Molding covering material, fire-resistant covering structural material, fire-resistant covering method and manufacturing method for molding covering material

Abstract

To provide a molding covering material and a fire-resistant covering structural material that suppress the detachment of expanded residue during a fire while maintaining good workability, and a fire-resistant covering method for covering a workpiece with molding covering materials, and a manufacturing method for molding covering materials.SOLUTION: A molding covering material 20A is formed from a fire-resistant material containing resin and a thermally expandable component, and is at least partially bent.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a molded covering material that is used to cover objects such as structural materials for buildings, a fire-resistant coated structural material that is covered with a molded covering material, a fire-resistant covering method for covering objects with a molded covering material, and a method for manufacturing a molded covering material. [Background technology]

[0002] Structural materials of buildings, which are important structural elements, are sometimes covered with fire-resistant materials to protect them from fire. Structural materials of buildings are generally made of steel. Furthermore, fire-resistant materials expand during a fire to form a heat-insulating layer, thereby protecting the structural materials of buildings from flames and heat during a fire. Conventionally, as a fire-resistant material, a fire-resistant sheet formed in advance from a fire-resistant resin composition containing thermally expandable graphite into a sheet shape has been known (see, for example, Patent Document 1). Fire-resistant sheets are generally fixed to structural materials with fixing members such as pins. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2-308046 Summary of the Invention [Problem to be solved by the invention]

[0004] When fire-resistant sheets are fixed to structural materials with fixing members such as pins, they are fixed at points, but when the insulating layer (residue) expands during a fire, it is often unable to be supported at points, causing the residue to tear and fall off. To prevent the expanded residue from falling off during a fire, improvements have been made to the structure, such as impregnating the fire-resistant sheet with glass cloth or arranging aluminum foil glass cloth to reinforce the fire-resistant sheet. However, although the strength of the fire-resistant sheet is increased by improving the structure of the fire-resistant sheet, there is a problem in that the workability of fixing the fire-resistant sheet to the structural material is deteriorated.

[0005] Therefore, an object of the present invention is to provide a molded coating material and a fire-resistant coated structural material that suppress the falling off of expanded residue during a fire and have good workability, as well as a fire-resistant coating method for coating an object with a molded coating material and a method for manufacturing a molded coating material. [Means for solving the problem]

[0006] The present invention has been made to solve the above problems, and the gist of the present invention is as follows. [1] A molded covering material formed from a fire-resistant material containing a resin and a thermally expandable component, and at least a portion of which is bent. [2] The molded covering material according to [1], having at least one corner. [3] The molded covering material according to [1] or [2], which is in sheet form. [4] The molded covering material according to any one of [1] to [3], wherein the resin is at least one selected from the group consisting of thermoplastic resins, thermosetting resins, and rubber materials. [5] The molded covering material according to any one of [1] to [4], wherein the thermally expandable component is thermally expandable graphite. [6] The molded covering material according to any one of [1] to [5], which has at least one obtuse corner. [7] The molded covering material according to any one of [1] to [6], which has an inner surface shaped to correspond to the outer surface shape of the object to be covered. [8] A fire-resistant coated structural material comprising the shaped coating material according to any one of [1] to [7] and an object to be coated with the shaped coating material. [9] A fire-resistant coating method, comprising coating an object with the formed coating material according to any one of [1] to [7].

[10] The fire-resistant coating method according to [9], wherein the formed coating material is adhered to the surface of the object to be treated.

[11] A method for producing a molded covering material according to any one of [1] to [7], which comprises molding the fire-resistant material to form a molded covering material by any one of extrusion molding, injection molding, cast molding, and dip molding. [Effects of the Invention]

[0007] According to the present invention, it is possible to provide a molded coating material and a fire-resistant coated structural material that suppress the falling off of expanded residue during a fire and have good workability, as well as a fire-resistant coating method for coating an object with a molded coating material and a method for manufacturing a molded coating material. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a schematic cross-sectional view showing a molded covering material according to a first embodiment and an object to be covered with the molded covering material. [Figure 2] 1 is a schematic cross-sectional view showing a fire-resistant coated structural material according to a first embodiment. [Figure 3] 2 is a schematic cross-sectional view showing the expansion residue after the fire-resistant coated structural material according to the first embodiment is heated. FIG. [Figure 4] FIG. 6 is a schematic cross-sectional view showing a molded covering material according to a second embodiment and an object to be covered by the molded covering material. [Figure 5] FIG. 4 is a schematic cross-sectional view showing a fire-resistant coated structural material according to a second embodiment. [Figure 6] FIG. 6 is a schematic cross-sectional view showing a seam of a molded covering material according to a second embodiment. [Figure 7] FIG. 6 is a schematic cross-sectional view showing the expansion residue after the fire-resistant coated structural material according to the second embodiment is heated. [Figure 8] FIG. 10 is a schematic cross-sectional view showing a shaped covering material according to a modified example of the second embodiment and an object to be covered by the shaped covering material. [Figure 9] FIG. 10 is a schematic cross-sectional view showing a fire-resistant coated structural material according to a modified example of the second embodiment. [Figure 10] FIG. 10 is a schematic cross-sectional view showing the expansion residue after the fire-resistant coated structural material according to the modified example of the second embodiment is heated. [Figure 11] 10A and 10B are schematic cross-sectional views showing the shape of corners of a molded covering material according to another embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, the present invention will be described with reference to embodiments. The molded covering material of the present invention is used by covering an object to be treated. The molded covering material is formed from a fire-resistant material containing a resin and a thermally expandable component, and has a partially curved shape. Therefore, when heated, the molded covering material can exhibit fire resistance due to the expansion of the thermally expandable component. Furthermore, because the molded covering material has a partially curved shape, it can be easily used on objects to be treated that have at least a portion of their surface curved, and this makes it easier to work with, for example, objects with complex shapes.

[0010] The shaped covering material of the present invention is in the form of a flexible sheet, and can be placed along the surface of an object to be covered to cover the object. The thickness of the sheet-like shaped covering material is not particularly limited, but is preferably 0.3 to 10 mm, more preferably 0.8 to 8 mm, and even more preferably 1 to 6 mm. Having a thickness of the shaped covering material equal to or greater than the above-mentioned lower limit can impart more appropriate fire resistance to the shaped covering material. Having a thickness of the shaped covering material equal to or less than the above-mentioned upper limit can prevent the shaped covering material from becoming thicker than necessary, and the shaped covering material can be easily produced by the production method described below.

[0011] [First embodiment] A specific example in which the workpiece is an H-shaped steel beam will be described below as a first embodiment with reference to FIG. 1. The H-shaped steel beam as the workpiece 30A has an H-shape in a cross section perpendicular to the longitudinal axis direction, and as shown in FIG. 1(a), has a plate-shaped web 31 and plate-shaped flanges 32 and 33 connected to both ends of the web 31. In the H-shaped steel beam, the web 31 is thinner than the flanges 32 and 33. The thickness of each of the flanges 32 and 33 is not particularly limited, but is, for example, 2 to 40 mm, preferably 3 to 23 mm, and more preferably 5 to 20 mm. The thickness of the web 31 is also not particularly limited, but is, for example, 1 to 20 mm, preferably 2 to 16 mm, and more preferably 4 to 12 mm.

[0012] In this specification, the surfaces perpendicular to the thickness direction of the plate-shaped web 31 will be referred to as surfaces 31A and 31B, the surfaces perpendicular to the thickness direction of the flange 32 will be referred to as surfaces 32A and 32B, respectively, and the surfaces perpendicular to the thickness direction of the flange 33 will be referred to as surfaces 33A and 33B. Furthermore, the end faces at one end of the H-shaped section will be referred to as end faces 32C and 33C, respectively, and the end faces at the other end will be referred to as other end faces 32D and 33D, respectively. In addition, the H-shaped steel, which is the workpiece 30A, has its surfaces connected to each other or its surfaces and end faces connected via corners 34.

[0013] In the first embodiment, an H-shaped steel beam is covered with a shaped covering material 20A. The shaped covering material 20A according to the first embodiment covers an object 30A to be covered with a single covering material in cross section. The shaped covering material 20A has an inner surface shaped to correspond to the outer surface shape of the H-shaped steel beam, which is the object to be covered. Specifically, as shown in FIG. 1(a), the shaped covering material 20A has inner surfaces corresponding to the web 31 (surfaces 31A and 31B), flange 32 (surfaces 32A and 32B, one end face 32C, the other end face 32D), and flange 33 (surface 33B, one end face 33C, the other end face 33D) in cross section, and has flat portions 21A to 21F that cover these. In addition, the connection portions of the flat portions 21A to 21F are formed by corner portions 24 corresponding to the corner portions 34 of the H-shaped steel beam. In this embodiment, the corners 24 are preferably curved surfaces (curved lines in cross section) connecting the planar portions 21A to 21F. However, the corners 24 may be formed by connecting straight lines, connecting straight lines and curved lines, or connecting curved lines in cross section. The corners 24 cause the molded covering material 20A to have a partially bent shape. Of the corners 24, the connection angle of corners 24 where flat surface portion 21B and flat surface portion 21D connect is an obtuse angle larger than a right angle, while the other corners 24 are right angles. In other words, corners 24 where flat surface portion 21B and flat surface portion 21D connect have a larger angle than corners 34 where the corresponding surface 32A of flange 32 connects to one end face 32C and the other end face 32D. In the following description, corners 24 that are obtuse angles and have an angle larger than the corresponding corners 34 will sometimes be referred to as corners 24D. Molded covering material 20A has an opening 27 provided on the opposite side of flat surface portion 21B. In cross section, space 28 surrounded by flat surfaces 21A to 21F communicates with the outside through opening 27. Molded covering material 20A has a symmetrical shape, with flat surfaces 21D, 21C, 21A, 21E, and 21F connected in this order to both ends of flat surface portion 21B.

[0014] As shown in FIG. 1(b), when coating the shaped coating material 20A on the workpiece 30A, it is advisable to first apply an adhesive to at least one of the outer surface of the workpiece 30A to be coated with the shaped coating material 20A or the surface of the shaped coating material 20A facing the workpiece 30A. Then, as shown in FIG. 1(a), the workpiece 30A is inserted into the interior through the opening 27, and the workpiece 30A is placed inside the shaped coating material 20A. Next, as shown in FIG. 1(b), the angle of the corner 24D is reduced in the direction in which the opening 27 closes, so that it becomes a right angle. As a result, the inner surfaces of the flat portions 21A to 21F are arranged along the outer surfaces of the web 31 (surfaces 31A, 31B), flange 32 (surfaces 32A, 32B, one end face 32C, the other end face 32D), and flange 33 (surface 33B, one end face 33C, the other end face 33D), and the shaped covering material 20A covers the workpiece 30A. In this case, the outer surface of the workpiece 30A and the surface (inner surface) of the shaped covering material 20A facing the workpiece 30A may be bonded via a pre-applied adhesive.

[0015] The adhesive may be any known adhesive capable of adhering a resin material to the material constituting the workpiece (steel in this embodiment), such as an epoxy adhesive, a cyanoacrylate adhesive, or a vinyl acetate adhesive, or may be a resin used in fire-resistant materials, such as polyvinyl chloride resin or acrylic resin. In the case of polyvinyl chloride resin, it may be a PVC paste. Depending on the type of adhesive, the adhesive may be cured after coating the workpiece 30A with the molded coating material 20A. For example, if the adhesive is a thermosetting adhesive, it may be heated. In the case of a hot melt adhesive, the workpiece 30A may be heated before coating. Furthermore, in the case of a paste PVC, the workpiece 30A may be heated before coating, and the adhesive may be secondarily heated after coating the workpiece 30A with the molded coating material 20A.

[0016] In this embodiment, the shaped covering material 20A is a flexible sheet and has corners 24 with angles larger than the corners 34 of the corresponding flanges 32, allowing it to be easily positioned along the surface of the workpiece 30A. Furthermore, since the shaped covering material 20A has corners 24, it is possible to simply align the corners 24 with the corners 34 of the workpiece 30A and then cover the workpiece 30A, further improving workability during application. Furthermore, because the inner surface of the shaped covering material 20A has a shape that corresponds to the outer surface of the workpiece, it is possible to cover the workpiece 30A with high adhesion, making it easier to achieve fire resistance. In addition, the corners 24D of the molded coating material 20A are at a larger angle than when applied, and the cross section is wider in one direction (left and right in Figure 1) than when coated, making it easier to coat the object 30A and improving formability, so that it can be easily molded using extrusion molding, as described below.

[0017] It is preferable that the molded covering material 20A is slightly larger than the corresponding portion to be covered of the workpiece 30A. Therefore, for example, the length of each of the flat portions 21A-21F in cross section may be slightly larger (for example, 2 mm or less, preferably 0.1 to 1 mm) than the length of the corresponding portion of the corresponding portion to be covered of the workpiece 30A. However, if the entire length is made larger and gaps become too large, the length may be appropriately reduced. Specifically, in this embodiment, the length of the surface of the flat portion 21A on the side of the workpiece 30A for covering the surfaces 31A and 31B of the web 31 in the cross section is preferably slightly longer than the length of the surface 31A (or 31B) of the web 31. Furthermore, the length of the surface of each flat portion 21B, 21C, and 21E on the side of the workpiece 30A in the cross section is preferably slightly longer than the length of the corresponding surfaces 32A, 32B, and 33B of the flanges 32 and 33. Furthermore, the length of the surface of each flat portion 21D and 21F on the side of the workpiece 30A in the cross section is preferably slightly longer than the length of the corresponding end faces 32C and 32D or 33C and 33D of the flanges 32 and 33. If the overall size of the shaped covering material 20A is too large, causing a large gap between the shaped covering material 20A and the workpiece 30A, the gap can be reduced by reducing the size of the shaped covering material 20A in appropriate portions. The size of the molded coating material 20A may deviate from the design value due to errors during molding, but by making the size of the molded coating material 20A slightly larger than the part to be coated, the object 30A can be properly coated even if it deviates from the design value.

[0018] In this embodiment, as shown in Fig. 2, the shaped covering material 20A covers the object 30A to be covered, thereby forming a fire-resistant covered structure 10A. In the fire-resistant covered structure 10A, the inner shape of the shaped covering material 20A and the outer shape of the object 30A to be covered are substantially the same shape, and the shaped covering material 20A covers the object 30A to be covered. It is preferable that the shaped covering material 20A be in contact with and cover the object 30A to be covered.

[0019] As shown in FIG. 3(a), the fire-resistant covering structural material 10A is disposed on a building 40. When the fire-resistant covering structural material 10A disposed on the building 40 is heated by a fire or the like, the formed covering material 20A expands and transforms into an expansion residue 20A' as shown in FIG. 3(b). Because the formed covering material 20A was disposed while covering the object 30A, the expansion residue 20A' continues to cover the object 30A after it has been heated and expanded. In other words, the expansion residue 20A' is formed close to the object 30A and is supported by the surface 32B of the flange 32 of the object 30A. Furthermore, frictional forces generated between the expansion residue 20A' and the surfaces 31A and 31B of the web 31, the surface 33B of the flange 33, and the surface 32A of the flange 32 prevent the expansion residue 20A' from falling off the object 30A. By retaining the expansion residue 20A' on the workpiece 30A, the expansion residue 20A' expands in the event of a fire and functions as an insulating layer, thereby protecting the structural materials of the building from flames and heat during a fire.

[0020] <Method of manufacturing molded covering material> In the present invention, the molded covering material is produced by molding a refractory material using a molding method such as extrusion molding, injection molding, cast molding, or dip molding. "Extrusion molding" refers to a method in which a refractory material is heated and pressurized to make it fluid, then continuously extruded along the shape of a mold (die), and then cut to produce a molded covering material. "Injection molding" refers to a molding method in which a refractory material is heated and pressurized to make it fluid, injected into a mold, solidified, and then released from the mold to produce a molded covering material. "Cast molding" refers to a molding method other than injection molding in which a liquid refractory material is poured into a mold, solidified by heating and cooling, and then released from the mold to produce a molded covering material. "Dip molding" refers to a molding method in which a core mold is immersed in liquid refractory material to form a coating of refractory material around the core mold, and after the coating solidifies, the coating is removed from the core mold to produce a molded covering material. In this case, the core mold to be used may have the same shape or outer shape as the object to be processed. Alternatively, the shaped coating material may be produced by a method combining cast molding and dip molding. For example, a core mold may be immersed in a mold filled with a fire-resistant material to coat the outer peripheral surface of the core mold with the fire-resistant material, thereby forming a part of the outer peripheral surface of the shaped coating material with the core mold and forming the other outer peripheral surface of the fire-resistant material with the inner surface of the mold, thereby forming the shaped coating material. Of these, extrusion molding and injection molding are preferred from the viewpoint of production productivity, and extrusion molding is more preferred.

[0021] The fire-resistant material used in this embodiment will be described in detail below. The fire-resistant material according to this embodiment is a resin composition containing a resin and a thermally expandable component.

[0022] <Resin> In this embodiment, the resin used in the fire-resistant material may be a thermoplastic resin, a thermosetting resin, a rubber substance, a photocurable resin, or a moisture-curable resin, and two or more selected from these may be used in combination. From the viewpoint of ease of molding, the resin used in the fire-resistant material is preferably a thermoplastic resin, a thermosetting resin, or a rubber substance, and among these, a thermoplastic resin is more preferred. By using a thermoplastic resin as the resin, the molded covering material can be easily molded by extrusion molding or injection molding, and in particular, moldability by extrusion molding can be improved.

[0023] Examples of thermoplastic resins include polyvinyl chloride (PVC), chlorinated polyvinyl chloride resin (CPVC), fluororesin, polyphenylene ether, modified polyphenylene ether, polyphenylene sulfide, polycarbonate, polyetherimide, polyetheretherketone, polyarylate, polyamide, polyamideimide, polybutadiene, polyimide, acrylic resin, polyacetal, polyamide, polyethylene (PE), polypropylene (PP), polyolefins such as ethylene vinyl acetate (EVA), polyesters such as ethylene-propylene-diene copolymer (EPDM), chloroprene (CR), polyethylene terephthalate, and polybutylene terephthalate, polycarbonate, polystyrene (PS), polyphenylene sulfide, acrylonitrile-butadiene-styrene copolymer (ABS), acrylonitrile-styrene-acrylonitrile copolymer (ASA), and acrylonitrile / ethylene-propylene-diene / styrene copolymer (AES). Polyvinyl chloride is preferred as the thermoplastic resin.

[0024] Examples of thermosetting resins include epoxy resins, phenolic resins, melamine resins, urea resins, unsaturated polyester resins, alkyd resins, polyurethanes, and thermosetting polyimides, with epoxy resins being preferred.

[0025] Examples of rubber materials include natural rubber, silicone rubber, styrene-butadiene rubber, isoprene rubber, butadiene rubber, chloroprene rubber, acrylonitrile-butadiene rubber, nitrile-butadiene rubber, butyl rubber, ethylene-propylene rubber, ethylene-propylene-diene rubber, urethane rubber, silicone rubber, and fluororubber. Also included are thermoplastic elastomers such as olefin-based thermoplastic elastomers (TPO), styrene-based thermoplastic elastomers (TPS), ester-based thermoplastic elastomers, amide-based thermoplastic elastomers, and vinyl chloride-based thermoplastic elastomers.

[0026] Examples of the photocurable resin include acrylic resin, etc. Examples of the moisture-curable resin include moisture-curable urethane resin, resin having a crosslinkable silyl group, etc.

[0027] The resin content in the fire-resistant material is preferably 10 to 60 mass %, more preferably 20 to 50 mass %, and even more preferably 25 to 45 mass %, based on the total amount of the fire-resistant material. If the resin content is equal to or greater than the lower limit, the resin can adequately retain the thermally expandable component. On the other hand, if the resin content is equal to or less than the upper limit, it becomes easier to incorporate a certain amount or more of components other than the resin, such as plasticizers and thermally expandable components, into the fire-resistant material.

[0028] <Thermal expansion component> The thermally expandable component contained in the fire-resistant material may be a thermally expandable layered inorganic material, a foaming agent, or the like. The thermally expandable layered inorganic material is a conventionally known substance that expands when heated, such as vermiculite or thermally expandable graphite, with thermally expandable graphite being preferred. The thermally expandable layered inorganic material may be in the form of particles or flakes. The thermally expandable layered inorganic material expands when heated to form large voids, and thus a molded covering material formed from the fire-resistant material can form a heat-insulating layer with excellent heat-insulating performance in the event of a fire.

[0029] Thermally expandable graphite is a type of crystalline compound obtained by treating powders of natural flaky graphite, pyrolytic graphite, kish graphite, or the like with an inorganic acid and a strong oxidizing agent to produce a graphite intercalation compound, which maintains the layered structure of carbon. Examples of inorganic acids include concentrated sulfuric acid, nitric acid, and selenic acid. Examples of strong oxidizing agents include concentrated nitric acid, persulfates, perchloric acid, perchlorates, permanganates, dichromates, and hydrogen peroxide. The thermally expandable graphite obtained by the acid treatment described above may be further neutralized with ammonia, aliphatic lower amines, alkali metal compounds, alkaline earth metal compounds, or the like.

[0030] The particle size of the thermally expandable graphite is preferably 20 to 200 mesh. When the particle size of the expandable graphite is within this range, it expands to easily form large-volume voids, improving fire resistance and dispersibility in resin. The average aspect ratio of the thermally expandable graphite is preferably 2 or more, more preferably 5 or more, and even more preferably 10 or more. There is no particular upper limit to the average aspect ratio of the thermally expandable graphite, but from the viewpoint of preventing cracking of the thermally expandable graphite, it is preferably 1,000 or less. When the average aspect ratio of the thermally expandable graphite is 2 or more, it expands and easily forms large-volume voids, thereby improving flame retardancy. The average aspect ratio of the thermally expandable graphite is determined by measuring the maximum dimension (major axis) and minimum dimension (minor axis) of each of 10 pieces of thermally expandable graphite, and averaging the values ​​obtained by dividing the maximum dimension (major axis) by the minimum dimension (minor axis). The major axis and minor axis of the thermally expandable graphite can be measured, for example, using a field emission scanning electron microscope (FE-SEM).

[0031] The blowing agent used in the thermally expandable component is a blowing agent that expands upon heating, preferably a nitrogen-containing compound-based blowing agent. When heated, the nitrogen-containing compound-based blowing agent thermally decomposes, sublimes, or vaporizes at a certain temperature or higher, generating gases such as nitrogen and ammonia. Therefore, a molded coating material formed from a fire-resistant material containing a nitrogen-containing compound-based blowing agent is likely to form a heat-insulating layer with excellent heat-insulating performance in the event of a fire.

[0032] Examples of nitrogen-containing compound-based blowing agents include phosphate-based compounds such as ammonium phosphate, ammonium polyphosphate, melamine phosphate, and melamine polyphosphate; melamine-based compounds such as melamine, methylol melamine, melamine cyanurate, and melamine-formaldehyde resin; Examples include azodicarboxylic acid metal salts such as azodicarbonamide and barium azodicarboxylate, azo compounds such as azobisisobutyronitrile, nitroso compounds such as N,N'-dinitrosopentamethylenetetramine, hydrazine derivatives such as hydrazodicarbonamide, 4,4'-oxybis(benzenesulfonylhydrazide) and toluenesulfonylhydrazide, and semicarbazide compounds such as toluenesulfonylsemicarbazide. Among these, phosphate-based compounds and melamine-based compounds are preferred from the viewpoint of foaming temperature, etc. The use of these foaming agents facilitates the formation of a heat-insulating layer with good heat-insulating properties on the molded coating material. Furthermore, the phosphate-based compound acts as a catalyst to promote the polymerization of the carbonizing agent (described later) when heated during a fire, and the phosphate-based compound itself forms an inorganic phosphate film, improving the fire resistance and heat-insulating properties of the coating film. Among the above-mentioned nitrogen-containing compound foaming agents, ammonium polyphosphate and melamine are preferred. The thermally expandable component may be used alone or in combination of two or more kinds.

[0033] The content of the thermally expandable component in the fire-resistant material is preferably 10 to 200 parts by mass, more preferably 20 to 140 parts by mass, and even more preferably 30 to 80 parts by mass, relative to 100 parts by mass of the resin contained in the fire-resistant material. By setting the content of the thermally expandable component to 10 parts by mass or more, the molded covering material formed from the fire-resistant material can expand appropriately when heated during a fire, allowing it to form a heat-insulating layer with excellent heat-insulating performance. Furthermore, by setting the content to 200 parts by mass or less, the proportion of resin in the fire-resistant material can be made above a certain level, making it easier to improve the mechanical strength of the molded covering material.

[0034] <Carbonizing agent> The fire-resistant material according to this embodiment may contain a carbonizing agent. When the molded covering material is heated by a fire and the thermally expandable component forms a thermally insulating layer, the carbonizing agent forms a carbonized layer, thereby improving the thermal insulation performance of the thermally expandable component. The carbonizing agent can be suitably used when a foaming agent, particularly a nitrogen-containing compound-based foaming agent, is used as the thermally expandable component. The carbonizing agent preferably polymerizes when heated during a fire to form a carbonized layer.

[0035] When the refractory material contains a carbonizing agent, it preferably further contains an acidic component that reacts with the carbonizing agent upon heating to promote polymerization. The acidic component may be an acidic substance that exhibits acidity at room temperature, or may be one that generates an acidic substance by decomposition upon heating. As the acidic component, phosphates, particularly polyphosphates, are preferred, and in particular, phosphate-based compounds that can also be used as the above-mentioned blowing agents are preferred, with ammonium polyphosphate being more preferred. That is, when the refractory material contains a carbonizing agent, it preferably contains the above-mentioned phosphate-based compound that also functions as a blowing agent. Furthermore, when the fire-resistant material contains a carbonizing agent, it is preferable that the fire-resistant material further contains a foaming agent other than phosphate in addition to the phosphate, from the viewpoint of allowing foaming to progress sufficiently in the event of a fire to form a heat-insulating layer with excellent heat insulation properties, and it is more preferable that the fire-resistant material further contains a melamine-based compound.

[0036] The carbonizing agent is preferably a polyhydric alcohol, and more preferably a polyhydric alcohol having three or more hydroxyl groups. By using a polyhydric alcohol, particularly a polyhydric alcohol having three or more hydroxyl groups, as the carbonizing agent, the carbonizing agent can appropriately form a carbonized layer. Specific examples of polyhydric alcohols used as carbonizing agents include polyhydric alkanols such as pentaerythritol, dipentaerythritol, tripentaerythritol, trimethylolpropane, ditrimethylolpropane, and tritrimethylolpropane, or dimers to tetramers thereof, and polysaccharides such as cellulose.

[0037] The content of the carbonizing agent in the fire-resistant material is preferably 2 to 40 parts by mass, more preferably 4 to 25 parts by mass, and even more preferably 6 to 20 parts by mass, relative to 100 parts by mass of the resin contained in the fire-resistant material. When the content of the carbonizing agent is 2 parts by mass or more, the heat insulating properties can be easily improved by the carbonized layer formed by the carbonizing agent. Also, when the content is 40 parts by mass or less, it is easy to achieve an effect commensurate with the content.

[0038] When the fireproof material contains a carbonizing agent, it preferably contains both a phosphate-based compound such as ammonium polyphosphate and a melamine-based compound, as described above. When the fireproof material contains both a phosphate-based compound and a melamine-based compound, the content of the phosphate-based compound is preferably 5 to 80 parts by mass, more preferably 15 to 65 parts by mass, and even more preferably 25 to 55 parts by mass, per 100 parts by mass of the resin contained in the fireproof material. Furthermore, the content of the melamine-based compound is preferably 2 to 25 parts by mass, more preferably 4 to 20 parts by mass, and even more preferably 6 to 15 parts by mass, per 100 parts by mass of the resin contained in the fireproof material. When both a phosphate-based compound and a melamine-based compound are contained, the mass ratio of the content of the melamine-based compound to the content of the phosphate-based compound (melamine-based compound / phosphate-based compound) is, for example, 1 / 20 to 1. However, it is preferable that the content of the phosphate-based compound is greater than the content of the melamine-based compound, and the mass ratio is preferably 1 / 15 to 9 / 10, and more preferably 1 / 8 to 1 / 2.

[0039] <Flame retardant> The fire-resistant material may further contain a flame retardant. Examples of the flame retardant include those other than the thermally expandable components described above, and specific examples include phosphate-containing flame retardants, boron-containing flame retardants, metal hydroxide-based flame retardants, halogen-based flame retardants, and other metal-containing compounds.

[0040] Examples of the phosphate-containing flame retardant include phosphates formed from a salt of phosphoric acid and at least one metal selected from Groups IA to IVB of the periodic table. The phosphoric acid is not particularly limited, and may be a monophosphoric acid such as phosphoric acid, phosphorous acid, or hypophosphorous acid, or may be pyrophosphoric acid, polyphosphoric acid, or the like. Examples of the metals of Groups IA to IVB of the periodic table include lithium, sodium, calcium, barium, iron (II), iron (III), and aluminum. The phosphate-containing flame retardant may be subjected to a known water resistance improving treatment such as treatment with a silane coupling agent or coating with a melamine resin.

[0041] Specific examples of phosphate-containing flame retardants include monophosphates, pyrophosphates, polyphosphates, and the like. The monophosphate salts are not particularly limited, and examples thereof include sodium salts such as monosodium phosphate, disodium phosphate, trisodium phosphate, monosodium phosphite, disodium phosphite, and sodium hypophosphite; potassium salts such as monopotassium phosphate, dipotassium phosphate, tripotassium phosphate, monopotassium phosphite, dipotassium phosphite, and potassium hypophosphite; lithium salts such as monolithium phosphate, dilithium phosphate, trilithium phosphate, monolithium phosphite, dilithium phosphite, and lithium hypophosphite; barium salts such as barium dihydrogen phosphate, barium hydrogen phosphate, tribarium phosphate, and barium hypophosphite; magnesium salts such as magnesium monohydrogen phosphate, magnesium hydrogen phosphate, trimagnesium phosphate, and magnesium hypophosphite; calcium salts such as calcium dihydrogen phosphate, calcium hydrogen phosphate, tricalcium phosphate, and calcium hypophosphite; zinc salts such as zinc phosphate, zinc phosphite, and zinc hypophosphite; and aluminum salts such as aluminum phosphite. The polyphosphate is not particularly limited, but examples thereof include aluminum polyphosphate. As the phosphate-containing flame retardant used in the fire-resistant material, an aluminum salt such as aluminum phosphite is preferred.

[0042] Examples of boron-containing flame retardants include borax, boron oxide, boric acid, borate salts, etc. Examples of boron oxide include diboron trioxide, boron trioxide, diboron dioxide, tetraboron trioxide, and tetraboron pentoxide. Examples of borates include borates of alkali metals, alkaline earth metals, and elements of Group 4, Group 12, or Group 13 of the periodic table. Specific examples include alkali metal borates such as lithium borate, sodium borate, potassium borate, and cesium borate, alkaline earth metal borates such as magnesium borate, calcium borate, and barium borate, zirconium borate, zinc borate, and aluminum borate. The boron-containing flame retardant used in the present invention is preferably a borate, more preferably zinc borate.

[0043] Examples of metal hydroxide flame retardants include metal hydroxides such as magnesium hydroxide, calcium hydroxide, aluminum hydroxide, iron hydroxide, nickel hydroxide, zirconium hydroxide, titanium hydroxide, zinc hydroxide, copper hydroxide, vanadium hydroxide, and tin hydroxide. Of the metal hydroxides, aluminum hydroxide is preferred.

[0044] Examples of halogen-based flame retardants include chlorine-based flame retardants and bromine-based flame retardants, with bromine-based flame retardants being preferred. Bromine-based flame retardants are not particularly limited as long as they are compounds containing bromine in their molecular structure, and examples thereof include aromatic brominated compounds. Specific examples of aromatic brominated compounds include monomeric organic bromine compounds such as hexabromobenzene, pentabromotoluene, hexabromobiphenyl, decabromobiphenyl, hexabromocyclodecane, decabromodiphenyl ether, octabromodiphenyl ether, hexabromodiphenyl ether, bis(pentabromophenoxy)ethane, ethylenebis(pentabromophenyl), ethylenebis(tetrabromophthalimide), and tetrabromobisphenol A; polycarbonate oligomers produced using brominated bisphenol A as a raw material; and copolymers of the polycarbonate oligomers with bisphenol A. Examples of the brominated epoxy compounds include brominated polycarbonates such as copolymers, diepoxy compounds produced by the reaction of brominated bisphenol A with epichlorohydrin, and monoepoxy compounds obtained by the reaction of brominated phenols with epichlorohydrin, and halogenated bromine compound polymers such as poly(brominated benzyl acrylate), brominated polyphenylene ether, brominated bisphenol A, condensates of cyanuric chloride and brominated phenol, brominated (polystyrene), poly(brominated styrene), brominated polystyrene such as crosslinked brominated polystyrene, and crosslinked or non-crosslinked brominated poly(α-methylstyrene).

[0045] Examples of metal-containing compounds other than the above compounds include metal oxides such as aluminum oxide, titanium oxide, calcium oxide, magnesium oxide, iron oxide, tin oxide, antimony oxide, and titanium oxide; metal carbonates such as calcium carbonate, magnesium carbonate, zinc carbonate, and barium carbonate; and metal sulfates such as calcium sulfate, barium sulfate, and magnesium sulfate. Of these, metal oxides and metal carbonates are preferred, with titanium oxide and calcium carbonate being more preferred. The flame retardants may be used alone or in combination of two or more of the above.

[0046] The content of the flame retardant in the fire-resistant material is preferably 5 to 120 parts by mass, more preferably 10 to 100 parts by mass, and even more preferably 20 to 70 parts by mass, per 100 parts by mass of the resin contained in the fire-resistant material. By setting the content of the flame retardant to 5 parts by mass or more, the flame retardancy of the molded covering material formed from the fire-resistant material can be improved by the flame retardant, while by setting the content to 120 parts by mass or less, other components such as resins and thermally expandable components can be contained in sufficient proportions in the fire-resistant material.

[0047] <Plasticizer> The fire-resistant material may contain a plasticizer. A plasticizer is preferably used when the resin component is a thermoplastic resin such as polyvinyl chloride resin. Specific examples of plasticizers include phthalate ester plasticizers such as di-2-ethylhexyl phthalate (DOP), dibutyl phthalate (DBP), diheptyl phthalate (DHP), and diisodecyl phthalate (DIDP); adipic acid esters such as di-2-ethylhexyl adipate (DOA), diisobutyl adipate (DIBA), and dibutyl adipate (DBA), and fatty acid ester plasticizers such as adipic acid polyester; epoxidized ester plasticizers such as epoxidized soybean oil; trimellitate ester plasticizers such as tri-2-ethylhexyl trimellitate (TO™) and triisononyl trimellitate (TINT™); phosphate ester plasticizers such as trimethyl phosphate (TMP) and triethyl phosphate (TEP); and process oils such as mineral oil. One or more plasticizers can be used. When the fireproof material contains a plasticizer, the content of the plasticizer in the fireproof material is preferably 40 to 240 parts by mass, more preferably 60 to 180 parts by mass, and even more preferably 70 to 120 parts by mass, per 100 parts by mass of the resin. When the content of the plasticizer is equal to or greater than these lower limits, good moldability is likely to be achieved, and when it is equal to or less than these upper limits, the molded article is provided with appropriate strength.

[0048] The total content of the resin and plasticizer is preferably 10% by mass or more and 90% by mass or less, more preferably 25% by mass or more and 80% by mass or less, and even more preferably 40% by mass or more and 70% by mass or less, based on the total amount of the fire-resistant material. By setting the content at or above these lower limits, good moldability can be achieved. Flexibility is also ensured, making bending and deformation easy. Setting the content at or below the upper limits makes it easier to incorporate a certain amount or more of components other than the resin and plasticizer, such as thermally expandable components, into the fire-resistant material. It becomes possible to blend components such as thermally expandable graphite and inorganic fillers in sufficient amounts. The total content of resin and plasticizer means the total content of both resin and plasticizer when both are contained, and means the content of resin alone when no plasticizer is contained.

[0049] <Other additives> The fire-resistant material may contain additives other than those described above, as needed, as long as the objectives of the present invention are not impaired. The type of additive is not particularly limited, and various additives can be used. Examples of such additives include inorganic fillers other than the flame retardants and thermally expandable components described above, lubricants, anti-shrinkage agents, crystal nucleating agents, colorants (pigments, dyes, etc.), ultraviolet absorbers, antioxidants, antiaging agents, flame retardant aids, antistatic agents, surfactants, vulcanizing agents, dispersants, and surface treatment agents. The amount of additive added can be appropriately selected without impairing the objectives of the present invention. These additives may be used alone or in combination of two or more.

[0050] The fireproof material according to this embodiment is preferably substantially solvent-free. Substantially solvent-free means that the fireproof material does not contain organic solvents or water, or, if contained, only trace amounts. Specifically, the total content of water and solvents in the fireproof material is preferably 3% by mass or less, more preferably 1% by mass or less, more preferably 0.5% by mass or less, and even more preferably 0.1% by mass or less, based on the total amount of the fireproof material. Being substantially solvent-free eliminates the need for drying after molding, improving workability and also facilitating a reduction in environmental impact.

[0051] The fire-resistant material can be obtained by mixing the components that make up the fire-resistant material, for example, by adding and mixing a resin, a thermally expandable component, and, if necessary, a carbonizing agent, a flame retardant, a plasticizer, and other additives.

[0052] When the resin is a thermoplastic resin, the fire-resistant material may be a plastisol. A plastisol is a thermoplastic resin present as particles dispersed in a sol-like state in a plasticizer. When the fire-resistant material is a plastisol, the sol-like thermoplastic resin is gelled by heating, and then further heated to further promote the melting state, causing the particle shape to disappear and allowing it to be integrated with the plasticizer, and then cooled to form a solid coating film. Plastisol is suitable when, for example, polyvinyl chloride or acrylic resin is used as the thermoplastic resin, and is particularly suitable when polyvinyl chloride is used. Plastisol using polyvinyl chloride is also called paste PVC. Furthermore, the fire-resistant material does not need to be a plastisol even if the resin is a thermoplastic resin, and even if the fire-resistant material contains a thermoplastic resin and a plasticizer, the fire-resistant material may be in a pre-molded state or may be a combination of the thermoplastic resin and the plasticizer. Therefore, when the thermoplastic resin is polyvinyl chloride, the fire-resistant material is preferably soft PVC containing polyvinyl chloride and a plasticizer.

[0053] [Second embodiment] Next, a specific example in which the workpiece is a square steel bar will be described as a second embodiment with reference to Fig. 4. Note that in the description of the second embodiment, the same parts as those in the first embodiment will not be described again.

[0054] The square steel as the workpiece 30B has a rectangular cross section perpendicular to the longitudinal axis direction, and has plate-like outer surfaces 35A to 35D surrounding the workpiece 30B as shown in Fig. 4(a). The outer surfaces 35A to 35D of the square steel as the workpiece 30B are connected to one another via corners 34.

[0055] In the second embodiment, the cross section of the square steel is covered with a shaped covering material 20B. The shaped covering material 20B has an inner surface shaped to correspond to the outer surface shape of the square steel to be covered. That is, as shown in FIG. 4(a), the shaped covering material 20B has flat portions 25A-25D that cover the respective outer surfaces 35A-35D of the square steel. The flat portion 25A is composed of two divided flat surfaces 25A1 and 25A2, and the outer surface 35A can be covered by joining the end 26A of the divided flat surface 25A1 and the end 26B of the divided flat surface 25A2. The connecting portions of the flat portions 25A-25D are composed of corner portions 24 corresponding to the corner portions 34 of the square steel. In this embodiment, the corner portions 24 are preferably curved surfaces (curved in cross section) that connect the flat portions 25A-25D. However, the corner portions 24 may also be composed of straight lines connected to each other in cross section. Molded covering material 20B has a shape in which a portion is bent by corners 24. In this embodiment, corners 24, which are the connection portions of flat portion 25B or flat portion 25D and flat portion 25C, are obtuse angles, and form corners 24D with a larger connection angle than the corresponding corners of the object to be treated, while corners 24, which are the connection portions of flat portion 25B or flat portion 25D and dividing planes 25A1, 25A2, are right angles, with the same angle as the corresponding corners of the object to be treated. Furthermore, molded covering material 20B has opening 27 between dividing planes 25A1 and 25A2, and space surrounded by plane portions 25A to 25D in cross section communicates with the outside of space through opening 27.

[0056] As shown in FIG. 4(b), when coating the object 30B with the shaped coating material 20B, an adhesive is first applied to at least one of the outer surface of the object 30B to be coated with the shaped coating material 20B or the surface of the shaped coating material 20B facing the object 30B. Then, as shown in FIG. 4(a), the object 30B is placed inside the shaped coating material 20B by fitting it into the interior through the opening 27. Next, as shown in FIG. 4(b), the angle of the corner 24D is reduced to a right angle as the opening 27 closes. This positions the inner surfaces of the flat portions 25A-25D along the outer surfaces 35A-35D of the object 30B, and the shaped coating material 20B coats the object 30B. At this time, the outer surface of the object 30B and the surface (inner surface) of the shaped covering material 20B facing the object 30B may be bonded together via a pre-applied adhesive.

[0057] In this embodiment, as shown in Fig. 5, the shaped covering material 20B covers the object 30B to be covered, thereby forming a fire-resistant covered structural material 10B. In the fire-resistant covered structural material 10B, the inner shape of the shaped covering material 20B and the outer shape of the object 30B to be covered are substantially the same shape, and the shaped covering material 20B covers the object 30B to be covered. It is preferable that the shaped covering material 20B be in contact with and cover the object 30B to be covered.

[0058] The planar portion 25A of the molded covering material 20B is composed of two divided planar surfaces 25A1 and 25A2. The outer surface 35A can be covered by joining the end 26A of the divided planar surface 25A1 and the end 26B of the divided planar surface 25A2. The joint between the end 26A and the end 26B may be configured so that the end 26A and the end 26B are butted together, as shown in FIG. 6(a), or may be configured so that the end 26B', which has a bend equal to the thickness of the end 26A, overlaps the end 26A, as shown in FIG. 6(b). The overlapping of the end 26A and the end 26B' ​​at the joint, as shown in FIG. 6(b), reinforces the joint and improves the covering retention function of the molded covering material 20B.

[0059] In the fire-resistant coated structural material 10B of this embodiment, the shaped coating material 20B is provided covering the workpiece 30B. Therefore, as shown in FIG. 7, the expansion residue 20B' formed after the shaped coating material 20B is heated and expands also covers the workpiece 30B. That is, the expansion residue 20B' formed after the shaped coating material 20B is heated is formed close to the workpiece 30B and is supported by the outer surface 35A of the workpiece 30B. Furthermore, the frictional force generated between the expansion residue 20B' and the outer surfaces 35B-35D prevents the expansion residue 20B' from falling off the workpiece 30B. By retaining the expansion residue 20B' on the workpiece 30B, the expansion residue expands during a fire and functions as a thermal insulating layer, protecting the building's structural materials from flames and heat during a fire.

[0060] [Modification of the second embodiment] Next, a modified example of the second embodiment of the present invention will be described in detail. In the second embodiment, the workpiece is shown as a square steel beam, but in the modified example of the second embodiment, the workpiece is a round steel beam.

[0061] The round steel as the workpiece 30C according to a modified example of the second embodiment has a round shape in a cross section perpendicular to the longitudinal axis direction, and has a cylindrical outer surface 35 as shown in FIG. 8(a).

[0062] In a modified example of the second embodiment, the cross section of the round steel bar is covered with a shaped covering material 20C. As shown in FIG. 8(a), the shaped covering material 20C covers the outer surface 35 of the round steel bar. That is, the shaped covering material 20C has a curved surface portion 25 for covering the entire outer surface 35. In cross section, the curved surface portion 25 has a U-shape with one end open by an opening 27, and becomes circular when both ends of the U are connected. Here, the inner surface of the curved surface portion 25 has a shape corresponding to the outer surface 35 of the round steel bar. Therefore, in cross section, the curved surface portion 25 consists of a curve (curved surface) with a curvature smaller than that of the workpiece 30C. As shown in FIG. 8(b), when coating the object 30C with the shaped coating material 20C, adhesive may be applied to at least one of the outer surface of the object 30C to be coated with the shaped coating material 20C or the surface of the shaped coating material 20C facing the object 30C. Then, as shown in FIG. 8(a), the object 30C is placed in the space 28 of the shaped coating material 20C by fitting the object 30C into the space 28 through the opening 27. Next, as shown in FIG. 8(c), the curved portion 25 is bent in the direction that closes the opening 27. The curved portion 25 is bent until its inner surface has the same curvature as the outer surface of the object 30C. This positions the inner surface of the curved portion 25, which has a circular cross section, along the outer surface of the object 30B, and the shaped coating material 20C coats the object 30C. At this time, the outer surface of the object 30C and the surface (inner surface) of the shaped covering material 20C facing the object 30C may be bonded together via an adhesive that has been applied in advance.

[0063] In this embodiment, as shown in Fig. 9, the shaped covering material 20C covers the object 30C to be covered, thereby forming a fire-resistant covered structural material 10C. In the fire-resistant covered structural material 10C, the inner shape of the shaped covering material 20C and the outer shape of the object 30C to be covered are substantially the same shape, and the shaped covering material 20C covers the object 30C to be covered. It is preferable that the shaped covering material 20C be in contact with and cover the object 30C to be covered.

[0064] In the fire-resistant coated structural material 10C of this embodiment, the shaped coating material 20C is provided covering the workpiece 30C. Therefore, as shown in FIG. 10 , the expansion residue 20C' formed after the shaped coating material 20C is heated and expanded also covers the workpiece 30C. That is, the expansion residue 20C' formed after the shaped coating material 20C is heated is formed close to the workpiece 30C and is supported by the outer surface 35 of the workpiece 30C. Furthermore, the frictional force generated between the expansion residue 20C' and the outer surface 35 prevents the expansion residue 20C' from falling off the workpiece 30C. By retaining the expansion residue 20C' on the workpiece 30C, the expansion residue expands during a fire and functions as an insulating layer, protecting the building's structural materials from flames and heat during a fire.

[0065] [Other embodiments] The shape of the shaped dressing of the present invention is not limited to the above and may be any shape as long as it is at least partially curved. Furthermore, the corners of the shaped dressing are not limited to right angles and may be shapes other than right angles. For example, the shaped covering material may have both a corner where two flat portions are connected and a curved surface, and in this case, the angle of at least one corner should be larger than the angle of the corresponding corner of the object to be covered, or the curvature of at least one curved surface should be smaller than the curvature of the corresponding curved surface of the object to be covered. The corner is not limited to a connection between two flat portions, but may be a connection between a flat portion and a curved portion, or a connection between two curved portions. Note that the connection between the curved portions may be a connection between curved portions with different curvatures. Furthermore, when the molded coating material is applied to the object to be coated, it is preferable that the angle of at least some of the corners or curved surfaces be made smaller or the curvature be made larger as described above, so that the inner surface of the molded coating material is positioned along the outer surface of the object to be coated. Of course, the shaped coating material may have all of its corners and curved surfaces matched to the angles of the corresponding corners of the object to be coated, and matched to the curvature of the opposing curved surfaces of the object to be coated.

[0066] As shown in Figure 11(a), the corners 24 of the shaped covering material may be shaped to follow the shape of the corners 34 of the workpiece, but as shown in Figures 11(b) and (c), the corners 24A, 24B of the shaped covering material may be thick to reinforce the corners of the shaped covering material.

[0067] In each of the above embodiments, the molded covering material is adhered to the surface of the workpiece with an adhesive to cover the workpiece, but the molded covering material may be fixed to the workpiece by means other than an adhesive. For example, the molded covering material may be fixed by a fastener such as a screw, a stapler, or the like. The fastener may also be a pinch member that secures the clamped member by clamping it from both sides with a pair of gripping parts. Alternatively, a pin such as a welding pin may be used as the fastener to fasten the formed coating material to the workpiece by stud welding or the like. Furthermore, double-sided adhesive tape may be used as a fixing device, and the formed covering material may be fixed to the object by placing the double-sided adhesive tape between the formed covering material and the object and applying pressure. In addition, if the molded covering material can be fixed to the workpiece by fitting it into a part of the workpiece, the fixing device can be omitted.

[0068] In each of the above embodiments, the workpiece is covered with a single piece of shaped covering material in cross section, but the workpiece 30A does not need to be covered with a single piece of shaped covering material in cross section, and may be covered with two or more pieces of shaped covering material. For example, when covering an H-beam with two shaped covering materials, the shaped covering material 20A may be divided at the center of the flat surface 21B in cross section, although this is not particularly limited. Dividing the shaped covering material 20A at the center of the flat surface 21B allows the two shaped covering materials of the same shape to cover the entire H-beam except for the flat surface 33A, so even when the shaped covering material is divided into two pieces, the two shaped covering materials can be formed using one mold.

[0069] Similarly, when covering a square steel beam with two shaped covering materials, the shaped covering material 20B may be divided at the center of the flat portion 25A and the flat portion 25C in cross section, although this is not particularly limited. In this case, the shaped covering material 20B is composed of two U-shaped shaped covering materials. In this case, when divided into two pieces, each divided member may have a shape similar to that shown in FIG. 4 except for being further divided at the flat portion 25C. The angle at the connection between the flat portion 25C and the flat portion 25B or the flat portion 25D may also be a right angle. This is because a U-shaped shaped covering material can be easily formed by extrusion molding or the like, even if all angles are right angles, and can easily cover the workpiece. Furthermore, when covering a square steel beam with two shaped covering materials, the shaped covering material may be divided at the opposing corners 24, 24, and each shaped covering material may be L-shaped.

[0070] Furthermore, when covering a round steel beam with two shaped covering materials, the shaped covering material 20C may be divided into two parts in cross section, although this is not particularly limited. In this case, the shaped covering material 20C is made up of two semicircular shaped covering materials.

[0071] In each of the above embodiments, the examples have been described in which the workpiece is an H-shaped steel beam, a square steel beam, or a round steel beam, but the present invention is not limited to H-shaped steel beams and square steel beams and can be applied to various types of steel materials, including L-shaped steel beams, angle steel beams, U-shaped steel beams, and round steel beams of any shape. In addition, in each of the above embodiments, the workpieces are H-beams and square steel beams with relatively simple surface shapes, but the present invention can also be applied to workpieces with complex surface shapes. Specific examples include connections between steel beams in buildings, and H-beams with stiffeners and braces.

[0072] Furthermore, for example, in a building or the like where there are connections between steel materials, the shaped covering material of the present invention (for example, the shaped covering materials 20A, 20B, and 20C shown in the first and second embodiments) may be used in the areas other than the steel connection areas, and a sheet-like shaped covering material without any bent portions may be used for the connection areas. The sheet-like shaped covering material without any bent portions may be folded as appropriate to cover the connection areas, or multiple sheets of shaped covering material may be used to cover the connection areas. The shaped covering material of the present invention may be used for both the portions other than the connection portions of the steel materials and the connection portions of the steel materials. In this case, for example, the shaped covering materials 20A, 20B, and 20C shown in the first and second embodiments may be used for the portions other than the connection portions of the steel materials, and a shaped covering material having a shape corresponding to the outer shape of the connection portions may be used for the connection portions. In this case, the connection portions may be covered with multiple sheets of shaped covering material or with a single sheet of shaped covering material. Furthermore, it is preferable to cover the connection portions with a shaped covering material formed by, for example, dip forming. A shaped covering material formed by dip forming can easily be formed into a shape corresponding to the outer surface of an object to be treated, even if the outer surface has a complex shape.

[0073] In the above description, an example has been given in which the workpiece is a steel material, but the workpiece may be a material other than steel, such as wood, metal material other than steel, concrete, brick, concrete block, stone, etc. However, the workpiece is preferably a metal material such as steel, and more preferably steel. Similarly, the molding core may be made of a material other than steel, but a metal material such as steel is preferred, and steel is more preferred. Metal materials such as steel are easily heated and hardly deform when heated. Therefore, for example, by coating a molding core made of heated metal with a fire-resistant material, it becomes easier to form a thick coating film without deforming the molding core.

[0074] The application of the object to be treated is not particularly limited, but it is preferably a component that needs to be protected in the event of a fire, and specific examples include structural materials for buildings and the bodies of various vehicles. That is, the molded covering material of the present invention is preferably used for structural materials for buildings and the bodies of vehicles. Structural materials are components that form the framework of a building and bear the forces acting on the building, such as the weight and load of the components that make up the building. In the event of a fire, structural materials in buildings become overheated and lose strength, or burn, causing the building to collapse, but by covering these surfaces with the molded covering material of the present invention, a heat insulating layer is formed on these surfaces in the event of a fire, thereby suppressing heating and combustion and preventing the building from collapsing.

[0075] Furthermore, by covering the surfaces of the components that make up the body of a vehicle with the molded covering material of the present invention, if a fire breaks out in one part of the vehicle, it can be prevented from spreading to the entire vehicle. Therefore, in a vehicle equipped with a battery such as a lithium-ion battery (LIB), even if the battery experiences thermal runaway due to an internal short circuit or the like and breaks out into fire, it is possible to prevent the fire from spreading to the entire vehicle. The vehicle may be a railway vehicle such as an automobile, an electric train, a steam locomotive, or a train, heavy civil engineering machinery such as a forklift or a power shovel, a cart, or an amusement park vehicle, or may be a non-vehicle such as a ship or an airplane, with automobiles being preferred. The fire-resistant material is preferably used for underbody coating, and therefore the object to be coated is preferably the underbody of an automobile. [Explanation of symbols]

[0076] 10A,10B,10C Fireproof coating structural material 20A,20B,20C Molded coating material 20A', 20B', 20C' Expansion residue 21A~21F flat section 24,24D Corner 25A~25D flat part 26A,26B End 27 Aperture 28 Space 30A,30B,30C Workpiece 31 Web 32,33 Flange 33A, 33B Surface (outer surface of workpiece) 32C,33C One end surface 32D,33D Other end surface 34 Corner

Claims

1. A molded covering material formed from a fire-resistant material including a resin and a thermally expandable component, and at least a portion of which is bent.

2. 10. The shaped dressing of claim 1 having at least one corner.

3. 10. The shaped dressing of claim 1 in sheet form.

4. 2. The molded covering material of claim 1, wherein the resin is at least one selected from the group consisting of thermoplastic resins, thermosetting resins, and rubber materials.

5. 10. The shaped coating of claim 1, wherein the thermally expandable component is thermally expandable graphite.

6. 10. The shaped dressing of claim 1 having at least one obtuse corner.

7. 2. The molded covering material according to claim 1, having an inner surface having a shape corresponding to the outer surface shape of the object to be covered.

8. A fire-resistant coated structural material comprising the shaped coating material according to any one of claims 1 to 7 and an object to be coated with the shaped coating material.

9. A fire-resistant coating method, comprising coating an object with the formed coating material according to any one of claims 1 to 7.

10. The fire-resistant coating method according to claim 9, wherein the shaped coating material is adhered to the surface of the workpiece.

11. A method for producing the molded coating material according to any one of claims 1 to 7, A method for producing a shaped covering material, comprising molding the fire-resistant material to form a shaped covering material by any one of extrusion molding, injection molding, cast molding and dip molding.

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