Wall structure

Abstract

To improve the fire resistance of a wall structure in which a fire-resistant coating layer is formed on a surface of a heat insulating layer made of polyurethane foam.SOLUTION: The wall structure includes a base material made of a noncombustible material, a fire-resistant coating layer, and a heat insulating layer formed between the base material and the fire-resistant coating layer. The heat insulating layer is made of polyurethane foam obtained by reacting a polyol composition with a polyisocyanate component. The polyol composition includes a polyol component, a urethane catalyst, a nurate catalyst, a chemical blowing agent and / or a physical blowing agent, a silicone foam stabilizer, and a flame retardant. The polyol component includes an unsaturated aliphatic polyester polyol, and a content of the unsaturated aliphatic polyester polyol is 50.0 mass% or more, a content of the silicone foam stabilizer is more than 10.0 pts.mass, and a content of the flame retardant is more than 10.0 pts.mass.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a wall structure, and more particularly to a wall structure in which a fire-resistant coating layer is formed on the surface of a heat insulating layer made of polyurethane foam having excellent flame retardancy. [Background technology]

[0002] Polyurethane refers to a polymeric compound having a urethane bond (-NH-C(O)O-). Polyurethane is generally obtained by reacting the hydroxyl group (-OH) of a polyol with the isocyanate group (-NCO) of a polyisocyanate. It is known that polyurethanes can exhibit a variety of properties by optimizing the type of polyol and / or polyisocyanate. For this reason, polyurethanes are used in various automobile parts, synthetic leather, paints, adhesives, etc. Furthermore, polyurethane foams made by foaming polyurethanes are used in insulation, cushioning materials, etc.

[0003] When polyurethane foam is used as a heat insulating material for a building structure, a polyol composition and a polyisocyanate are supplied to a two-component coating machine, and the mixture of the polyol composition and the polyisocyanate is sprayed onto a substrate surface to form a polyurethane foam on the substrate surface. Therefore, such polyurethane foam is required to have flame retardancy to such an extent that it will not be ignited by fire such as welding sparks at the construction site.

[0004] In order to prevent the spread of fire in architectural structures in the event of a fire, polyurethane foams used in architectural structures are preferably made of highly fire-resistant materials. Furthermore, in buildings with interior restrictions such as apartment buildings, hospitals, and schools, when in-situ foamed rigid polyurethane foam is installed in the interior of the building, it is mandatory to cover the surface with a fire-resistant coating layer made of a non-combustible material, a semi-non-combustible material, or a flame-retardant material. Therefore, various proposals have been made for this type of wall structure.

[0005] For example, Patent Document 1 states: a spray polyurethane foam comprising a polyisocyanurate structure; An inorganic coating layered on the surface of sprayed polyurethane foam A composite insulation material comprising: The document states that polyurethane foams having a polyisocyanurate structure have high resistance to heat loads, so that even if part of the inorganic coating is damaged, damage to the internal polyurethane foam is suppressed.

[0006] Patent Document 2 does not describe a method for forming a fire-resistant coating layer on the surface of polyurethane foam, but (A) A slurry containing Portland cement and an aqueous solution containing magnesium sulfate are transported to a spray nozzle by separate pumps and mixed in the spray nozzle. (B) The mixture is sprayed onto the surface of the steel frame from a spray nozzle. A method for applying a spray-applied fire-resistant coating composition is disclosed.

[0007] Patent documents 3 and 4 state: (A) Granular rock wool and cement are dry mixed to form cement-containing rock wool; (B) Mix water and cement in a mixer to form a cement slurry; (C) Cement-containing rock wool and cement slurry are discharged separately from the nozzle tip, then merged, and the mixture is sprayed onto the surface of rigid polyurethane foam. A method for constructing a non-combustible insulated structure is disclosed.

[0008] Patent Document 5 states: (A) Between the columns, wall panels consisting of a layer of foamed resin heat-insulating material and a layer of non-combustible material are installed. (B) From the outdoor side of the column, spray foam resin onto the entire outdoor surface of the column and part of the outdoor surface of the wall panel located adjacent to the column to form a heat insulating material. The resulting wall structure is disclosed.

[0009] As described in Patent Documents 1, 3, and 4, coating the surface of a polyurethane foam with a fire-resistant coating layer improves the fire resistance of the polyurethane foam. However, conventional polyurethane foams have insufficient fire resistance. Therefore, in order to suppress the spread of fire in the event of a fire, it has been necessary to make the fire-resistant coating layer thicker. [Prior art documents] [Patent documents]

[0010] [Patent Document 1] Japanese Patent Publication No. 2023-129045 [Patent Document 2] Japanese Patent Application Publication No. 08-151246 [Patent Document 3] Japanese Patent Application Laid-Open No. 2014-141868 [Patent Document 4] Japanese Patent Application Laid-Open No. 2016-008158 [Patent Document 5] Japanese Patent Application Publication No. 2017-190576 Summary of the Invention [Problem to be solved by the invention]

[0011] The problem to be solved by the present invention is to improve the fire resistance of a wall structure in which a fire-resistant coating layer is formed on the surface of a heat insulating layer made of polyurethane foam. Another problem that the present invention aims to solve is to reduce the thickness of a fire-resistant coating layer in a wall structure in which a fire-resistant coating layer is formed on the surface of an insulating layer made of polyurethane foam, without reducing the fire resistance of the wall structure. [Means for solving the problem]

[0012] In order to solve the above problems, a wall structure according to a first embodiment of the present invention comprises: A substrate made of a non-combustible material; a fire-resistant coating layer; a heat insulating layer formed between the substrate and the fire-resistant coating layer; Equipped with the heat insulating layer is made of a polyurethane foam obtained by reacting a polyol composition with a polyisocyanate component, The polyol composition is The composition comprises a polyol component, a urethane catalyst, a nurate catalyst, a chemical blowing agent and / or a physical blowing agent, a silicone foam stabilizer, and a flame retardant; the polyol component comprises an unsaturated aliphatic polyester polyol; The content of the unsaturated aliphatic polyester polyol is 50.0 mass% or more, The content of the silicone foam stabilizer is more than 10.0 parts by mass, The content of the flame retardant is more than 10.0 parts by mass It consists of things.

[0013] The wall structure according to the second embodiment of the present invention comprises: A substrate made of a non-combustible material; a fire-resistant coating layer having a thickness of less than 10 mm; a heat insulating layer formed between the substrate and the fire-resistant coating layer; Equipped with Total heat output of 8MJ / m in a cone calorimeter test according to ISO-5600 2 The following is the result. [Effects of the Invention]

[0014] When a polyurethane foam is produced under a high isocyanate index using a polyol composition containing a relatively large amount of a silicone foam stabilizer and a flame retardant, the flame retardancy of the polyurethane foam is improved. (A) Highly flame-retardant isocyanurate rings are introduced into polyurethane. (B) The flame retardant suppresses the spread of combustion in polyurethane foam. (C) When a polyurethane foam is produced using a polyol composition containing a relatively large amount of a silicone foam stabilizer, a large amount of fine bubbles are formed in the polyurethane foam, which reduces the thermal conductivity of the polyurethane foam; and (D) The silicone foam stabilizer oriented on the resin surface promotes the formation of a carbonized layer containing silicon during combustion, suppressing the volatilization of flammable gases. It is thought that...

[0015] Furthermore, when a polyurethane foam is produced under a high isocyanate index using a polyol composition containing a relatively large amount of a silicone foam stabilizer and a flame retardant, the flame retardancy of the polyurethane foam is improved when an unsaturated aliphatic polyester polyol is used as the polyol component. This is thought to be because secondary polymerization occurs due to the combustion heat, promoting the formation of a char layer. Therefore, when such polyurethane foam is used as a heat insulating layer in a wall structure, the fire resistance of the wall structure is improved, and the thickness of the fire resistant coating layer can be reduced without reducing the fire resistance of the wall structure. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is a cross-sectional schematic view of a wall structure according to a first embodiment of the present invention. [Figure 2] The photographs show the appearance of a test piece with a fire-resistant coating layer of approximately 11 mm thickness and a test piece with a fire-resistant coating layer of approximately 3 mm thickness. DETAILED DESCRIPTION OF THE INVENTION

[0017] An embodiment of the present invention will be described in detail below. [1. Wall structure (1)] Fig. 1 shows a cross-sectional schematic diagram of a wall structure according to a first embodiment of the present invention. In Fig. 1, the dimensions of each part are drawn larger or smaller than the actual dimensions for ease of viewing. In FIG. 1, the wall structure 10 is a substrate 12 made of a non-combustible material; a fire-resistant coating layer 16; A heat insulating layer 14 formed between the substrate 12 and the fire-resistant coating layer 16 It is equipped with:

[0018] The wall structure 10 is (a) a first moisture barrier layer 18 interposed between the substrate 12 and the thermal insulation layer 14; and / or (b) A second moisture barrier layer 20 inserted between the heat insulating layer 14 and the fire-resistant coating layer 16 It may further comprise: The wall structure 10 may further comprise a primer layer 22 interposed between the insulation layer 14 and the fire-resistant coating layer 16 .

[0019] [1.1. Base material] [1.1.1. Materials] The substrate 12 is made of a non-combustible material. There are no particular limitations on the material of the substrate 12, as long as it is a non-combustible material. Examples of materials for the substrate 12 include gypsum board, galvanized steel sheet, concrete, mortar, flexible board, cement board, lightweight aerated concrete (ALC), brick, and tile.

[0020] 1.1.2. Thickness The thickness of the base material 12 is not particularly limited, and an optimum value can be selected depending on the material of the base material 12, the use of the wall structure 10, and the like.

[0021] 1.2. Insulation Layer [1.2.1. Materials] A heat insulating layer 14 is formed between the substrate 12 and the fire-resistant coating layer 16 . Here, "the heat insulating layer 14 is formed between the substrate 12 and the fire-resistant coating layer 16" means that (a) When no other layer (first moisture-proof layer 18) is inserted at the interface between the substrate 12 and the heat-insulating layer 14, the heat-insulating layer 14 is formed directly on the surface of the substrate 12. (b) When another layer is inserted at the interface between the substrate 12 and the insulating layer 14, this means that the other layer is formed on the surface of the substrate 12, and then the insulating layer 14 is formed on the surface of the other layer.

[0022] In the present invention, the heat insulating layer 14 is made of a polyurethane foam obtained by reacting a polyol composition with a polyisocyanate component. Specifically, the heat insulating layer 14 is formed by applying a mixture of a polyol composition and a polyisocyanate component to the surface of the substrate and curing the coating. The application method is not particularly limited, but spray coating using a two-component coater is generally used. Also, "undercoat" means (a) When the heat insulating layer 14 is formed directly on the surface of the substrate 12, the substrate 12 is referred to. (b) When another layer (first moisture-proof layer 18) is formed on the surface of the substrate 12 and the heat-insulating layer 14 is formed thereon, this refers to the other layer.

[0023] In the present invention, the polyol composition used to form the heat insulating layer 14 is The composition comprises a polyol component, a urethane catalyst, a nurate catalyst, a chemical blowing agent and / or a physical blowing agent, a silicone foam stabilizer, and a flame retardant; the polyol component comprises an unsaturated aliphatic polyester polyol; The content of the unsaturated aliphatic polyester polyol is 50.0 mass% or more, The content of the silicone foam stabilizer is more than 10.0 parts by mass, The content of the flame retardant is more than 10.0 parts by mass It consists of things. This is different from the conventional method. Details of the polyol composition and the polyisocyanate component will be described later.

[0024] 1.2.2. Thickness The thickness of the heat insulating layer 14 is not particularly limited, and an optimum value can be selected depending on the composition of the heat insulating layer 14, the use of the wall structure 10, and the like.

[0025] If the thickness of the insulating layer 14 is too thin, the insulating properties of the wall structure 10 may become insufficient. Therefore, the thickness of the insulating layer 14 is preferably 10 mm or more. The thickness is more preferably 15 mm or more, 20 mm or more, or 25 mm or more. On the other hand, if the thickness of the insulating layer 14 becomes too thick, not only will the insulating effect saturate, but the proportion of organic matter contained in the wall structure 10 will increase, which may reduce the fire resistance of the wall structure 10. Therefore, the thickness of the insulating layer 14 is preferably 500 mm or less. The thickness is more preferably 450 mm or less, 400 mm or less, or 350 mm or less.

[0026] [1.3. Fire-resistant coating layer] [1.3.1. Materials] As described above, the heat insulating layer 14 is formed between the substrate 12 and the fire-resistant coating layer 16 . Here, "the heat insulating layer 14 is formed between the substrate 12 and the fire-resistant coating layer 16" means that (a) When no other layer (second moisture barrier layer 20, primer layer 22) is inserted at the interface between the heat insulating layer 14 and the fire-resistant coating layer 16, the fire-resistant coating layer 16 is formed directly on the surface of the heat insulating layer 14. (b) When another layer is inserted at the interface between the insulating layer 14 and the fire-resistant coating layer 16, this means that the other layer is formed on the surface of the insulating layer 14, and then the fire-resistant coating layer 16 is formed on the surface of the other layer.

[0027] The material of the fire-resistant coating layer 16 is not particularly limited as long as it can impart fire resistance to the wall structure 10 . In particular, the fire-resistant coating layer 16 is preferably obtained by applying a coating material A containing a lightweight aggregate, an inorganic filler, and a binder to the surface of the base and then curing the coating film. In the present invention, the method for applying the coating material A is not particularly limited, but spray coating using a spray gun is usually performed. Moreover, it is preferable that the paint A further contains a reinforcing material. Here, the "base" is (a) When the fire-resistant coating layer 16 is formed directly on the surface of the heat insulating layer 14, it refers to the heat insulating layer 14. (b) When other layers (second moisture-proof layer 20, primer layer 22) are formed on the surface of the heat-insulating layer 14 and the fire-resistant coating layer 16 is formed thereon, this refers to the other layers.

[0028] "Lightweight aggregate" means a material with a density of 2.0 g / cm 3 Coarse aggregate with a density of less than 2.3 g / cm 3 Lightweight aggregate refers to fine aggregate of less than 10 ...

[0029] "Inorganic filler" refers to inorganic compounds other than lightweight aggregates and binders. Examples of inorganic fillers include aluminum hydroxide, calcium carbonate, talc, clay, silica powder, silica sand, zeolite, silica, diatomaceous earth, and ettrinite. Aluminum hydroxide is particularly preferred as an inorganic filler. Aluminum hydroxide is a filler that undergoes a dehydration reaction when heated. A fire-resistant coating layer 16 containing aluminum hydroxide has the effect of improving the fire resistance of the fire-resistant coating layer 16 by absorbing heat during the dehydration reaction.

[0030] The term "binder" refers to an additive that acts to bind lightweight aggregate and inorganic filler together. Examples of binders include dolomite plaster, cement, gypsum, and lime. Dolomite plaster is particularly preferred as a binder. Dolomite plaster is a hardening agent that hardens by reacting with carbon dioxide, and is therefore suitable as a binder.

[0031] The term "reinforcing material" refers to an additive that has the effect of improving the strength of the fire-resistant coating layer 16. Examples of reinforcing materials include glass fiber, carbon fiber, vinylon fiber, polypropylene (PP) fiber, stainless steel fiber, and rock wool. Glass fiber is particularly preferable as a reinforcing material. Glass fiber is suitable as a reinforcing material that increases the strength of the fire-resistant coating layer 16. Reinforcing materials can be added as needed.

[0032] [1.3.2. Content] The content of each component contained in the fire-resistant coating layer 16 is not particularly limited, and an optimal amount can be selected depending on the purpose. Here, the "content" of each component refers to the ratio of the mass of each component to the total mass of the fire-resistant coating layer 16.

[0033] For example, the content of the lightweight aggregate contained in the fire-resistant coating layer 16 is preferably 3 mass % or more and 80 mass % or less. The content of the inorganic filler in the fire-resistant coating layer 16 is preferably 20 mass % or more and 80 mass % or less. The content of the binder in the fire-resistant coating layer 16 is preferably 10 mass % or more and 70 mass % or less. Furthermore, the content of the reinforcing material contained in the fire-resistant coating layer 16 is preferably 0 mass % or more and 67 mass % or less.

[0034] Thickness The thickness of the fire-resistant coating layer 16 is not particularly limited, and an optimum value can be selected depending on the composition of the fire-resistant coating layer 16, the use of the wall structure 10, and the like.

[0035] Generally, the thicker the fire-resistant coating layer 16, the more improved the fire resistance of the wall structure 10. To achieve this effect, the thickness of the fire-resistant coating layer 16 is preferably 2 mm or more, and more preferably 3 mm or more, or 4 mm or more. On the other hand, making the thickness of the fire-resistant coating layer 16 thicker than necessary does not make a difference in effectiveness and is of no practical benefit. Therefore, the thickness of the fire-resistant coating layer 16 is preferably 15 mm or less. The thickness is more preferably 12 mm or less, less than 10 mm, 9 mm or less, 8 mm or less, or 7 mm or less.

[0036] The wall structure 10 according to the present invention uses a special polyurethane foam as the heat insulating layer 14, which allows the thickness of the fire-resistant coating layer 16 to be thinner than in conventional wall structures. Furthermore, there has never been a conventional example of a wall structure that exhibits high fire resistance even when the thickness of the fire-resistant coating layer is less than 10 mm.

[0037] [1.4. First moisture barrier, second moisture barrier] [1.4.1. Materials] The first and second moisture barrier layers 18 and 20 are inserted when it is necessary to block moisture between the outside and inside of the wall structure 10. The wall structure 10 may be provided with either the first moisture barrier layer 18 or the second moisture barrier layer 20, or may be provided with both.

[0038] The materials of the first moisture barrier layer 18 and the second moisture barrier layer 20 are not particularly limited as long as they can provide moisture resistance to the wall structure 10 . In particular, the first moisture barrier layer 18 and the second moisture barrier layer 20 are preferably obtained by applying an asphalt-based emulsion containing asphalt and a styrene-butadiene copolymer to the surface of the substrate and then curing the coating. In the present invention, there are no particular limitations on the method for applying the asphalt-based emulsion. Here, the "base" is (a) When the first moisture-proof layer 18 is formed directly on the surface of the substrate 12, the substrate 12 is referred to. (b) When the second moisture-proof layer 18 is formed directly on the surface of the heat-insulating layer 14, it refers to the heat-insulating layer 14.

[0039] When the first moisture barrier layer 18 or the second moisture barrier layer 20 is formed using an asphalt-based emulsion, the amount of asphalt contained in the asphalt-based emulsion is not particularly limited, and the optimal value can be selected depending on the purpose.

[0040] 1.4.2 Thickness The thickness of the first moisture barrier layer 18 and the second moisture barrier layer 20 may each be zero. However, when the first moisture barrier layer 18 and / or the second moisture barrier layer 20 are inserted for the purpose of providing moisture barrier properties, if the thickness of the first moisture barrier layer 18 and / or the second moisture barrier layer is too thin, moisture barrier properties may be insufficient. Therefore, the thickness of the first moisture barrier layer 18 and the second moisture barrier layer is preferably 0.1 mm or more. The thickness is more preferably 0.2 mm or more, or 0.3 mm or more. On the other hand, if the first moisture barrier layer 18 and the second moisture barrier layer 20 are too thick, not only will the moisture barrier effect saturate, but the proportion of organic matter contained in the wall structure 10 will increase, which may reduce the fire resistance of the wall structure 10. Therefore, the thickness of each of the first moisture barrier layer 18 and the second moisture barrier layer 20 is preferably 1.0 mm or less. The thickness is more preferably 0.9 mm or less, or 0.8 mm or less.

[0041] [1.5. Primer layer] [1.5.1. Materials] When paint A for forming a fire-resistant coating layer 16 is applied to the surface of the substrate, the primer layer 22 may be inserted between the substrate and the fire-resistant coating layer 16 to ensure adhesive or cohesive strength between the substrate and the fire-resistant coating layer 16. Here, the "base" is (a) When the primer layer 22 is formed directly on the surface of the thermal insulation layer 14, it refers to the thermal insulation layer 14. (b) When the primer layer 22 is formed directly on the surface of the second moisture-proof layer 20, it refers to the second moisture-proof layer 20.

[0042] The material of the primer layer 22 is not particularly limited as long as it can ensure adhesive strength or cohesive strength. In particular, the primer layer 22 is preferably obtained by applying a paint B containing a primer material to the surface of the base and curing the coating film. In the present invention, the method for applying the paint B is not particularly limited. Examples of primer materials include acrylic primer materials (for example, modified acrylic ester copolymers), rubber primer materials, urethane primer materials, epoxy primer materials, and silicone primer materials.

[0043] Thickness The thickness of the primer layer 22 is not particularly limited, and an optimum thickness can be selected depending on the purpose.

[0044] [2. Wall structure (2)] The wall structure according to the second embodiment of the present invention comprises: A substrate made of a non-combustible material; a fire-resistant coating layer having a thickness of less than 10 mm; a heat insulating layer formed between the substrate and the fire-resistant coating layer; Equipped with Total heat output of 8MJ / m in a cone calorimeter test according to ISO-5600 2 The following is the result.

[0045] The wall structure according to this embodiment is as follows: (a) a first moisture barrier interposed between the substrate and the thermal insulation layer; and / or (b) A second moisture barrier inserted between the insulation layer and the fire-resistant coating layer. It may further comprise: The wall structure according to this embodiment may further include a primer layer inserted between the heat insulating layer and the fire-resistant coating layer.

[0046] [2.1. Base material, fire-resistant coating layer, heat-insulating layer, moisture-proof layer, primer layer] The details of the substrate, the fire-resistant coating layer, the heat insulating layer, the moisture-proof layer, and the primer layer are the same as those in the first embodiment, and therefore will not be described again.

[0047] 2.2. Total heat generation "Gross calorific value" means the total calorific value from the start to the end of combustion, as measured by a cone calorimeter test in accordance with ISO-5600. The wall structure of the present invention uses a special polyurethane foam with high heat resistance as the insulating layer, so the total heat generation is lower than that of a wall structure using conventional polyurethane foam. By optimizing the composition and thickness of each component of the wall structure, the total heat generation is reduced to 8MJ / m. 2 Further optimization of each component will result in a total heat output of 7MJ / m 2 Below, 6MJ / m 2 Below, 5MJ / m 2 Below, 4MJ / m 2 Less than or equal to 3MJ / m 2 The following is the result.

[0048] 3. Insulation Layer Materials The heat insulating layer 14 according to the present invention is made of a polyurethane foam obtained by reacting a polyol composition with a polyisocyanate component.

[0049] 3.1. Polyol Composition The polyol composition according to the present invention comprises: A polyol component; a urethane catalyst; a nurate catalyst; a chemical and / or physical blowing agent; A silicone foam stabilizer, Flame retardants and Includes:

[0050] 3.1.1. Ingredients [A. Polyol component] The polyol composition according to the present invention includes a polyol component. Polyol is one of the main raw materials for synthesizing polyurethane.

[0051] In the present invention, the polyol component contains at least an unsaturated aliphatic polyester polyol. The polyol component may consist solely of the unsaturated aliphatic polyester polyol, or may contain a polyol other than the unsaturated aliphatic polyester polyol (hereinafter also referred to as a "second polyol"). Examples of the second polyol include aromatic polyester polyols and ether-based polyols.

[0052] The polyol composition may contain any one kind of unsaturated aliphatic polyester polyol, or may contain two or more kinds. Furthermore, when the polyol composition further contains a second polyol in addition to one or more unsaturated aliphatic polyester polyols, the polyol composition may contain any one of the second polyols, or may contain two or more of the second polyols.

[0053] The term "unsaturated aliphatic polyester polyol" refers to a polyester polyol having an unsaturated aliphatic chemical structure. Examples of unsaturated aliphatic polyester polyols include: (a) polyester polyols obtained by reacting unsaturated aliphatic polybasic acids such as maleic acid and fumaric acid with polyhydric alcohols; (b) Polyester polyol having a terminal structure derived from acrylic acid or the like etc. The term "aromatic polyester polyol" refers to a polyester polyol obtained by reacting an aromatic polybasic acid such as orthophthalic acid, isophthalic acid, terephthalic acid, or phthalic anhydride with a polyhydric alcohol.

[0054] Examples of ether polyols include: (a) polyhydric alcohols such as ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, butylene glycol, neopentyl glycol, glycerin, pentaerythritol, trimethylolpropane, sorbitol, and sucrose; (b) Polyether polyols obtained by adding alkylene oxides such as ethylene oxide and propylene oxide to polyhydric alcohols etc.

[0055] The number of functional groups, molecular weight, and hydroxyl value of the unsaturated aliphatic polyester polyol are not particularly limited, and an optimum one can be selected depending on the purpose in an appropriate ratio with isocyanate. Furthermore, when the polyol component contains a second polyol, the number of functional groups, molecular weight, and hydroxyl value of the second polyol are not particularly limited, and an optimum one can be selected depending on the purpose in an appropriate ratio with the isocyanate.

[0056] [B. Urethane catalyst] "Urethane catalyst" refers to a catalyst that has the effect of promoting the reaction (resinification reaction) between polyol and polyisocyanate. In addition to promoting the resinification reaction, urethane catalysts usually also have the effect of promoting the reaction (foaming reaction) between water and polyisocyanate.

[0057] In the present invention, the type of urethane catalyst is not particularly limited, and an optimum catalyst can be selected depending on the purpose. Examples of urethane catalysts include amine catalysts and metal catalysts. The polyurethane composition may contain any one type of urethane catalyst, or may contain two or more types.

[0058] Examples of the amine catalyst include: 1,2-dimethylimidazole, 1-methylimidazole, N·(N',N'-dimethylaminoethyl)-morpholine, tetramethylguanidine, Dimethylaminoethanol, triethylenediamine, N-methyl-N'-(2hydroxyethyl)-piperazine, N,N,N',N'-tetramethylpropane 1,3-diamine, N,N,N',N'-tetramethylethylenediamine, N,N,N',N",N"-pentamethyl-(3-aminopropyl)ethylenediamine, N,N'-dimethylpiperazine, N,N,N',N'-tetramethylhexane-1,6-diamine, N,N,N',N",N"-pentamethyldipropylene-triamine, N-(2-hydroxyethyl)morpholine, ethylene glycol bis(3-dimethyl)-aminopropyl ether, N,N-dimethylcyclohexylamine, N-methyl-N'-(2-dimethylamino)ethylpiperazine etc.

[0059] Examples of metal catalysts include: (a) tin catalysts such as stannous octoate and dibutyltin dilaurate; (b) phenylmercury propionate, (c) lead octenate, (d) bismuth catalysts, such as bismuth carboxylates; (e) zinc catalysts, such as zinc(II) carboxylate; etc.

[0060] [C. Nurate catalyst] The term "nurate catalyst" refers to a catalyst that has the effect of promoting the trimerization reaction of polyisocyanate and producing an isocyanurate ring. When a polyol composition containing a nurate catalyst is reacted with a polyisocyanate, a polyurethane foam containing an isocyanurate ring is obtained. Since the isocyanurate ring has higher thermal stability than the urethane bond, the polyurethane foam containing an isocyanurate ring exhibits high flame retardancy.

[0061] In the present invention, the type of nurate catalyst is not particularly limited, and an optimum one can be selected depending on the purpose. The polyurethane composition may contain any one type of nurate catalyst, or may contain two or more types.

[0062] Nurate catalysts include, for example: (a) quaternary ammonium salts, (b) Alkali metal salts of carboxylic acids such as potassium octylate, potassium 2-ethylhexanoate, and sodium acetate; (c) Nitrogen-containing aromatic compounds such as tris(dimethylaminomethyl)phenol, 2,4-bis(dimethylaminomethyl)phenol, and tris(dimethylaminopropyl)hexahydrotriazine; (d) Tertiary ammonium salts such as trimethylammonium salts, triethylammonium salts, and triphenylammonium salts etc.

[0063] [D. Foaming Agent] The term "foaming agent" refers to an additive that has the effect of generating bubbles in the raw material mixture during the process of resinification of the liquid raw material mixture. In the present invention, the blowing agent is (a) A physical blowing agent that generates gas upon pressure reduction or heating; or (b) Chemical foaming agents that generate gas by thermal decomposition or chemical reaction Either of the above may be used.

[0064] The polyol composition may contain either a physical blowing agent or a chemical blowing agent, or may contain both. The polyol composition may contain one type of physical blowing agent, or may contain two or more types. Furthermore, the polyol composition may contain one type of chemical blowing agent, or may contain two or more types.

[0065] Examples of physical foaming agents include: (a-1) Hydrocarbons such as cyclopentane, isopentane, and normal pentane, (a-2) Halogen-based compounds such as methylene chloride, trichlorofluoromethane, dichlorodifluoromethane, nonafluorobutyl methyl ether, pentafluoroethyl methyl ether, and pentafluoroisopropyl methyl ether; etc.

[0066] Examples of chemical foaming agents include: (b-1) Water that reacts with isocyanate groups to generate CO2; (b-2) Azodicarbonamide that generates nitrogen, carbon monoxide, carbon dioxide, or ammonia gas upon thermal decomposition etc.

[0067] [E. Silicone foam stabilizer] "Foam stabilizer" refers to an additive that has the effect of making the size and distribution of bubbles uniform. When a polyol composition containing a foam stabilizer is reacted with a polyisocyanate, a polyurethane foam having uniform cell size and distribution can be obtained.

[0068] In the present invention, a silicone foam stabilizer is used as the foam stabilizer. When a polyol composition containing a silicone foam stabilizer is reacted with a polyisocyanate, a polyurethane foam having high flame retardancy can be obtained. This is because: (a) A large number of fine bubbles are formed in the polyurethane foam, which reduces the thermal conductivity of the polyurethane foam, and (b) The silicone foam stabilizer oriented on the resin surface promotes the formation of a carbonized layer containing silicon during combustion, suppressing the volatilization of flammable gases. It is thought that...

[0069] Furthermore, when the number of active hydrogen groups contained in the foam stabilizer is small, the foam stabilizer also functions as an additive for reducing the hydroxyl value of the polyol composition. Therefore, when a foam stabilizer having a small number of active hydrogen groups or no active hydrogen groups is used, it becomes easier to increase the isocyanate index while maintaining a volume ratio of the polyol composition to the polyisocyanate close to 1:1 when producing a polyurethane foam.

[0070] [F. Flame retardants] "Flame retardant" means an additive that has the effect of making polyurethane foam flame-retardant. When a polyol composition containing a flame retardant is reacted with a polyisocyanate, a polyurethane foam exhibiting high flame retardancy can be obtained.

[0071] Examples of flame retardants include: (a) Powder flame retardants such as phosphorus-based flame retardants and ammonium polyphosphate; (b) Liquid flame retardants such as phosphate ester flame retardants etc. The polyol composition may contain any one of these flame retardants, or may contain two or more of them.

[0072] Furthermore, when the flame retardant contains a small number of active hydrogen groups, the flame retardant also functions as an additive for reducing the hydroxyl value of the polyol composition. Therefore, when a flame retardant containing a small number of active hydrogen groups or no active hydrogen groups is used, it becomes easier to increase the isocyanate index while maintaining a volume ratio of the polyol composition to the polyisocyanate close to 1:1 during the production of polyurethane foam.

[0073] [3.1.2. Content] [A. Content of Unsaturated Aliphatic Polyester Polyol] The term "content (mass %) of unsaturated aliphatic polyester polyol" refers to the ratio of the mass of unsaturated aliphatic polyester polyol to the total mass of the polyol components.

[0074] If the content of the unsaturated aliphatic polyester polyol is too low, the flame retardancy may decrease. Therefore, the content of the unsaturated aliphatic polyester polyol must be 50 mass% or more. The content is preferably 60 mass% or more, 70 mass% or more, or 80 mass% or more.

[0075] [B. Urethane catalyst content] The "urethane catalyst content (parts by mass)" refers to the mass of the urethane catalyst when the total mass of the polyol components is taken as 100.

[0076] If the content of the urethane catalyst is too low, the resinification reaction will not proceed smoothly. Therefore, the content of the urethane catalyst is preferably 3.0 parts by mass or more. The content is more preferably 4.0 parts by mass or more, or 5.0 parts by mass or more. On the other hand, if the content of the urethane catalyst is excessive, the curing may proceed too rapidly, resulting in poor workability. Therefore, the content of the urethane catalyst is preferably 15.0 parts by mass or less. The content is more preferably 14.0 parts by mass or less, or 13.0 parts by mass or less.

[0077] [C. Nurate Catalyst Content] The "content (parts by mass) of the nurate catalyst" refers to the mass of the nurate catalyst when the total mass of the polyol component is taken as 100.

[0078] If the content of the nurate catalyst is too low, the trimerization reaction will be difficult to proceed. Therefore, the content of the nurate catalyst is preferably 6.0 parts by mass or more, more preferably 7.0 parts by mass or more, or even 8.0 parts by mass or more. On the other hand, if the content of the nurate catalyst is excessive, excess isocyanurate rings are generated, which may result in excessively high hardness of the polyurethane foam. Therefore, the content of the nurate catalyst is preferably 12.0 parts by mass or less. The content is more preferably 11.0 parts by mass or less, or 10.0 parts by mass or less.

[0079] [D. Chemical Foaming Agent Content] The "content (parts by mass) of chemical foaming agent" refers to the mass of the chemical foaming agent when the total mass of the polyol components is taken as 100.

[0080] When a suitable amount of physical foaming agent is contained in the polyol composition, the content of the chemical foaming agent may be zero. However, when a chemical foaming agent is added to the polyol composition, the reaction heat may accelerate the nurate reaction or the urethanization reaction. To achieve such an effect, the content of the chemical foaming agent is preferably 0.1 parts by mass or more. The content is more preferably 0.2 parts by mass or more, or 0.3 parts by mass or more.

[0081] On the other hand, if the content of the chemical foaming agent is excessive, the amount of isocyanate groups will relatively decrease, and the formation of nurate rings may be inhibited. Therefore, the content of the chemical foaming agent is preferably 1.0 parts by mass or less. The content is more preferably 0.9 parts by mass or less, or 0.8 parts by mass or less.

[0082] [E. Physical foaming agent content] The "content (parts by mass) of the physical foaming agent" refers to the mass of the physical foaming agent when the total mass of the polyol components is taken as 100.

[0083] When an appropriate amount of chemical foaming agent is contained in the polyol composition, the content of the physical foaming agent may be zero. However, adding a physical foaming agent to the polyol composition may decrease the density of the foam and the thermal conductivity. To achieve this effect, the content of the physical foaming agent is preferably 1.0 part by mass or more. The content is more preferably 5.0 parts by mass or more, 10.0 parts by mass or more, or 15.0 parts by mass or more.

[0084] On the other hand, if the content of the physical blowing agent is excessive, the reactivity may decrease due to endothermic heat caused by evaporation, and the thermal conductivity may increase due to interconnected cells. Therefore, the content of the physical blowing agent is preferably 50.0 parts by mass or less. The content is more preferably 45.0 parts by mass or less, or 40.0 parts by mass or less.

[0085] [F. Silicone foam stabilizer content] The "content (parts by mass) of silicone foam stabilizer" refers to the mass of the silicone foam stabilizer when the total mass of the polyol components is taken as 100.

[0086] Generally, the higher the content of silicone foam stabilizer, the better the flame retardancy of the polyurethane foam. Furthermore, when the number of active hydrogen groups contained in the silicone foam stabilizer is small, the higher the content of silicone foam stabilizer, the lower the hydroxyl value of the polyol composition. As a result, when producing polyurethane foam, the isocyanate index of the raw material mixture can be increased, facilitating spray application using a two-component coater. To achieve this effect, the content of silicone foam stabilizer is preferably more than 10.0 parts by mass. The content is more preferably 15.0 parts by mass or more, or 20.0 parts by mass or more.

[0087] On the other hand, if the content of the silicone foam stabilizer is excessive, the polyurethane foam will have reduced elongation and be prone to cracking. Therefore, the content of the silicone foam stabilizer is preferably 50.0 parts by mass or less. The content is more preferably 45.0 parts by mass or less, 40.0 parts by mass or less, or 35.0 parts by mass or less.

[0088] [G. Flame Retardant Content] The "content (parts by mass) of the flame retardant" refers to the mass of the flame retardant when the total mass of the polyol component is taken as 100.

[0089] Generally, the higher the content of the flame retardant, the better the flame retardancy of the polyurethane foam. Furthermore, when the number of active hydrogen groups contained in the flame retardant is small, the higher the content of the flame retardant, the lower the hydroxyl value of the polyol composition. As a result, when producing a polyurethane foam, the isocyanate index of the raw material mixture can be increased, facilitating spray application using a two-component coater. To achieve this effect, the content of the flame retardant is preferably more than 10.0 parts by mass. The content is more preferably 15.0 parts by mass or more, or 20.0 parts by mass or more.

[0090] On the other hand, if the content of the flame retardant is excessive, the polyurethane foam will have reduced elongation and be prone to cracking. Therefore, the content of the flame retardant is preferably 60.0 parts by mass or less. The content is more preferably 50.0 parts by mass or less, 40.0 parts by mass or less, or 30.0 parts by mass or less.

[0091] [3.2. Polyisocyanate component] [3.2.1. Materials] In the present invention, the type of polyisocyanate contained in the polyisocyanate component is not particularly limited, and an optimum material can be selected depending on the purpose. The polyisocyanate may have two isocyanate groups in one molecule, or may have three or more isocyanate groups in one molecule. The polyisocyanate component may contain one kind of polyisocyanate, or may contain two or more kinds of polyisocyanates.

[0092] Examples of bifunctional aromatic isocyanates include: 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, m-phenylene diisocyanate, p-phenylene diisocyanate, 4,4'-diphenylmethane diisocyanate (4,4'-MDI), 2,4'-diphenylmethane diisocyanate (2,4'-MDI), 2,2'-diphenylmethane diisocyanate (2,2'-MDI), xylylene diisocyanate, 3,3'-dimethyl-4,4'-biphenylenediisonate, Examples include 3,3'-dimethoxy-4,4'-biphenylene diisocyanate.

[0093] Examples of bifunctional alicyclic isocyanates include: Cyclohexane-1,4-diisocyanate, isophorone diisocyanate, dicyclohexylmethane-4,4'-diisocyanate, Examples include methylcyclohexane diisocyanate.

[0094] Examples of bifunctional aliphatic isocyanates include: Butane-1,4-diisocyanate, hexamethylene diisocyanate, Isopropylene diisocyanate, methylene diisocyanate, lysine isocyanate Examples of difunctional or higher isocyanates include polymeric MDI and trifunctional or higher isocyanates.

[0095] Examples of tri- or higher functional isocyanates include: 1-methylbenzol-2,4,6-triisocyanate, 1,3,5-trimethylbenzene-2,4,6-triisocyanate, biphenyl-2,4,4'-triisocyanate, diphenylmethane-2,4,4'-triisocyanate, methyldiphenylmethane-4,6,4'-triisocyanate, 4,4'-dimethyldiphenylmethane-2,2',5,5'tetraisocyanate, triphenylmethane-4,4',4"-triisocyanate, etc.

[0096] 3.2.2. Isocyanate Index "Isocyanate index" refers to the ratio of the equivalent weight of isocyanate groups of the polyisocyanate in the raw material mixture to the equivalent weight of active hydrogen groups in the raw material mixture, multiplied by 100.

[0097] The larger the isocyanate index, the more easily the trimerization reaction proceeds, and the more easily an isocyanurate ring is formed in the polyurethane foam. To achieve this effect, the isocyanate index is preferably 200 or more. The isocyanate index is more preferably 210 or more, 220 or more, 230 or more, or 240 or more. On the other hand, if the isocyanate index is too high, excess isocyanurate rings are formed, which may result in an excessively high hardness of the polyurethane foam. Therefore, the isocyanate index is preferably 320 or less. The isocyanate index is more preferably 310 or less, 300 or less, or 290 or less.

[0098] 3.2.3. Volume ratio "Volume ratio" refers to the ratio of the volume of the polyol composition (V P ) to the volume of the polyisocyanate component (V I ) ratio (=V I / V P )

[0099] The heat insulating layer 14 can be produced by supplying a polyol composition and a polyisocyanate component to a two-component coating machine and spraying the mixture of the polyol composition and the polyisocyanate component onto the surface of the substrate. In this case, it is preferable to supply the components A and B to the two-component coating machine so that the volume ratio of the polyol composition (component A) containing various additives to the polyisocyanate component (component B) is approximately 1:1. This is because if the volumes of the components A and B are significantly different, it becomes difficult to spray the components A and B while maintaining a constant volume ratio.

[0100] By optimizing the composition of the polyol composition (especially the content of flame retardants and foam stabilizers with few active hydrogen groups), it is possible to achieve a high V while maintaining a high isocyanate index. I / V P The ratio V can be set to 0.8 / 1.2 or more and 1.2 / 0.8 or less. By further optimizing the composition of the polyol composition, V I / V Pis greater than or equal to 0.85 / 1.15 and less than or equal to 1.15 / 0.85, or greater than or equal to 0.9 / 1.1 and less than or equal to 1.1 / 0.9.

[0101] If a thick insulating layer 14 is formed by a single spray coating, the density of the insulating layer 14 may be excessively reduced, resulting in deformation of the insulating layer 14. Therefore, when forming a thick insulating layer 14, it is preferable to spray the layer to a thickness of 20 mm or less per coating and to repeat the spray coating multiple times. It is also preferable to spray the second and subsequent coatings after the previously formed foam has hardened.

[0102] [4. Effect] When a polyurethane foam is produced under a high isocyanate index using a polyol composition containing a relatively large amount of a silicone foam stabilizer and a flame retardant, the flame retardancy of the polyurethane foam is improved. (A) Highly flame-retardant isocyanurate rings are introduced into polyurethane. (B) The flame retardant suppresses the spread of combustion in polyurethane foam. (C) When a polyurethane foam is produced using a polyol composition containing a relatively large amount of a silicone foam stabilizer, a large amount of fine bubbles are formed in the polyurethane foam, which reduces the thermal conductivity of the polyurethane foam; and (D) The silicone foam stabilizer oriented on the resin surface promotes the formation of a carbonized layer containing silicon during combustion, suppressing the volatilization of flammable gases. It is thought that...

[0103] Furthermore, when a polyurethane foam is produced under a high isocyanate index using a polyol composition containing a relatively large amount of a silicone foam stabilizer and a flame retardant, the flame retardancy of the polyurethane foam is improved when an unsaturated aliphatic polyester polyol is used as the polyol component. This is thought to be because secondary polymerization occurs due to the combustion heat, promoting the formation of a char layer. Therefore, when such polyurethane foam is used as a heat insulating layer in a wall structure, the fire resistance of the wall structure is improved, and the thickness of the fire resistant coating layer can be reduced without reducing the fire resistance of the wall structure. [Example]

[0104] (Examples 1 to 5, Comparative Examples 1 to 3) 1. Sample Preparation 1.1. Examples 1 to 5 [1.1.1. Raw materials] The substrate was a gypsum board with a thickness of 9.5 mm. The following paints were used to form the fire-resistant coating layer. (A) Paint 1: "Taica Alock (for HFO)" manufactured by Stylite Kogyo Co., Ltd. (B) Paint 2: "Dancoat (registered trademark) A" manufactured by Ohashi Chemical Industry Co., Ltd.

[0105] The following polyols were used: (a) Polyester polyol 1 (acrylic polyester polyol, hydroxyl value 200 mg KOH / g, product number: PE-2009, manufactured by Sanyo Chemical Industries, Ltd.) (b) Polyester polyol 2 (terephthalic acid-based polyester polyol, hydroxyl value 200, product number: RLK-087, manufactured by Air Water Performance Chemicals) (c) Polyether polyol (hydroxyl value 315, product number: FB512B, manufactured by AGC Corporation)

[0106] The following flame retardants and foam stabilizers were used. (a) Flame retardant (halogen-containing phosphate ester, tris(chloropropyl)phosphate (TCPP), manufactured by Daihachi Chemical Industry Co., Ltd.) (b) Foam stabilizer (silicone foam stabilizer, hydroxyl value 72.7 mg KOH / g, product number: SH193, manufactured by Dow Toray Industries, Inc.)

[0107] The following urethane catalysts and nurate catalysts were used: (a) Urethane catalyst 1 (tertiary amine catalyst, product number: H1, manufactured by HUNTSMAN) (b) Urethane catalyst 2 (tertiary amine catalyst, product number: PC206, manufactured by EVONIK) (c) Nurate catalyst 1 (quaternary ammonium catalyst, product number: TOYOCAT TRX, manufactured by Tosoh Corporation) (d) Nurate catalyst 2 (potassium catalyst, product number: K15, manufactured by EVONIK) (e) Urethane catalyst 3 (zinc catalyst, product number: BICAT Z, manufactured by SHEPHERD CHEMICAL JAPAN)

[0108] The chemical foaming agent, physical foaming agent, and polyisocyanate used were as follows: (a) Blowing agent 1: Chemical blowing agent (water) (b) Blowing agent 2: Physical blowing agent (liquid blowing agent (LBA), manufactured by HONEYWELL) (c) Polyisocyanate (crude MDI, product number: MR-200, manufactured by Tosoh Corporation)

[0109] 1.1.2. Preparation of polyurethane foam The above raw materials were mixed in a predetermined ratio to obtain a polyol composition. The content of each component is as follows.

[0110] [Table 1]

[0111] Next, the polyol composition and polyisocyanate were supplied to a two-component coater and sprayed onto a substrate at a material liquid temperature of 40°C and a material pressure of 6 MPa to a thickness of approximately 15 mm, allowing the raw material mixture to react and foam. Hereinafter, the polyurethane foam obtained in this manner will also be referred to as the "developed product." The spray machine used was an FS2000 manufactured by BASF INOAC Polyurethanes Co., Ltd. The spray gun used was a Fusion CS manufactured by Graco.

[0112] After the polyurethane foam was cured, the paint for forming a fire-resistant coating layer was sprayed onto the surface of the polyurethane foam using a spray gun, and the coating was cured to obtain a three-layer laminate. The amount of paint applied was such that the thickness of the fire-resistant coating layer would be 3 mm to 11 mm. A test piece having a planar shape of 99 mm x 99 mm was cut out from the obtained laminate and used for testing.

[0113] 1.2. Comparative Examples 1 to 3 A heat insulating layer was formed on the surface of the substrate in the same manner as in Examples 1 to 5, except that EB-6000 manufactured by BASF INOAC Polyurethanes Ltd. was used as the polyurethane foam constituting the heat insulating layer. Next, a fire-resistant coating layer was formed on the surface of the heat insulating layer to prepare a laminate having a three-layer structure in the same manner as in Examples 1 to 5. The thickness of the fire-resistant coating layer was set to 6 mm or 11 mm.

[0114] 2. Test Method The obtained test specimen was subjected to a cone calorimeter test in accordance with ISO 5660. The test specimen was exposed to a radiant heat intensity of 50 kW / m 2 The total heat release rate (THR) and maximum heat release rate (HRR) were calculated when the sample was heated at 200 kW / m for 5 minutes. 2 The time elapsed was calculated. In addition, the test piece was heated under the same conditions, and the time required for the first ignition was measured.

[0115] The test pieces were also heated under the same conditions. After the test, the presence or absence of deformation that would be harmful to fire safety was evaluated. (a) If a crack occurs that penetrates the insulation layer, (b) The thickness of the insulation layer shrinks by 25% or more; or (c) If the shrinkage of the insulation layer in the lateral direction is 10% or more. was rated as "harmful deformation." Furthermore, after the cone calorimeter test, the presence or absence of detachment of the fire-resistant coating layer was visually evaluated.

[0116] [3. Results] The results are shown in Table 2. Figure 2 shows photographs of the appearance of a test piece (left) with a fire-resistant coating layer approximately 11 mm thick, and a test piece (right) with a fire-resistant coating layer approximately 3 mm thick. The following can be seen from Table 2 and Figure 2.

[0117] (1) In all of Comparative Examples 1 to 3, no deformation harmful to fire prevention was observed, and the maximum heat generation rate was 200 kW / m continuously for more than 10 seconds. 2 However, in all of Comparative Examples 1 to 3, the total calorific value did not exceed 8 MJ / m 2 This exceeded the standard for "flame-retardant materials." (2) In Comparative Examples 1 to 3, ignition occurred after a predetermined time had elapsed. There was a tendency that the thicker the fire-resistant coating layer, the longer the ignition time.

[0118] (3) In all of Examples 1 to 5, no deformation harmful to fire prevention was observed, and the maximum heat release rate was 200 kW / m continuously for more than 10 seconds. 2 Furthermore, in all of Examples 1 to 5, the total calorific value did not exceed 8 MJ / m 2 The value was below the standard for "flame retardant materials." (4) None of Examples 1 to 5 ignited within the test time. (5) In particular, Examples 1 to 3 exhibited higher fire resistance than Comparative Examples 1 to 3, even though the thickness of the fire-resistant coating layer was less than 10 mm.

[0119] (6) In Comparative Example 1, after the cone calorimeter test, peeling of the fire-resistant coating layer was observed. In contrast, peeling of the fire-resistant coating layer was not observed in Comparative Examples 2 to 3 and Examples 1 to 5. In particular, in Examples 1 to 3, peeling of the fire-resistant coating layer was not observed, even though the thickness of the fire-resistant coating layer was equal to or less than that of Comparative Example 1.

[0120] [Table 2]

[0121] Although the embodiments of the present invention have been described in detail above, the present invention is not limited to the above embodiments, and various modifications are possible within the scope of the gist of the present invention. [Industrial Applicability]

[0122] The wall structure according to the present invention can be used as a wall material for buildings with interior restrictions, such as apartment buildings, hospitals, and schools.

Claims

1. A substrate made of a non-combustible material; a fire-resistant coating layer; a heat insulating layer formed between the substrate and the fire-resistant coating layer; Equipped with the heat insulating layer is made of a polyurethane foam obtained by reacting a polyol composition with a polyisocyanate component, The polyol composition is The composition comprises a polyol component, a urethane catalyst, a nurate catalyst, a chemical blowing agent and / or a physical blowing agent, a silicone foam stabilizer, and a flame retardant; the polyol component comprises an unsaturated aliphatic polyester polyol; The content of the unsaturated aliphatic polyester polyol is 50.0 mass% or more, The content of the silicone foam stabilizer is more than 10.0 parts by mass, The content of the flame retardant is more than 10.0 parts by mass. Consists of wall structure. however, The "content (mass%) of unsaturated aliphatic polyester polyol" refers to the ratio of the mass of the unsaturated aliphatic polyester polyol to the total mass of the polyol component, The "content (parts by mass) of the silicone-based foam stabilizer" refers to the mass of the silicone-based foam stabilizer when the total mass of the polyol component is taken as 100, The "content (parts by mass) of the flame retardant" refers to the mass of the flame retardant when the mass of the polyol component is taken as 100.

2. 2. The wall structure of claim 1, wherein the fire-resistant coating layer has a thickness of less than 10 mm.

3. The wall structure of claim 1, further comprising a first moisture barrier layer inserted between the base material and the insulating layer, and / or a second moisture barrier layer inserted between the insulating layer and the fire-resistant coating layer.

4. The wall structure of claim 1 further comprising a primer layer interposed between the thermal insulation layer and the fire-resistant coating layer.

5. A substrate made of a non-combustible material; a fire-resistant coating layer having a thickness of less than 10 mm; a heat insulating layer formed between the substrate and the fire-resistant coating layer; Equipped with Total calorific value in cone calorimeter test according to ISO-5600 is 8MJ / m 2 is wall structure.

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