and heat-insulating material is formed by firing the reactive heat-resistant composition (slurry) which is its material to cause hardening (ceramicization). That is, the heat-resistant and heat-insulating material (fiber-reinforced heat-resistant ceramics) is obtained by impregnating an inorganic fiber aggregate with a reactive heat-resistant composition (slurry) which is the material of the heat-resistant composition (ceramics), and then performing a firing treatment. The heat insulation part 14 is formed by shaping the heat-resistant and heat-insulating material (fiber-reinforced heat-resistant ceramics) into a predetermined shape (for example, cylindrical shape). The firing treatment is not particularly limited as long as the reactive heat-resistant composition (slurry) is fired to obtain the heat-resistant composition (ceramics). For example, the heat insulation part 14 can be formed by forming the inorganic fiber aggregate 21 impregnated with the reactive heat-resistant composition (slurry) into a sheet shape, a strip shape, etc., winding it around the outer surface of the rigid part 15, and firing it in this state using a heating furnace or the like.

[0074] (2-1) Inorganic fiber aggregate The inorganic fiber aggregate 21 is formed by intertwining a plurality of inorganic fibers. By fiber-reinforcing the heat-resistant composition 22, which is a ceramic, it is possible to impart strength to the heat insulation part 14 and also to impart heat insulation properties. The inorganic fibers are not particularly limited, but non-combustible fibers are preferred. Specifically, examples of the inorganic fibers include glass fibers, slag fibers, alumina fibers, asbestos fibers, and in addition, carbon fibers, steel wool, stainless steel fibers, etc. Among these, glass fibers, slag fibers, alumina fibers, and asbestos fibers are more preferable as inorganic fibers from the viewpoints of easy availability, heat insulation properties, and fire resistance performance. The inorganic fibers may be used alone, selected from the above-mentioned ones, or two or more kinds may be used in combination. For example, the inorganic fibers can be those containing only glass fibers, or those containing glass fibers and one or more selected from slag fibers, alumina fibers, and asbestos fibers. Examples of the types of glass fibers include E glass, S glass, T glass, silica glass, etc. For the inorganic fibers, only one kind or two or more kinds of glass fibers selected from these can be used. However, the higher the softening point, the more the heat resistance performance of the heat insulation part using it can be improved. Therefore, those with a softening point of 800°C or higher are preferred, those with 900°C or higher are more preferred, and those with 1000°C or higher are even more preferred. Specifically, examples of glass fibers with a softening point of 800°C or higher include E glass (softening point: about 840°C), S glass (softening point: about 970°C), T glass (softening point: 1000°C or higher), and silica glass (softening point: about 1700°C or higher). Examples of glass fibers with a softening point of 900°C or higher include S glass, T glass, and silica glass. Examples of glass fibers with a softening point of 1000°C or higher include T glass and silica glass.

[0075] The fiber diameter and fiber length of the inorganic fibers are not particularly limited. The fiber diameter of the inorganic fibers is usually 2μm to 30μm, preferably 5μm to 30μm, more preferably 5μm to 20μm, and still more preferably 5 to 15μm. The lower limit of the fiber length of the inorganic fiber is usually 10 mm or more, preferably 20 mm or more, more preferably 30 mm or more, and still more preferably 50 mm or more. The upper limit of the fiber length of the inorganic fiber is usually 100 mm or less, preferably 80 mm or less.

[0076] The shape and form of the inorganic fiber aggregate 21 are not particularly limited. Examples of the shape and form of the inorganic fiber aggregate 21 include a sheet, a needle mat, a board, a felt, a non-woven fabric, a film-like body, a paper-like body, a woven fabric, and the like. The inorganic fiber aggregate 21 has different densities and bulkiness depending on its shape and form.

[0077] When the shape and form of the inorganic fiber aggregate 21 are a non-woven fabric, a paper-like body, a woven fabric, etc., the inorganic fiber aggregate 21 has a high density. In this case, the inorganic fiber aggregate 21 tends to have excellent fire resistance by containing more inorganic fibers. Specifically, the basis weight of the inorganic fiber aggregate 21 in this case is preferably 150 g / m 2 or more and 900 g / m 2 or less, more preferably 200 g / m 2 or more and 600 g / m 2 or less.

[0078] When the shape and form of the inorganic fiber aggregate 21 are a sheet, a needle mat, a board, a felt, etc., the inorganic fiber aggregate 21 has a bulky shape. In this case, the heat insulation part 14 containing the inorganic fiber aggregate 21 contains more air bubbles 23 and tends to have excellent heat insulation properties. Specifically, the basis weight of the inorganic fiber aggregate 21 in this case can be about 1 / 4 to 1 / 2 of the basis weight of the above-mentioned high-density one.

[0079] The density (bulk specific gravity) of the inorganic fiber aggregate 21 is not particularly limited, but in the state where the heat insulation part 14 is formed, the lower limit is preferably 50 Kg / m 3 or more, more preferably 150 Kg / m 3 or more, still more preferably 250 Kg / m 3It can be the above. Also, the upper limit of the density (bulk specific gravity) is preferably 350 Kg / m 3 or less, more preferably 330 Kg / m 3 or less, still more preferably 300 Kg / m 3 or less. In this case, the balance between the strength, weight reduction, and heat insulation properties in the heat insulation part 14 can be made suitable. Note that the density (bulk specific gravity) of the inorganic fiber aggregate in the state before compression is not particularly limited, but is preferably 20 Kg / m 3 or more and 250 Kg / m 3 or less, more preferably 65 Kg / m 3 or more and 230 Kg / m 3 or less, still more preferably 80 Kg / m 3 or more and 200 Kg / m 3 or less.

[0080] Only one layer of the inorganic fiber aggregate 21 may be included in the heat insulation part 14, or it may be included in the heat insulation part 14 in a form where two or more layers are laminated. The thickness of the inorganic fiber aggregate 21 is not particularly limited. In the state where the heat insulation part 14 is formed, the thickness is preferably 0.5 mm to 200 mm, more preferably 2 mm to 150 mm, and still more preferably 5 to 100 mm. Note that the thickness of the inorganic fiber aggregate in the state before the heat insulation part 14 is formed is not particularly limited, but is preferably 1 mm to 300 mm, more preferably 4 mm to 200 mm, and still more preferably 10 to 150 mm. The thickness of the inorganic fiber aggregate 21 described above is the total thickness of the entire inorganic fiber aggregate 21. That is, when two or more layers of the inorganic fiber aggregate 21 are included in the heat insulation part 14 in a laminated form, the thickness of the inorganic fiber aggregate 21 is the total thickness of two or more layers of the inorganic fiber aggregate 21.

[0081] (2-2) Heat-resistant composition The heat-resistant composition 22 is a ceramic obtained by curing (ceramicizing) a reactive heat-resistant composition (slurry) by firing, and also binds the inorganic fibers of the inorganic fiber aggregate 21 in the heat insulation part 14. The heat-resistant composition 22 is not particularly limited as long as it has heat resistance. Specifically, the heat-resistant composition 22 is selected from, for example, kaolin-based heat-resistant materials, mullite-based heat-resistant materials, alumina-based heat-resistant materials, silicon-based heat-resistant materials, chamotte-based heat-resistant materials, chromium-based heat-resistant materials, carborundum-based heat-resistant materials, and magnesia-based heat-resistant materials, etc. From the viewpoints of reactivity and heat resistance, kaolin-based heat-resistant materials, mullite-based heat-resistant materials, and alumina-based heat-resistant materials are preferable.

[0082] The ratio of the inorganic fiber aggregate 21 to the heat-resistant composition 22 in the heat insulation part 14 is not particularly limited. However, when the mass of the inorganic fiber aggregate 21 is M1 and the mass of the heat-resistant composition 22 is M2, the ratio (M1 / M2) of M1 to M2 can preferably be 1.0 or more and 4.0 or less, more preferably 1.2 or more and 3.5 or less, and still more preferably 1.5 or more and 3.0 or less. The bulk specific gravity (density) of the heat-resistant composition 22 contained in the heat insulation part 14 is not particularly limited. However, from the viewpoint of imparting excellent refractory performance to the heat insulation part 14 such that it does not melt in the temperature range of 1000 °C or higher, in the state where the heat insulation part 14 is formed (that is, the ceramized state), the lower limit is preferably 12.5 Kg / m 3 or more, more preferably 37.5 Kg / m 3 or more, and still more preferably 62.5 Kg / m 3 or more. Also, the upper limit of the bulk specific gravity (density) can preferably be 350 Kg / m 3 or less, more preferably 330 Kg / m 3 or less, and still more preferably 300 Kg / m 3 or less. Note that the ceramized heat-resistant composition 22 may have crystal water in its crystal structure depending on the type of material used for the reactive heat-resistant composition, or hydroxyl groups may be generated at the stage of being pulverized by oxidative decomposition due to weathering. Due to the functions of such crystal water and hydroxyl groups, excellent heat resistance can be exhibited.

[0083] (2-3) Reactive heat-resistant composition The reactive heat-resistant composition is a material for obtaining the heat-resistant composition 22 which is a ceramic. This reactive heat-resistant composition contains a clay mineral, a heat-resistant ceramic, an inorganic oxide sol, etc., and is in a slurry state. During firing for forming the heat-resistant composition 22, the reactive heat-resistant composition can greatly improve the heat resistance of the inorganic fiber aggregate 21 by reacting with the inorganic fibers of the inorganic fiber aggregate 21 described above. For example, when the inorganic fiber is a glass fiber, the inorganic fiber aggregate 21 made of glass fiber usually has a heat resistance of 400°C to 800°C, but by using the reactive heat-resistant composition, its heat resistance can be improved to 1000°C or higher. The mass ratio of the reactive heat-resistant composition to the inorganic fiber aggregate 21 when impregnating etc. is not particularly limited, but taking the mass of the inorganic fiber aggregate 21 as M1 and the mass of the reactive heat-resistant composition as M3, the ratio (M1 / M3) of M1 to M3 can preferably be 1.0 or more and 4.0 or less, more preferably 1.2 or more and 3.5 or less, still more preferably 1.5 or more and 3.0 or less.

[0084] The inorganic fiber aggregate 21 used together with the reactive heat-resistant composition (heat-resistant composition 22) can be used in a state compressed in the thickness direction as described above, and in that state, the density (bulk specific gravity) can be increased to, for example, 250 Kg / m 3 ~300 Kg / m 3 Thereby. When such an inorganic fiber aggregate 21 with increased density (bulk specific gravity) is used together with the reactive heat-resistant composition (heat-resistant composition 22), the obtained heat insulation part 14 is very lightweight, has toughness and strong rigidity, and its heat resistance is extremely high at 1100°C to 1250°C. Such a heat insulation part 14 is superior in heat resistance, heat insulation, toughness, and workability compared to ordinary refractory panels such as gypsum boards, cement boards, calcium silicate boards, and ALC panels (lightweight cellular concrete panels), and is lightweight, so it is also useful as a building material for high-rise buildings and apartment houses, etc. In particular, it is also useful as a heat insulation and fireproof material for pure wooden, high-rise buildings and apartment houses with a hybrid structure of wooden and steel frame structures.

[0085] (2-4) Clay minerals The above-mentioned clay minerals act on the heat-resistant ceramics contained in the reactive heat-resistant composition, impart viscosity to the reactive heat-resistant composition, and make it easy to form a slurry. The clay minerals are not particularly limited, and crystalline clay minerals, amorphous clay minerals, quasicrystalline clay minerals, etc. can be used. Among these, crystalline clay minerals such as sepiolite and halloysite are preferred, and sepiolite is particularly preferred. Sepiolite is mainly composed of magnesium silicate hydrate, and its viscosity hardly changes even when the temperature changes, and it can maintain a high viscosity even at high temperatures. Therefore, by suitably adhering the reactive heat-resistant composition (slurry) to the surface of the inorganic fibers of the inorganic fiber aggregate 21 and causing a solid-phase reaction, the heat-resistant composition can suitably bond the inorganic fibers to each other, and a high-strength heat-insulating part 14 can be obtained.

[0086] The composition of sepiolite is not particularly limited, but SiO2: 50 parts by weight to 70 parts by weight and MgO2: 25 parts by weight or less are preferred. Further, it may contain Al2O3: 2 parts by weight to 4 parts by weight, CaO: 1 part by weight to 2 parts by weight, etc. The average particle size of sepiolite is not particularly limited, but 5 μm to 10 μm is preferred. In this case, not only is it easy to adhere to the surface of the inorganic fibers, but it also penetrates into the inside of the inorganic fiber aggregate 21 and easily causes a solid-phase reaction. The specific surface area of sepiolite is not particularly limited, but it is preferably 200m 2 ~400m 2 and more preferably 250m 2 ~350m 2 In this case, the efficiency of the solid-phase reaction can be maintained high.

[0087] When only heat-resistant ceramics and inorganic oxide sol are mixed, the clay minerals may cause precipitation of the heat-resistant ceramics, and are also useful for preventing this precipitation. Clay minerals, particularly clay minerals, increase the viscosity of the reactive heat-resistant composition, so the reactivity with inorganic fibers can be enhanced. In addition, when silica sol is used as the inorganic oxide sol, by using sepiolite as the clay mineral, sepiolite that can maintain high viscosity even at high temperatures and silica sol with low molecular weight and excellent reactivity are combined with the heat-resistant ceramics, thereby obtaining a heat-resistant composition that can withstand high temperatures.

[0088] (2-5) Heat-resistant ceramics The above heat-resistant ceramics react with the inorganic fibers of the inorganic fiber aggregate 21 and improve the heat resistance of the inorganic fibers, thereby contributing to the improvement of the fire resistance performance. In the heat insulation part 14 made of a heat insulation material (fiber-reinforced heat-resistant ceramics), the heat resistance can be adjusted according to the type of this heat-resistant ceramics. The heat-resistant ceramics are not particularly limited. Specifically, the heat-resistant ceramics are, in addition to natural minerals such as clay, kaolin-based ceramics (such as kaolinite), mullite-based ceramics (such as mullite), alumina-based ceramics (such as alumina), silicon-based ceramics (silicate salts such as calcium silicate, magnesium silicate, silica (silicic acid), silica alumina (aluminum silicate), etc.), chamotte-based ceramics, chromium-based ceramics, carborundum-based ceramics, magnesia-based ceramics, and phosphate-based ceramics, etc., and it is preferably one or more selected therefrom.

[0089] Among the above-mentioned heat-resistant ceramics, silicon-based ceramics (silicate salts such as calcium silicate, magnesium silicate, aluminum silicate, etc.), kaolin-based ceramics (such as kaolinite), mullite-based ceramics (such as mullite), and alumina-based ceramics (such as alumina) are preferred. Among these, fibrous ceramics (for example, hydroxyapatite, etc.) and silicate salts (for example, calcium silicate, etc.) can be preferably used. Furthermore, the silicate salts are preferably hydrates of silicate salts such as hydrated calcium silicate, hydrated aluminum silicate, hydrated magnesium silicate, etc. The heat-resistant ceramics can be appropriately selected from those described above in order to obtain a desired heat-resistant temperature (1000 °C or higher, particularly 1100 °C or higher, further 1200 °C or higher, particularly 1400 °C to 1800 °C). The particle size of the heat-resistant ceramics is not particularly limited. From the viewpoint of improving reactivity, a small particle size is preferable, and specifically, it is preferably 15 μm or less.

[0090] (2-6) Inorganic oxide sol The above inorganic oxide sol is mixed with the clay mineral contained in the reactive heat-resistant composition to make the reactive heat-resistant composition into a uniform slurry. The reactive heat-resistant composition made into a uniform slurry by this inorganic oxide sol can undergo a uniform curing reaction (ceramicization) when impregnated into the inorganic fiber aggregate 21 and fired. Further, since the inorganic oxide sol has good dispersibility and extremely small particles, it exhibits high reactivity in the solid-phase reaction, and furthermore, since it is excellent in entanglement with inorganic fibers, it can form a heat-resistant, strongly bonded heat-insulating part 14 with strong binding properties. The inorganic oxide sol is not particularly limited, but a dispersion in which inorganic oxides are dispersed and contained in an aqueous medium can be used. Specifically, examples of the inorganic oxide sol include silica sol (colloidal silica), alumina sol, titania sol, zirconia sol, and the like. The content of the inorganic oxide in the inorganic oxide sol is not particularly limited. When the inorganic oxide sol is 100 parts by weight, the content of the inorganic oxide can be preferably 20 to 40 parts by weight, more preferably 25 to 35 parts by weight. In this case, the inorganic fibers of the inorganic fiber aggregate 21 can be easily and sufficiently bound to each other.

[0091] Among those described above, silica sol (colloidal silica) and alumina sol are preferable as the inorganic oxide sol. Silica sol (colloidal silica) and alumina sol are easy to select in terms of various particle sizes, particle size distributions, shapes, etc., and can conform to the required physical properties such as heat resistance, binding properties, and hardness. For example, when silica sol is fired, the silanol groups [Si-OH] on the surface of the silica sol contribute to chemical bonding, creating numerous contact points between the inorganic fibers that bind together, thus greatly improving the strength of the heat insulation part 14. In particular, when the inorganic fibers are glass fibers, the silica sol gathers in the gaps between the glass fibers due to capillary action, and the glass fibers can be firmly bonded together by the dehydration condensation reaction of the silanol groups. In particular, fibrous sols (such as alumina nanofiber sol) as silica sol can be combined with fibrous minerals (such as sepiolite) as clay minerals, and further combined with fibrous ceramics (such as hydroxyapatite) as heat-resistant ceramics to further improve heat resistance.

[0092] 〔Other components〕 The reactive heat-resistant composition may contain other components such as, for example, thickeners, curing accelerators, penetrants, etc., according to desire, in addition to the three components of clay minerals, heat-resistant ceramics, and inorganic oxide sols. The thickener is used as an auxiliary agent to increase the viscosity of the reactive heat-resistant composition, and examples include carboxymethyl cellulose (CMC), sodium polyacrylate, sizing agents, etc. The content of the thickener is not particularly limited, and when the total solid content of the reactive heat-resistant composition is 100 parts by weight, it is usually 2 to 5 parts by weight. The curing accelerator is used as a curing accelerator to promote the curing of the reactive heat-resistant composition, and examples include sodium hexametaphosphate, etc. The content of the curing accelerator is not particularly limited, and when the total solid content of the reactive heat-resistant composition is 100 parts by weight, it is usually 0.2 to 0.5 parts by weight. The penetrant is used to make the reactive heat-resistant composition easily penetrate into the inorganic fiber aggregate 21, and examples include sodium dialkyl sulfosuccinate, etc. The content of the penetrant is not particularly limited, and when the total solid content of the reactive heat-resistant composition is 100 parts by weight, it is usually 0.2 to 1.0 parts by weight.

[0093] 〔2〕Buildings The building of the present invention includes columns and / or beams formed using the above-mentioned fire-resistant structural material 10. Shown in FIG. 1 is a column 10A formed using the fire-resistant structural material 10, and shown in FIG. 2 is a beam 10B formed using the fire-resistant structural material 10. In a normal building, its framework is formed by combining vertical and horizontal members. A column is a vertical member that supports the building by bearing the force (load) applied to the building, and a beam is a horizontal member that supports the building by bearing the force (load) applied to the building. That is, columns and beams are important structural materials for supporting a building, and their load-bearing capacity, rigidity, strength, etc. are related to the resistance of the building such as seismic resistance and wind pressure resistance. In the case of a wooden building, among the horizontal members that support the building, the one that supports the roof is called a ridge beam, the one that extends in the same direction as the ridge beam is called a purlin, and the one that extends in the direction intersecting the ridge beam is called a beam. However, in this specification, all horizontal members that support the building such as the ridge beam, purlin, and beam are included in the "beam". Also, in the case of a steel-frame building, in this specification, all vertical members forming its framework are included in the "column", and all horizontal members forming its framework are included in the "beam".

[0094] As shown in FIG. 1, the column 10A includes an outer shell material 11 and a core material 12 inserted inside the outer shell material 11, and is formed in a square column shape. The outer shell material 11 is formed in a long square tubular shape using heat-resistant steel. The core material 12 includes a non-combustible part 13, a heat-insulating part 14, and a rigid part 15. This core material 12 is formed in a square column shape having an outer diameter substantially the same as the inner diameter of the outer shell material 11, and is filled inside the outer shell material 11 without a gap.

[0095] The non-combustible part 13 is formed in a square column shape by combining a plurality (four in FIG. 1) of wooden materials made of angle bars. The plurality of wooden materials forming the non-combustible part 13 are each subjected to a flame-retardant treatment and have excellent fire-resistant performance. Also, the non-combustible part 13 is formed to have an outer diameter substantially the same as the inner diameter of the rigid part 15 by combining a plurality of wooden materials, and is filled inside the rigid part 15 without a gap.

[0096] The heat insulation part 14 covers the outer surface of the rigid part 15 and is filled without gaps between the outer shell material 11 and the core material 12. The heat insulation part 14 includes an inorganic fiber aggregate 21 and a heat-resistant composition 22 contained in the inorganic fiber aggregate 21, can exhibit excellent heat resistance performance, and has air bubbles 23 formed in the inorganic fiber aggregate 21, and can exhibit excellent heat insulation performance.

[0097] The rigid part 15 is formed from a square tube-shaped steel pipe, and heat-resistant steel is used as the material of the steel pipe. The rigid part 15 encloses a non-combustible part 13 formed by combining a plurality of wood materials. Further, the rigid part 15 can exhibit excellent strength and rigidity by being filled with the non-combustible part 13 without gaps inside it, and being substantially integrated with the non-combustible part 13.

[0098] As shown in FIG. 2, the beam 10B includes an outer shell material 11 and a core material 12 inserted inside the outer shell material 11, and is formed in a vertically long square column shape. The outer shell material 11 is formed in a long vertically long square tube shape using heat-resistant steel. The core material 12 includes a non-combustible part 13, a heat insulation part 14, a first rigid part 15A, and a second rigid part 15B. This core material 12 is formed in a square column shape having an outer diameter substantially the same as the inner diameter of the outer shell material 11, and is filled without gaps inside the outer shell material 11.

[0099] The non-combustible part 13 is formed by combining a plurality (eight in FIG. 2) of wood materials made of square timbers. Each of the plurality of wood materials forming the non-combustible part 13 has been subjected to a flame-retardant treatment and has excellent fire resistance performance. Further, the non-combustible part 13 is formed to form a vertically long square column shape together with the second rigid part 15B by combining a plurality of wood materials, and is filled without gaps inside the first rigid part 15A.

[0100] The heat insulation part 14 covers the outer surface of the first rigid part 15A and is filled without a gap between the outer shell material 11 and the core material 12. The heat insulation part 14 includes an inorganic fiber aggregate 21 and a heat-resistant composition 22 contained in the inorganic fiber aggregate 21, can exhibit excellent heat-resistant performance, has air bubbles 23 formed in the inorganic fiber aggregate 21, and can exhibit excellent heat insulation performance.

[0101] The first rigid part 15A is formed from a square tubular steel pipe, and heat-resistant steel is used as the material of the steel pipe. The first rigid part 15A integrates the non-combustible part 13 and the second rigid part 15B formed by combining a plurality of wood materials. The second rigid part 15B is formed from an H-shaped steel section, and heat-resistant steel is used as the material of the steel section. The second rigid part 15B has concave depressions on both side parts, and a plurality of wood materials forming the non-combustible part 13 are accommodated in the depressions. Note that four wood materials forming the non-combustible part 13 are accommodated in each of the depressions on one side of the second rigid part 15B in FIG. 2. Since the non-combustible part 13 is accommodated without a gap in the depressions on both sides of the second rigid part 15B, the non-combustible part 13 is substantially integrated. Further, since the first rigid part 15A is filled without a gap with the second rigid part 15B and the non-combustible part 13 that are substantially integrated inside it, excellent strength and rigidity can be exhibited.

[0102] When the above-mentioned column 10A and beam 10B are exposed to a high temperature during a fire, the outer shell material 11 loses strength and rigidity in a certain short time (about 10 minutes). However, the core material 12 withstands the high temperature during a fire due to the heat insulation part 14, and the heat insulation performance thereof prevents and delays the heat of the high temperature during a fire from being transmitted to the rigid part 15 (the first rigid part 10A and the second rigid part 10B) and the non-combustible part 13. Also, when the heat insulation part 14 cannot withstand the high temperature during a fire and the heat of the high temperature during a fire is transmitted to the rigid part 15 (the first rigid part 10A and the second rigid part 10B) and the non-combustible part 13, first, the rigid part 15 (the first rigid part 10A and the second rigid part 10B) withstands the high temperature during a fire, so that the strength and rigidity of the column 10A and the beam 10B can be maintained.

[0103] Furthermore, since the non-combustible part 13 is made of a wood material that has been fire-retardant treated, it will not burn even when exposed to high temperatures during a fire, and by carbonizing, it can maintain its shape and strength over a long period of time. Even when the columns 10A and the beams 10B are exposed to high temperatures during a fire, at least one of the heat-insulating part 14, the rigid parts 15 (the first rigid part 10A and the second rigid part 10B), and the non-combustible part 13 provided in the core material 12 can withstand the high temperatures during a fire, so that the strength and rigidity can be maintained over a long period of time. For this reason, the columns 10A and the beams 10B can maintain their strength and rigidity over a long period of time during a fire, and in particular, can have the performance of meeting the requirement of 2-hour fire resistance in the Building Standards Law, and more preferably, can have the performance of meeting the requirement of 3-hour fire resistance.

[0104] (1) Wooden building As a specific example of a building provided with columns and / or beams formed using the above-mentioned fire-resistant structural material 10, a wooden building can be cited. Wooden buildings generally belong to low-rise or mid-rise buildings, and specifically, can include houses with 1 to 3 floors, residences (including apartment houses), warehouses, parking lots, and apartment houses, buildings, warehouses, etc. with 3 to 5 floors. As a wooden building, for example, a building 60 as shown in FIG. 4 can be cited. This building 60 has a so-called "wall structure" in which the external force applied to the building (frame) is supported by shear walls 61 and rigid floors 62, which are planar structural materials. That is, the building 60 has a foundation 63 and a base 64 as a substructure for supporting the building on the ground. On the base 64, a box-shaped frame is constructed by the shear walls 61 and the rigid floors 62, so that the shear walls 61 and the rigid floors 62 are configured as a wall structure that supports the external force applied to the frame.

[0105] (1-1) Floor In the case where the building 60 with a wall structure has a plurality of floors (two in the figure) vertically, it can be provided with through columns 65 that pass vertically through the plurality of floors (see Fig. 4). The through columns 65 are important structural members (vertical framing members) that support the weight of the building 60, and the above-mentioned fire-resistant structural members (see Fig. 1) can be used. That is, when the fire-resistant structural member 10 (see Fig. 1) is used for the through column 65, the fire-resistant structural member 10 has high rigidity and has the performance (load pressure) required to support the weight of the building 60 as the through column 65. Also, even if a fire breaks out in the building 60, the through column 65 using the fire-resistant structural member 10 (see Fig. 1) exhibits excellent fire-resistant performance and will not burn out or be lost, and can prevent the building 60 from collapsing due to fire for a long time.

[0106] In addition, when the through column 65 using the fire-resistant structural member 10 is provided with a rigid portion 15 formed of a steel pipe and / or a section steel for the core material 12, the performance (load pressure) of supporting the weight of the building 60 is significantly improved. In particular, when the material of the steel pipe and / or section steel forming the rigid portion 15 is a fire-resistant steel, a nickel alloy, a chromium alloy, a nickel-chromium alloy, etc., the fire-resistant performance can also be improved. During a fire, the through column 65 using the fire-resistant structural member 10 can withstand the fire by itself and can prevent the rigid portion 15 from being directly exposed to heat for a long time. For this reason, the through column 65 using the fire-resistant structural member 10 can maintain the load pressure improved by the rigid portion 15 for a long time even under the situation during a fire. The building 60 supported by such through columns 65, although having a plurality of floors, can suppress collapse due to fire. Specifically, the building 60 having the through column 65 using the fire-resistant structural member 10 can meet the requirement of 2-hour fire resistance in the Building Standards Act and can also meet the requirement of 3-hour fire resistance.

[0107] (1-2) Shear wall The load-bearing wall 61 is constructed of a framework material 120 formed by combining a vertical frame 121 and a horizontal frame 122, and a panel 150 fixed to the framework material 120. The vertical frame 121 can be regarded as a column 10A, and the above-mentioned fire-resistant structural material 10 (see FIG. 1) can be used. Also, the horizontal frame 122 can be regarded as a beam 10B, and the above-mentioned fire-resistant structural material (see FIG. 2) can be used. When the load-bearing wall 61 has the vertical frame 121 and the horizontal frame 122 using the above-mentioned fire-resistant structural material 10, it will have excellent fire-resistant performance and can be a so-called fire-resistant wall. Specifically, the load-bearing wall 61 as a fire-resistant wall can meet the requirement of 2-hour fire resistance in the Building Standards Law, and can also meet the requirement of 3-hour fire resistance.

[0108] (1-3) Floor structure The wooden building 60 has a floor structure constructed by a plurality of joists 621 combined in a frame shape and a floor board 622 attached above the joists 621 (see FIG. 5). In the floor structure, the joists 621 and the floor board 622 construct a rigid floor 62, and this rigid floor 62 constitutes a so-called "wall type structure" that supports the external force applied to the building (frame).

[0109] The rigid floor 62 can have a fire-resistant structure, and in this case, the floor structure can be constructed as a fire-resistant floor structure. That is, in the rigid floor 62, the joists 621 are the main structural materials (horizontal members) that support the weight of the building 60, and can be made using the above-mentioned fire-resistant structural material (see FIG. 2). The joists 621 using the fire-resistant structural material 10 (see FIG. 2) have excellent fire-resistant performance even if a fire occurs in the building 60, and can be spared from burning and loss. In this case, it is possible to prevent the building 60 from collapsing due to the floor collapsing or the like in a fire. Specifically, the rigid floor 62 as a fire-resistant floor structure can meet the requirement of 2-hour fire resistance in the Building Standards Law, and can also meet the requirement of 3-hour fire resistance.

[0110] (1-4) Frame structure As wooden buildings, in addition to the above-mentioned "wall structure", there are those with a so-called "frame structure" that supports external forces applied to the building (structure) with columns and beams. That is, a building with a frame structure has a foundation and a base as a substructure that supports the building on the ground. On the base, a frame-shaped structure (structure) composed of columns (including through-columns that pass vertically through multiple floors) and beams (including ridge beams and girders) is constructed to support the external forces applied to the building with the structure. For a wooden building with a frame structure, for example, the fire-resistant structural material 10 in FIG. 1 can be used as a column, and the fire-resistant structural material 10 in FIG. 2 can be used as a beam. Columns and beams using the fire-resistant structural material 10 have excellent fire resistance even if a fire breaks out in the building, so they can be spared from burning or being lost, and can prevent the building from collapsing by supporting the building for a long time. Specifically, a wooden building with a frame structure using the fire-resistant structural material 10 for columns and beams can meet the requirement of 2-hour fire resistance in the Building Standards Law and can also meet the requirement of 3-hour fire resistance.

[0111] (2) Steel-frame buildings As a specific example of a building equipped with columns and / or beams formed using the above-mentioned fire-resistant structural material 10, a steel-frame building can be cited. A steel-frame building can belong to any of low-rise buildings, mid-rise buildings, and high-rise buildings. Specifically, it can include houses with 1 to 3 floors, residences (including apartment houses), warehouses, parking lots, and houses with 3 floors or more, apartment houses, warehouses, parking lots, buildings, etc. Regarding steel-frame buildings, examples of their structural forms include the rigid frame structure, the braced structure, and the truss structure. The rigid frame structure is a structure in which columns and beams are completely fixed (rigidly joined) to form a square frame-shaped framework. The braced structure is a structure in which columns and beams form a square frame-shaped framework, and the framework is reinforced with cross braces. The truss structure is a structure in which a triangular frame-shaped framework is formed by a plurality of structural members, and a large number of triangular frame-shaped frameworks are combined. In a state where a large number of frameworks are combined, the structural member extending horizontally is regarded as a beam, and the structural member extending in the direction intersecting the beam is regarded as a column.

[0112] The above fire-resistant structural member 10 can be used in any of the structural forms of the rigid frame structure and the braced structure as a column if it is the fire-resistant structural member 10 in FIG. 1, or as a beam if it is the fire-resistant structural member 10 in FIG. 2. Further, the above fire-resistant structural member 10 can also be used for the cross braces of the braced structure and the structural members forming the triangular frame-shaped framework in the truss structure. In the case of a steel-frame building having a plurality of floors vertically, that is, a building having multiple floors of two stories or more, usually, columns are passed vertically through a plurality of floors. Further, a steel-frame building can be provided with intermediate columns passed vertically within one floor as needed on each floor.

[0113] In a steel-frame building, by using steel materials (metal materials) for columns and beams, the load-bearing capacity, rigidity, strength, etc. of the columns and beams are high, and generally, the resistance such as seismic resistance and wind pressure resistance is higher than that of wooden buildings. However, when steel materials (metal materials) are exposed to a high temperature (about 500 ° C.), their strength is reduced by half, softened, deformed, or melted. Therefore, in a steel-frame building in which such steel materials (metal materials) are used for columns and beams, there is a high possibility that the columns and beams will collapse because they cannot support the weight of the building during a fire.

[0114] When the columns and beams using the fire-resistant structural member 10 are provided with the rigid portion 15, since the rigid portion 15 is formed of a steel pipe or the like, they have a load-bearing capacity, rigidity, strength, etc. comparable to or higher than those of the columns and beams of a general steel-frame building using steel materials (metal materials) for columns and beams. In addition, for the columns and beams using the fire-resistant structural material 10, the heat-insulating portion 14 covers the rigid portion 15 from the outside, suppressing the transmission of high heat during a fire to the rigid portion 15 and suppressing the softening of the rigid portion 15. Further, for the columns and beams using the fire-resistant structural material 10, the non-combustible portion 13 disposed inside the core material 12 carbonizes and hardens during a fire, reinforcing the rigid portion 15 and preventing its deformation. Therefore, in a steel-frame building having columns and beams using the fire-resistant structural material 10, even if a fire occurs, the fire-resistant structural material 10 exhibits excellent fire-resistant performance to prevent deformation of the columns and beams, etc., and can prevent collapse over a long period of time. Specifically, a steel-frame building using the fire-resistant structural material 10 for columns and beams can meet the requirement of 2-hour fire resistance in the Building Standards Act, and can also meet the requirement of 3-hour fire resistance.

[0115] (3) Walls, floors, and ceilings of a building In a wooden building and / or a steel-frame building, a fire-resistant structure can be constructed by using panels made of a fire-resistant material including the same material as the above heat-insulating portion 14, that is, a fire-resistant material including an inorganic fiber aggregate and a heat-resistant composition. Specific examples of where the above panels are used include, for a wooden building, the panel 150 (see Fig. 4) constituting the load-bearing wall 61, the floor board 622 and the ceiling board 67 (see Fig. 5) for constructing the floor structure (rigid floor 62). In addition to these, examples of where the above panels are used include exterior wall materials and siding materials for decorating the outside of the building, or panels on the surface of walls for partitioning rooms or partitioning a room from a corridor inside the building, non-fixed walls such as movable partitions, partitions, and the like, sliding doors, and doors.

[0116] The method of attaching the above panels is not particularly limited, and they may be fixed to columns, beams, etc. using nails, screws, etc., adhered to columns, beams, etc. using adhesives, etc., or attached to columns, beams, etc. using one-touch joints, etc. In addition, the above panel can be improved in strength by laminating structural plywood, fire-resistant panels such as gypsum board and calcium silicate board. In particular, when a wood-based board such as structural plywood is laminated, the fire resistance performance can also be improved by using the above-mentioned flame-retardant treated wood-based board. The panel made of the above fire-resistant material has excellent fire resistance performance, can withstand high temperatures during a fire, and can prevent cracking. As a result, it is possible to suppress the occurrence of flashover in which the flames leaking from cracks in the wall material during a fire spread to other rooms. Furthermore, since the panel made of the above fire-resistant material is porous with air bubbles derived from the inorganic fiber aggregate, it has suitable heat insulation and sound insulation as a building material. Note that the panel made of the above fire-resistant material can exhibit a fire resistance performance of not burning in a temperature range of 1000 °C or higher. Such a fire resistance performance of not burning in a temperature range of 1000 °C or higher is specifically, preferably, a performance that satisfies the requirement of 2-hour fire resistance in the Building Standards Law, and more preferably, a performance that satisfies the requirement of 3-hour fire resistance.

Industrial Applicability

[0117] The fire-resistant structural material of the present invention is widely used in the construction field, and can be preferably used particularly for constructing building walls, floors and structures.

Explanation of Symbols

[0118] 10; Fire-resistant structural material, 10A; Column, 10B; Beam, 11; Outer shell material, 12; Core material, 13; Non-combustible part, 111; Wood material 14; Heat insulation part, 21; Inorganic fiber aggregate, 22; Heat-resistant composition, 15; Rigid part, 15A; First rigid part, 15B; Second rigid part, 60; Wooden building, 65; Through column.

Claims

1. A fire-resistant structural material comprising an outer shell material formed into a long cylindrical shape using a metal material and a core material inserted into the outer shell material, The core material is a non-combustible portion made of a wood material impregnated with at least one combustion inhibitor selected from the group consisting of a phosphorus-based combustion inhibitor, a boron-based combustion inhibitor, and a halogen-based combustion inhibitor, and a silicate compound, the silicate compound being hardened; A fire-resistant structural material comprising: an insulating part including an inorganic fiber aggregate; and a heat-resistant composition contained in the inorganic fiber aggregate.

2. The core material further includes a rigid portion formed from a steel pipe and / or a shaped steel, The noncombustible portion is disposed inside the rigid portion, 2. The fire-resistant structural material according to claim 1, wherein the heat insulating portion is disposed between the rigid portion and the outer shell material.

3. The fire-resistant structural material according to claim 2 , wherein the non-combustible portion is formed into a columnar shape from one or more of the wooden materials and is filled inside the rigid portion.

4. The fire-resistant structural material according to claim 2 , wherein the heat insulating portion covers the rigid portion from the outside.

5. 2. The fireproof structural material according to claim 1, wherein the inorganic fiber aggregate in the heat insulating portion contains one or more types of glass fiber selected from the group consisting of E-glass, S-glass, T-glass, and silica glass.

6. A building comprising columns and / or beams formed using the fire-resistant structural material according to claim 1 or 2.

Images