Flat deck, fireproof compartment structure, and method for manufacturing flat deck

Abstract

To provide a flat deck which can be connected to an adjacent flat deck while the entire inside of a rib is filled with a filler and has excellent fireproof properties, a fireproof compartment structure, and a method for manufacturing the flat deck.SOLUTION: Provided is a flat deck including a flat portion 11, a rib 12 protruding from one surface 11D of the flat portion 11, and a filler 13 provided inside the rib 12. The rib 12 has a hollow portion 12a having a cavity therein and a connecting portion 12b connecting the hollow portion 12a to the one surface 11D, and the filler 13 is filled inside the hollow portion 12a and the connecting portion 12b of the rib 12.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a flat deck used in a building structure, a fire compartment structure, and a method for manufacturing a flat deck. [Background technology]

[0002] Conventionally, flat decks have been used to construct floor or roof structures of building structures such as reinforced concrete and steel-reinforced concrete. A flat deck has a plurality of ribs extending in the longitudinal direction and having internal cavities formed on the underside of the flat portion, and has a flat upper surface (see, for example, Patent Document 1). In floor or roof structures, flat decks are used, for example, as formwork material for pouring concrete onto the upper surface of the flat portion.

[0003] In architectural structures, fire compartment structures are often formed using facing materials such as gypsum board. To prevent the spread of flames in the event of a fire and to ensure sound insulation and thermal insulation in compartments other than the fire compartment structure, it is necessary to eliminate gaps between the fire compartment structure and the floor structure or roof structure. For example, if a flat deck is installed on the floor structure, when a partition material for forming a compartment such as a fire compartment structure is butted against its underside, gaps will form between the floor structure and the partition material due to the cavities inside the ribs. Therefore, in the area where the partition material butts, the ribs must be removed by cutting the flat deck, for example. The rib removal work is usually performed on-site after the concrete has been poured. Removing the ribs on the construction site is time-consuming and poses safety issues.

[0004] To solve this problem, a flat deck with ribs filled with filler has been proposed. When the flat deck is filled with filler, the cavities inside the ribs prevent gaps from forming between the floor structure and the partition material, making it possible to omit the work of removing the ribs. Furthermore, when constructing a plurality of flat decks side by side, it is known to connect the flat decks by inserting claws provided at the ends of the flat decks into the ribs of adjacent flat decks. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Laid-Open No. 2017-110453 Summary of the Invention [Problem to be solved by the invention]

[0006] However, flat decks with ribs filled with filler have construction difficulties because the filler prevents the insertion of the claws, making it impossible to connect the flat decks using the ribs. To address this issue, studies have been conducted to design a structure in which the portions of the ribs into which the claws are inserted are left unfilled with filler, but this creates problems such as complicated processes and reduced fire resistance.

[0007] Therefore, the present invention can provide a flat deck, fire compartment structure, and method for manufacturing a flat deck that has excellent fire resistance and can be connected to adjacent flat decks while the entire inside of the rib is filled with filler. [Means for solving the problem]

[0008] The present invention has been made to solve the above problems, and the gist of the present invention is as follows. [1] A flat deck comprising a flat portion, a rib protruding from one surface of the flat portion, and a filler provided inside the rib, wherein the rib has a hollow portion with a cavity inside and a connecting portion connecting the hollow portion to the one surface, and the filler is filled inside the hollow portion and the connecting portion of the rib. [2] A flat deck as described in [1], wherein any of the connection portions filled with the filler can be fitted with the claw portions of an adjacent flat deck. [3] A flat deck according to [1] or [2], wherein the filling is a foam. [4] The flat deck according to any one of [1] to [3], wherein the filler is an organic foam. [5] The flat deck described in [4], wherein the organic foam is polyurethane foam. [6] The density of the filling material in the hollow portion is 10 kg / m 3 More than 200kg / m 3 A flat deck according to any one of [1] to [5] below. [7] The density of the filler in the connection part is 10 kg / m 3 More than 100kg / m 3 A flat deck according to any one of [1] to [6] below. [8] The filling material has a radiant heat intensity of 50 kW / m in a heat generation test using a cone calorimeter in accordance with ISO 5660-1. 2 The total heat generation amount for 20 minutes after the start of heating is 8MJ / m 2 A flat deck according to any one of [1] to [7] below. [9] The flat deck according to any one of [1] to [8], wherein the rib has an injection port at the bottom for injecting the filling material.

[10] A fire compartment structure comprising a flat deck according to any one of [1] to [9] and a non-combustible material filling the spaces between the ribs on one side of the flat portion of the flat deck.

[11] A method for manufacturing a flat deck comprising a flat portion, a rib protruding from one surface of the flat portion, and a filler, wherein the rib has a hollow portion with a cavity inside and a connecting portion connecting the hollow portion to the one surface, the method comprising a step of filling the filler inside the rib while the steel plate temperature at the connecting portion is between 60°C and 150°C. [Effects of the Invention]

[0009] According to the present invention, it is possible to provide a flat deck, a fire compartment structure, and a method for manufacturing a flat deck that has excellent fire resistance and can be connected to adjacent flat decks while having a filler filled throughout the inside of the rib. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1(a) is a plan view showing a flat deck according to an embodiment of the present invention, and FIG. 1(b) is a cross-sectional view taken along the line AA in FIG. 1(a). [Figure 2] FIG. 3 is a cross-sectional view showing a connected state of the flat deck according to the embodiment of the present invention. [Figure 3] FIG. 1 is a perspective view showing a flat deck (before filling with a filler) according to an embodiment of the present invention. [Figure 4] 3A to 3C are cross-sectional views showing steps in a method for manufacturing a flat deck according to an embodiment of the present invention. [Figure 5] 1 is a cross-sectional view showing a fire compartment structure according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0011] <Flat deck> As shown in Figures 1(a) and (b), the flat deck 1 according to an embodiment of the present invention comprises a flat portion 11, ribs 12 (121, 122) protruding from one surface 11D of the flat portion 11 and having a hollow space therein, and a filler 13 provided inside the rib 12.

[0012] The flat deck 1 has a flat portion 11 having an upper surface 11U that is flat or has minute irregularities formed thereon, and a lower surface 11D of the flat portion 11 from which a plurality of ribs 121, 122 protrude. The ribs 121, 122 are arranged in the horizontal direction (the X-axis direction in FIG. 1). While FIG. 1 shows an example in which two ribs are provided, the number of ribs is not particularly limited. Each of the ribs 121, 122 is a protrusion with an internal cavity and extends in the vertical direction (the Y-axis direction in FIG. 1). Both ends of each rib 12 in the longitudinal direction are configured to be closed, and can be closed by crushing, or can be configured using a closing member. The flat deck 1 can be obtained, for example, by roll forming or press forming a metal plate such as a steel plate or other material.

[0013] As shown in Figure 1(b), the cross-sectional shape of the rib 12 of the flat deck 1 includes a hollow portion 12a with a hollow formed therein and a connecting portion 12b connecting the lower surface 11D and the hollow portion 12a. The cross-sectional shape (XZ plane) of the hollow formed by the hollow portion 12a is not particularly limited and can be various shapes such as a triangle, a rectangle, or a circle as long as a hollow is formed inside. The connecting portion 12b is arranged so that the width narrows from the hollow portion 12a and a pair of plate-like portions meet, and each plate-like portion connects the upper end of the hollow portion 12a to the lower surface 11D.

[0014] The flat deck 1 has claws 14 that protrude from the underside 11D of the flat portion 11 and connect to the ribs 12 of an adjacent flat deck. The claws 14 are provided on one side end 18A of the flat portion 11. The claws 14 are formed, for example, by bending the flat portion 11. The claws 14 can be fitted by inserting them into one of the connection portions 12b of an adjacent flat deck 1. As shown in Fig. 2, adjacent flat decks 1 can be connected to each other by inserting and fitting the claw portion 14 into one of the connecting portions 12b of adjacent flat decks 1. In the following description, the connecting portion 12b into which the claw portion 14 is inserted may be referred to as the connecting portion 15. As shown in Fig. 2, the claw portion 14 is inserted into the gap between the pair of plate-like portions that make up the connecting portion 15 through an upper opening between the pair of plate-like portions and fitted therein. Note that the claw portion 14 may be provided on a portion of the side end portion 18A in the Y-axis direction, and therefore may be fitted into a portion of the connecting portion 12b in the Y-axis direction. Therefore, the entire connecting portion 12b in the Y-axis direction does not need to serve as the coupling portion 15 into which the claw portion 14 is inserted, and it is sufficient for only a portion to serve as the coupling portion 15.

[0015] In this embodiment, the filler 13 is a foam. By using a foam as the filler 13, the specific gravity is reduced, and the weight of the entire building material can be reduced. The foam used for the filler 13 is preferably an organic foam. The organic foam for the filler 13 is preferably one selected from the group consisting of, for example, polyurethane foam, phenol foam, styrene foam, PVC foam, and polyolefin foam such as polyethylene foam, and among these, either polyurethane foam or phenol foam is more preferable, and polyurethane foam is even more preferable. Furthermore, examples of foams (inorganic foams) other than organic foams include water glass and foamed concrete.

[0016] The filler 13 is filled inside the hollow portions 12a and connecting portions 12b of the ribs 12. It is preferable that the filler 13 be filled inside the hollow portions 12a and connecting portions 12b of all of the multiple ribs 12 provided on the flat deck 1. As will be described later, a foam used as the filler 13 is generally injected into the hollow portions 12a of the ribs 12 and foamed to fill them. Therefore, when foam is used as the filler 13, the foam fills not only the voids of the hollow portions 12a but also the gaps in the connecting portions 12b. Therefore, when an attempt is made to insert the claws 14 of adjacent flat decks into the connecting portions 12b (connecting portions 15), the claws 14 are obstructed by the filler 13 filling the connecting portions 15, and the flat decks may not be able to be connected. However, in this embodiment, as will be described in the manufacturing method below, for example, by controlling the temperature of the steel plate that makes up the connecting portions 15 and reducing the density of the filler 13 that fills the connecting portions 15, it becomes possible to insert the claws 14 into the connecting portions 15 even if the entire interior of the rib 12, including the connecting portions 15, is filled with the foam filler 13. Note that the filler 13 that fills the connecting portions 15 only needs to have a density that allows it to be compressed or deformed to an extent that does not hinder the insertion of the claws 14 when inserted. This makes it possible to connect multiple flat decks while filling the hollow portions 12a of the rib 12 and the connecting portions 12b (connecting portions 15) with the filler 13.

[0017] <density> The density of the filler 13 filling the hollow portion 12a is not particularly limited, but is, for example, 10 kg / m 3 More than 200kg / m 3 It is sufficient if it is less than 10 kg / m 3 More than 100kg / m 3 Less than 15 kg / m is preferable. 3 More than 90kg / m 3 More preferably, it is 20 kg / m or less. 3 More than 70kg / m 3 It is more preferable that the density of the filler 13 is equal to or less than the upper limit value. By making the density of the filler 13 equal to or less than the upper limit value, the filler 13 becomes lightweight, and the load on the building structure can be reduced. Furthermore, by making the density of the filler 13 equal to or more than the lower limit value, the desired flame retardancy and non-combustibility can be easily achieved. The density of the filler 13 filling the connecting portion 15 is not particularly limited, but is preferably 10 kg / m 3 More than 100kg / m 3 It is preferable that the saturation is 15 kg / m or less. 3 More than 80kg / m 3 More preferably, it is 20 kg / m or less. 3 More than 70kg / m 3 It is even more preferable that the density of the filler 13 is equal to or less than the upper limit value. By setting the density of the filler 13 to be equal to or less than the upper limit value, it is possible to prevent the insertion of the claws 14 of an adjacent flat deck from being hindered. Furthermore, by setting the density of the filler 13 to be equal to or more than the lower limit value, it is easier to achieve the desired flame retardancy and non-combustibility. The density of the filler 13 can be measured in accordance with JIS K7222:2005. The density of the filler 13 refers to the core density of the filler 13, ie, the density of the portion excluding the skin layer which is the interface between the filler 13 and the inner surface of the rib 12.

[0018] The flat deck 1 is provided with a plurality of ribs 121, 122, but it is not necessary to make the connection portions 12b of all of the ribs 121, 122 function as the connecting portions 15; it is sufficient to adjust the density of the filler 13 filling the connection portion 12b corresponding to the connecting portion 15 so that the connection portion 12b of at least one rib 121 functions as the connecting portion 15. Also, it is not necessary to make the entire connection portion 12b of one rib 121 function as the connecting portion 15; it is sufficient to adjust the density of the filler 13 filling the portion of the connection portion 12b corresponding to the connecting portion 15 so that at least a part of the connection portion 12b functions as the connecting portion 15.

[0019] The density of the connecting parts that function as connecting parts is adjusted to the above-mentioned density, while the density of the filler filled inside the connecting parts that do not function as connecting parts may be higher than the density of the filler filled inside the connecting parts that function as connecting parts. If the density of the filler filled inside the connecting parts is high, temperature control, which will be described later, is not necessary, which is advantageous in the manufacturing process. The density of the filler filled inside the connecting part that does not function as a connecting part is, for example, 10 kg / m 3 lower than the density of the filler filled inside the connecting part that functions as a connecting part. 3 It may be higher than 30kg / m 3 More than 200kg / m 3 It may be less than 40kg / m 3 More than 150kg / m 3 It may be higher or lower. The connection portion that does not constitute a connecting portion referred to here may be a connection portion in the rib on which the connecting portion is provided, or a connection portion in a rib other than the rib on which the connecting portion is provided. However, from the viewpoint of simplifying the manufacturing process, it is preferable that the density of the filling material filled inside the connection portion of the rib other than the rib on which the connecting portion is provided be adjusted to at least the density as described above.

[0020] Considering the construction in which the claws 14 are inserted and fitted, the rib 121 on which the connecting portion 15 is provided should be the rib provided closest to the side end 18B among the multiple ribs arranged in the X-axis direction of the flat deck. When the claws 14 are fitted and connected to the rib provided closest to the side end 18B, the overlapping portion of the flat decks in the X-axis direction can be reduced, and the flat portion 11 can be used effectively.

[0021] Each of the ribs 121, 122 has an injection port 16 (see FIG. 3) at the bottom for injecting a filler. By having the injection port 16 at the bottom, the ribs 121, 122 can inject the filler 13 from the bottom toward the connecting portion 12b, allowing the filler 13 to be distributed throughout the hollow portion 12a of the rib and the inside of the connecting portion 12b. In addition, the bottom surface portion is preferably the surface that forms the bottom surface of the rib in the case of a triangle or a rectangle as shown in Figure 1, but in the case of structures other than a triangle or a rectangle, such as a circle, the bottom surface portion is the part that can be seen from the bottom side. Furthermore, one injection port 16 may be provided in each rib, or two or more injection ports 16 may be provided.

[0022] <Total heat generation> From the viewpoint of enhancing fire resistance, the filler 13 is preferably a fire-resistant material. The fire-resistant material means a material that exhibits performance equivalent to a fire-retardant material (hereinafter referred to as "fire-retardant material") as defined in the Building Standards Act and the Enforcement Order of the Building Standards Act, but is preferably a material that exhibits performance equivalent to a quasi-noncombustible material (hereinafter referred to as "quasi-noncombustible material"), and more preferably a material that exhibits performance equivalent to a noncombustible material (hereinafter referred to as "noncombustible material"). Performance equivalent to a fire-retardant material means a material that exhibits a radiant heat intensity of 50 kW / m in a heat generation test using a cone calorimeter tester in accordance with ISO5660-1. 2 When heated at 5 minutes, the total heat generated is 8MJ / m 2 In addition, performance equivalent to semi-non-combustible materials means that the total heat generated after 10 minutes is 8MJ / m 2 In addition, performance equivalent to non-combustible materials means that the total heat generated after 20 minutes is 8MJ / m 2 It means the following:

[0023] The organic foam such as polyurethane foam used as filler 13 may have performance equivalent to at least one of a flame-retardant material, a semi-non-combustible material, and a non-combustible material, and preferably has performance equivalent to a non-combustible material. When measuring the organic foam in accordance with the ISO-5660 test method, a test sample is prepared by cutting the organic foam into a length of 10 cm, a width of 10 cm, and a thickness of 5 cm, and a heat generation test is performed using the test sample with a cone calorimeter tester.

[0024] <Flat deck manufacturing method> The method for manufacturing a flat deck according to this embodiment will be described below. The method for manufacturing a flat deck according to this embodiment is a method for manufacturing a flat deck that includes a flat portion 11, a rib 12 protruding from one surface 11D of the flat portion 11, and a filler 13, wherein the rib 12 has a hollow portion 12a having an internal cavity and a connecting portion 12b that connects the hollow portion 12a to the one surface 11D. The method for manufacturing a flat deck according to this embodiment includes a step of filling the inside of the rib 12 with the filler 13 while the steel plate temperature at the connecting portion 12b is kept at 60°C or higher and 150°C or lower. According to the above manufacturing method, the filler 13 filling the connecting portion 15 can be appropriately foamed to have a density that does not hinder the insertion of the claw portion 14 of the adjacent flat deck.

[0025] The steel plate temperature of the connection portion 12b is preferably 62°C or higher and 140°C or lower, more preferably 64°C or higher and 130°C or lower, from the viewpoint of adjusting the density of the filler 13 filling the connecting portion 15 to a predetermined range.

[0026] Hereinafter, the method for manufacturing a flat deck according to this embodiment will be described with reference to FIG. First, the flat deck 1, which has been bent to form ribs 12 (hollow portions 12a and connecting portions 12b) protruding from one surface 11D of the flat portion 11 and having hollows therein, is heated in a heating furnace 40 (see FIG. 4(a)). The flat deck 1 is heated to a temperature of 70 to 90°C in the heating furnace 40. Next, heat sources 41 and 42 are placed around the corresponding connecting portions 12b (see FIG. 4(b)) to adjust the temperature of the steel plate constituting the connecting portions 12b, which function as the connecting portions 15 of the flat deck 1 removed from the heating furnace 40, to a temperature of 60 to 150°C. Specifically, the flat deck 1 is rotated so that the bottom portion, where the injection port 16 for injecting the filler is provided, faces upward and the flat portion 11 faces downward. The heat source 41 is placed on the upper surface 11U of the flat portion 11, and heat sources 421 and 422 are placed on both sides of the connecting portions 12b. Heating is then performed using heat sources 41, 42 until the temperature of the steel plate at connection portions 12b reaches a state of 60°C or higher and 150°C or lower. Then, when the temperature of the steel plate at connection portions 12b reaches a predetermined range, filler 13 is injected through injection port 16 to fill the inside of rib 12. Through the above steps, filler 13 filling connection portions 12b, which function as linking portions 15, can be adjusted to a density within a predetermined range, and filler 13 can be filled throughout the entire inside of rib 12.

[0027] Here, the temperature of the steel plate in the flat portion 11 heated by the heat source 41 is preferably 62° C. or higher and 140° C. or lower, and more preferably 64° C. or higher and 130° C. or lower. The steel plate temperature in the flat portion 11 refers to the temperature of the steel plate in the portion connected to the connecting portion 12b of the flat portion 11. The steel plate temperature of the pair of plate-shaped parts that are heated by the heat source 42 and that make up the connecting part 12b is preferably 62°C or higher and 140°C or lower, and more preferably 64°C or higher and 130°C or lower.

[0028] (Polyurethane foam) The polyurethane foam constituting the filler 13 will be described in more detail. The polyurethane foam used in this embodiment is formed from a polyurethane composition. Specifically, the polyurethane foam used in this embodiment is a reaction product obtained by reacting and foaming a polyurethane composition obtained by mixing a liquid polyol and a liquid polyisocyanate. The polyurethane composition is in a liquid state immediately after being prepared by mixing the various components so that it can be easily injected into the interior of the rib 12 and can fill the hollow portions 12a and connecting portions 12b of the rib 12 without any gaps. A suitable application method for the polyurethane foam that fills and closes the hollow portions 12a and connecting portions 12b of the ribs 12 is discharge filling using a discharge device that discharges a liquid polyurethane composition. For example, when the polyurethane composition is a two-component curing type, the discharge device used is one that includes a mixing section that mixes the first and second components and a discharge port that discharges the resulting polyurethane composition. Examples of such discharge devices that can be used include high-pressure foaming machines, low-pressure foaming machines, other mixing and dispensing systems, spray guns, caulking guns, and the like.

[0029] The polyurethane composition that forms the polyurethane foam generally contains a liquid polyol and a liquid polyisocyanate.

[0030] [Polyol liquid] The polyol liquid used in this embodiment contains a polyol, a flame retardant, and a catalyst. The polyol liquid is mixed with a polyisocyanate liquid, which will be described later, to form a polyurethane composition, which is then filled into the hollow portion (i.e., the inside of the rib 12). The polyurethane composition is filled along the inner wall of the hollow portion, from near the filling position toward a position away from the filling position, such as the end of the hollow portion, and foams and hardens to form a polyurethane foam that corresponds to the shape of the hollow portion. The liquid polyol used in the present embodiment, as described in detail above, exhibits stable foaming behavior and fluidity for a certain period of time even after being mixed with the liquid polyisocyanate, allowing it to be distributed throughout the entire interior of a structure even at positions distant from the filling position, thereby providing excellent filling properties when filled into hollow spaces in a structure together with the liquid polyisocyanate. Therefore, even when flame retardancy is imparted by a flame retardant, uniform and sufficient adhesion can be obtained within the elongated hollow space, allowing the formation of a polyurethane foam that satisfies filling requirements in confined spaces.

[0031] [Polyol] The polyol contained in the polyol liquid is a compound having two or more hydroxyl groups. As the polyol, any polyol other than the reaction retarder may be used, specifically, any polyol having no carboxyl group may be used. In the present invention, examples of the polyol include polyester polyol, polyether polyol, polylactone polyol, polycarbonate polyol, and polymer polyol. The polyol preferably contains at least one selected from polyester polyol and polyether polyol, and more preferably contains polyester polyol. The polyester polyol is preferably used in an amount of 20 parts by mass or more, more preferably 50 parts by mass or more, even more preferably 80 parts by mass or more, and particularly preferably 100 parts by mass, per 100 parts by mass of the polyol.

[0032] <Polyester polyol> Examples of polyester polyols include aromatic polyester polyols and aliphatic polyester polyols, but considering the flame retardancy of the resulting polyurethane foam, it is preferable to use aromatic polyester polyols. The aromatic polyester polyol is preferably a condensate of an aromatic dicarboxylic acid such as o-phthalic acid (phthalic acid), m-phthalic acid (isophthalic acid), p-phthalic acid (terephthalic acid), or naphthalenedicarboxylic acid with a glycol. Among these, the polyol preferably contains a phthalic acid-based polyester polyol, which is a condensate of phthalic acid and a glycol, and more preferably contains a p-phthalic acid-based polyester polyol, which is a condensate of p-phthalic acid and a glycol. The glycol is not particularly limited, but it is preferable to use low molecular weight aliphatic glycols known as constituent components of polyester polyols, such as ethylene glycol, propylene glycol, and diethylene glycol.

[0033] The content of the aromatic polyester polyol is preferably 50 parts by mass or more, more preferably 70 parts by mass or more, even more preferably 90 parts by mass or more, and still more preferably 100 parts by mass, based on 100 parts by mass of the polyol. As described above, the aromatic polyester polyol is preferably a phthalic acid-based polyester polyol, and therefore, an embodiment in which the content of the phthalic acid-based polyester polyol is within the above range is more preferable.

[0034] <Polyether polyol> Examples of polyether polyols include polyoxyalkylene polyols obtained by ring-opening addition polymerization of alkylene oxide to an initiator having two or more active hydrogen atoms. Specific examples of initiators include aliphatic polyhydric alcohols (e.g., glycols such as ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, 1,4-butanediol, 1,3-butanediol, 1,6-hexanediol, neopentyl glycol, cyclohexylene glycol, and cyclohexanedimethanol; triols such as trimethylolpropane and glycerin; tetrafunctional alcohols such as pentaerythritol; and highly functional alcohols such as sucrose and sorbitol), aliphatic amines (e.g., alkylenediamines such as ethylenediamine, propylenediamine, butylenediamine, hexamethylenediamine, and neopentyldiamine; alkanolamines such as monoethanolamine and diethanolamine), and aromatic amines (e.g., aniline, tolylenediamine, xylylenediamine, diphenylmethanediamine, and Mannich condensation products). These may be used alone or in combination of two or more.

[0035] The polyether polyol is preferably a tolylenediamine-based polyether polyol, a Mannich-based polyether polyol, a sucrose-based polyether polyol, a sorbitol-based polyether polyol, or an ethylenediamine-based polyether polyol. These polyether polyols may be used alone or in combination of two or more.

[0036] The tolylenediamine-based polyether polyol is a polyether polyol obtained using tolylenediamine as an initiator. The same applies to sucrose-based polyether polyols, sorbitol-based polyether polyols, and ethylenediamine-based polyether polyols. The Mannich polyether polyol is a polyether polyol obtained by utilizing the Mannich reaction, which is a Mannich condensation product having two or more hydroxyl groups in the molecule, or a polyether polyol obtained by adding an alkylene oxide to such a Mannich condensation product. More specifically, it is a Mannich condensation product obtained by the Mannich reaction of at least one of phenol and its alkyl-substituted derivatives, formaldehyde, and alkanolamine, or a polyether polyol obtained by ring-opening addition polymerization of this compound with at least one of ethylene oxide and propylene oxide.

[0037] Examples of polylactone polyols include polypropiolactone glycol, polycaprolactone glycol, and polyvalerolactone glycol. Examples of polycarbonate polyols include polyols obtained by dealcoholization reaction of hydroxyl group-containing compounds such as ethylene glycol, propylene glycol, butanediol, pentanediol, hexanediol, octanediol, and nonanediol with ethylene carbonate, propylene carbonate, and the like.

[0038] Examples of polymer polyols include polymers obtained by graft polymerizing an ethylenically unsaturated compound such as acrylonitrile, styrene, methyl acrylate, or methacrylate with an aromatic polyol, alicyclic polyol, aliphatic polyol, or polyester polyol, polybutadiene polyol, or hydrogenated products thereof.

[0039] The average hydroxyl value of the polyol used in the present invention is preferably from 100 to 500 mgKOH / g, more preferably from 150 to 450 mgKOH / g, and even more preferably from 170 to 350 mgKOH / g, from the viewpoint of improving the flame retardancy of the polyurethane foam. When one type of polyol is used, the average hydroxyl value is the hydroxyl value of that one type of polyol, and when two or more types of polyols are used, it is the average value of the hydroxyl groups in accordance with the blending ratio of the two or more types of polyols. For example, when two types of polyols, polyol (d1) and polyol (d2), are used as polyols, the hydroxyl value of polyol (d1) is X1, the blending ratio is m1, and the hydroxyl value of polyol (d2) is X2, the blending ratio is m2, the average hydroxyl value is expressed by the following formula: Note that the blending ratio is based on mass. Average hydroxyl value (mgKOH / g)=X1×(m1 / (m1+m2))+X2×(m2 / (m1+m2)) The hydroxyl value is a value measured in accordance with JIS K1557-1:2007.

[0040] [catalyst] The polyol liquid used in this embodiment contains a catalyst. The catalyst contains a resinification catalyst and a trimerization catalyst. By containing the resinification catalyst and the trimerization catalyst, the urethanization reaction and the trimerization reaction can be appropriately promoted, and a polyurethane foam with excellent foaming properties and flame retardancy can be obtained.

[0041] In the polyol liquid, the mass ratio (hereinafter also referred to as parts ratio) of the content of the resinification catalyst to the content of the trimerization catalyst is 0.4 to 1.0. If the ratio of the number of parts of the resinification catalyst to the trimerization catalyst is less than 0.4, two-stage foaming behavior due to the trimerization catalyst and the resinification catalyst is likely to occur, making it difficult to obtain uniform and sufficient adhesion within the elongated hollow portion. From the above perspective, the ratio of the number of parts of the resinification catalyst to the trimerization catalyst is preferably 0.43 or more, more preferably 0.46 or more, and even more preferably 0.49 or more. Furthermore, if the ratio of the number of parts of the resinification catalyst to the trimerization catalyst exceeds 1.0, the flame retardancy of the resulting polyurethane foam will be insufficient. From the above perspective, the ratio of the number of parts of the resinification catalyst to the trimerization catalyst is preferably 0.90 or less, more preferably 0.85 or less, and even more preferably 0.80 or less. The above-mentioned ratios in parts are based on the content of the resinification catalyst and trimerization catalyst themselves. For example, resinification catalysts and trimerization catalysts are often sold as products dissolved in a solvent, and in such cases, the content of the resinification catalyst and trimerization catalyst refers to the amount of catalyst itself dissolved in the solvent, not including the amount of solvent.

[0042] <Resinification catalyst> The resinification catalyst is a catalyst that promotes the reaction between polyol and polyisocyanate. Examples of the resinification catalyst include amine catalysts such as imidazole compounds and piperazine compounds, and metal catalysts. When using an amine catalyst, it is preferable to use one other than the above-mentioned reaction retarders, more specifically, an amine catalyst other than the above-mentioned acid-blocked catalyst. The amine catalyst may be the same as or different from the amino compound capable of generating the acid-blocked catalyst. As the amine catalyst, an imidazole compound is preferred. Examples of imidazole compounds include tertiary amines in which the secondary amine at the 1-position of the imidazole ring is substituted with an alkyl group, an alkenyl group, or the like. Specific examples include N-methylimidazole, 1,2-dimethylimidazole, 1-ethyl-2-methylimidazole, 1-methyl-2-ethylimidazole, 1,2-diethylimidazole, and 1-isobutyl-2-methylimidazole. Other examples include imidazole compounds in which the secondary amine in the imidazole ring is substituted with a cyanoethyl group. Furthermore, examples of the piperazine compound include tertiary amines such as N-methyl-N',N'-dimethylaminoethylpiperazine and trimethylaminoethylpiperazine. Examples of the amine catalyst include, in addition to imidazole compounds and piperazine compounds, various tertiary amines such as pentamethyldiethylenetriamine, triethylamine, N-methylmorpholinebis(2-dimethylaminoethyl)ether, N,N,N',N",N"-pentamethyldiethylenetriamine, N,N,N'-trimethylaminoethyl-ethanolamine, bis(2-dimethylaminoethyl)ether, N,N-dimethylcyclohexylamine, diazabicycloundecene, triethylenediamine, tetramethylhexamethylenediamine, and tripropylamine.

[0043] Examples of metal catalysts include metal salts of lead, tin, bismuth, copper, zinc, cobalt, nickel, etc., and preferably organic acid metal salts of lead, tin, bismuth, copper, zinc, cobalt, nickel, etc. More preferred are organic acid tin salts such as dibutyltin dilaurate, dioctyltin dilaurate, and dioctyltin versatate, and organic acid bismuth salts such as bismuth trioctate and bismuth tris(2-ethylhexanoate), and among these, organic acid bismuth salts are preferred. The resinification catalyst may be used alone or in combination of two or more. The resinification catalyst is preferably at least one selected from amine-based catalysts and metal-based catalysts, and among them, amine-based catalysts are more preferred from the viewpoint of controlling the reaction rate with a reaction retarder and making it easier to suppress variations in density of the polyurethane foam.

[0044] The content of the resinification catalyst in the polyol liquid is preferably 0.1 to 15 parts by mass, more preferably 1 to 10 parts by mass, and even more preferably 2 to 8 parts by mass, per 100 parts by mass of the polyol. When the content of the resinification catalyst is within this range, the reaction between the polyol and the isocyanate tends to proceed appropriately. Furthermore, when a resinification catalyst and a trimerization catalyst are used in combination, by adjusting the content of the resinification catalyst within the above range and the content of the trimerization catalyst within the specified range described below, the ability of the polyurethane composition to fill hollow spaces in structures is improved, and the physical properties of the resulting polyurethane foam, such as flame retardancy, are also improved.

[0045] <Trimerization catalyst> The trimerization catalyst reacts with the isocyanate groups contained in the polyisocyanate to trimerize them and promote the formation of isocyanurate rings. The trimerization catalyst may be one other than the reaction retarders described below, and it is preferable to use a trimerization catalyst other than the acid-blocked catalyst described below. Specifically, nitrogen-containing aromatic compounds such as tris(dimethylaminomethyl)phenol, 2,4-bis(dimethylaminomethyl)phenol, and 2,4,6-tris(dialkylaminoalkyl)hexahydro-S-triazine; alkali metal carboxylates such as potassium acetate, potassium 2-ethylhexanoate, and potassium octoate; and tertiary ammonium salts such as trimethylammonium salts, triethylammonium salts, and triphenylammonium salts. Examples of quaternary ammonium salts include quaternary ammonium carboxylates. Examples of the carboxylic acid in the quaternary ammonium carboxylate include carboxylic acids having about 1 to 10 carbon atoms, such as 2-ethylhexanoic acid, 2,2-dimethylpropanoic acid, acetic acid, and formic acid. Examples of the quaternary ammonium ion in the quaternary ammonium carboxylate include triethylmethylammonium ion, tetramethylammonium ion, tetraethylammonium ion, tetraphenylammonium ion, hydroxybutyltrimethylammonium ion, and hydroxypropyltrimethylammonium ion. The trimerization catalyst may be used alone or in combination of two or more kinds. The trimerization catalyst is preferably at least one of an alkali metal carboxylate and a quaternary ammonium salt, more preferably an alkali metal carboxylate, and even more preferably potassium 2-ethylhexanoate.

[0046] The content of the trimerization catalyst is preferably 0.1 to 20 parts by mass, more preferably 1 to 18 parts by mass, and even more preferably 5 to 15 parts by mass, relative to 100 parts by mass of the polyol. When the content of the trimerization catalyst is within this range, the trimerization reaction can proceed appropriately. Furthermore, when the resinification catalyst and the trimerization catalyst are used in combination, adjusting the content of the resinification catalyst and the content of the trimerization catalyst to fall within the respective ranges described above improves the ability of the polyurethane composition to fill hollow spaces in the structure, and improves the physical properties, such as flame retardancy, of the resulting polyurethane foam.

[0047] The polyol liquid used in this embodiment preferably has a catalyst content of 0.3 to 8 mass%, more preferably 0.5 to 7 mass%, and even more preferably 1 to 6 mass%. When the catalyst content is equal to or greater than the above-mentioned lower limit, the reaction between the polyol and the polyisocyanate is sufficient, making it easier to obtain a polyurethane foam with excellent flame retardancy. When the catalyst content is equal to or less than the above-mentioned upper limit, the reactivity between the polyol and the polyisocyanate is appropriate, making it easier to fill the entire hollow portion of the structure with the composition and to suppress variations in the density of the polyurethane foam. The catalyst amount of the catalyst described above is the amount of the catalyst itself based on the total amount of the polyol liquid. For example, the catalyst is often sold as a product dissolved in a solvent, and in this case, the catalyst content does not include the amount of the solvent in which the catalyst is dissolved, but means the amount of the catalyst itself dissolved in the solvent.

[0048] [Flame retardant] The polyol liquid contains a flame retardant, which can more effectively enhance flame retardancy and impart high flame retardancy to the polyurethane foam. The flame retardant may be a solid flame retardant or a liquid flame retardant. A solid flame retardant is a flame retardant that is solid at room temperature (23°C) and normal pressure (1 atmosphere).

[0049] <Solid flame retardant> From the viewpoint of more effectively enhancing flame retardancy, the solid flame retardant is preferably at least one selected from the group consisting of red phosphorus-based flame retardants, boron-containing flame retardants, bromine-containing flame retardants, phosphate-containing flame retardants, chlorine-containing flame retardants, antimony-containing flame retardants, metal hydroxides, and needle-like fillers.

[0050] <Red phosphorus flame retardant> The red phosphorus-based flame retardant may consist of red phosphorus alone, or may be red phosphorus coated with a resin, metal hydroxide, metal oxide, or the like, or may be red phosphorus mixed with a resin, metal hydroxide, metal oxide, or the like. The resin that coats or mixes with red phosphorus is not particularly limited, but examples include thermosetting resins such as phenolic resin, epoxy resin, unsaturated polyester resin, melamine resin, urea resin, aniline resin, and silicone resin. From the viewpoint of flame retardancy, metal hydroxides are preferred as the compound to be coated or mixed. The metal hydroxide to be used may be appropriately selected from those described below.

[0051] The blending amount of the red phosphorus-based flame retardant is preferably 3 to 60 parts by mass, more preferably 10 to 50 parts by mass, and even more preferably 20 to 45 parts by mass, relative to 100 parts by mass of the polyol. By making the blending amount of the red phosphorus-based flame retardant equal to or greater than these lower limits, the effect of including the red phosphorus-based flame retardant can be easily exerted. On the other hand, by making the blending amount equal to or less than the upper limits, foaming is not inhibited by the red phosphorus-based flame retardant.

[0052] <Boron-containing flame retardants> 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, elements of Groups 4, 12, and 13 of the periodic table, and ammonium. 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, aluminum borate, and ammonium borate. The boron-containing flame retardants may be used alone or in combination of two or more. Preferably, the boron-containing flame retardant is a borate, more preferably zinc borate.

[0053] The amount of the boron-containing flame retardant is not particularly limited, but is preferably 3 to 45 parts by mass, more preferably 5 to 40 parts by mass, and even more preferably 10 to 25 parts by mass, per 100 parts by mass of polyol. By setting the amount of the boron-containing flame retardant to be equal to or greater than these lower limits, the effect of the boron-containing flame retardant is more easily exerted, and flame retardancy is improved. On the other hand, by setting the amount to be equal to or less than the upper limits, foaming is not inhibited by the boron-containing flame retardant.

[0054] <Bromine-containing flame retardants> The bromine-containing flame retardant is not particularly limited as long as it contains bromine in its molecular structure and is a compound that is solid at room temperature and normal pressure, and examples thereof include brominated aromatic ring-containing aromatic compounds. Examples of the brominated aromatic ring-containing aromatic compound include monomeric organic bromine compounds such as hexabromobenzene, pentabromotoluene, hexabromobiphenyl, decabromobiphenyl, decabromodiphenyl ether, octabromodiphenyl ether, hexabromodiphenyl ether, bis(pentabromophenoxy)ethane, ethylenebis(pentabromophenyl), ethylenebis(tetrabromophthalimide), and tetrabromobisphenol A.

[0055] The brominated aromatic ring-containing aromatic compound may also be a bromine compound polymer. Specific examples include brominated polycarbonates such as polycarbonate oligomers produced using brominated bisphenol A as a raw material, copolymers of the polycarbonate oligomers with bisphenol A, and diepoxy compounds produced by reacting brominated bisphenol A with epichlorohydrin. Further examples include brominated epoxy compounds such as monoepoxy compounds obtained by reacting brominated phenols with epichlorohydrin, poly(brominated benzyl acrylate), brominated phenol condensates of brominated polyphenylene ether, brominated bisphenol A, and cyanuric chloride, brominated (polystyrene), poly(brominated styrene), brominated polystyrenes such as crosslinked brominated polystyrene, and crosslinked or non-crosslinked brominated poly(methylstyrene). Furthermore, compounds other than brominated aromatic ring-containing aromatic compounds such as hexabromocyclododecane may also be used. These bromine-containing flame retardants may be used alone or in combination of two or more. Among the above, brominated aromatic ring-containing aromatic compounds are preferred, and among them, monomeric organic bromine compounds such as ethylenebis(pentabromophenyl) are preferred.

[0056] The blending amount of the bromine-containing flame retardant is preferably 3 to 60 parts by mass, more preferably 10 to 50 parts by mass, and even more preferably 20 to 45 parts by mass, per 100 parts by mass of the polyol. By blending the amount of the bromine-containing flame retardant at or above these lower limits, the effect of the inclusion of the bromine-containing flame retardant is easily exhibited. On the other hand, by blending the amount at or below the upper limits, foaming is not inhibited by the bromine-containing flame retardant.

[0057] <Phosphate-containing flame retardants> Examples of phosphate-containing flame retardants include phosphates formed from salts of various phosphoric acids with at least one metal or compound selected from metals of Groups IA to IVB of the periodic table, ammonia, aliphatic amines, aromatic amines, and heterocyclic compounds containing nitrogen in the ring. The phosphoric acid is not particularly limited, but examples thereof include monophosphoric acid, pyrophosphoric acid, and polyphosphoric acid. Examples of metals in Groups IA to IVB of the periodic table include lithium, sodium, calcium, barium, iron (II), iron (III), and aluminum. Examples of the aliphatic amine include methylamine, ethylamine, diethylamine, triethylamine, ethylenediamine, piperazine, etc. Examples of the aromatic amine include aniline, o-toliidine, 2,4,6-trimethylaniline, anisidine, 3-(trifluoromethyl)aniline, etc. Examples of the heterocyclic compound containing nitrogen in the ring include pyridine, triazine, melamine, etc.

[0058] Specific examples of phosphate-containing flame retardants include monophosphates such as aluminum triphosphate, pyrophosphates, polyphosphates, etc. Here, the polyphosphates are not particularly limited, but examples include ammonium polyphosphate, piperazine polyphosphate, melamine polyphosphate, ammonium amide polyphosphate, aluminum polyphosphate, etc. The phosphate-containing flame retardant may be one or more of the above-mentioned compounds.

[0059] The amount of the phosphate-containing flame retardant is not particularly limited, but is preferably 3 to 40 parts by mass, more preferably 5 to 35 parts by mass, and even more preferably 10 to 30 parts by mass, per 100 parts by mass of polyol. By setting the amount of the phosphate-containing flame retardant to be equal to or greater than these lower limits, the effect of the phosphate-containing flame retardant is more easily exhibited. On the other hand, by setting the amount to be equal to or less than the upper limits, foaming is not inhibited by the phosphate-containing flame retardant.

[0060] <Chlorine-containing flame retardants> Chlorine-containing flame retardants include those commonly used in flame-retardant resin compositions, such as polychlorinated naphthalene, chlorendic acid, and dodecachlorododecahydrodimethanodibenzocyclooctene, which is sold under the trade name "Dechlorane Plus." The blending amount of the chlorine-containing flame retardant is not particularly limited, but is preferably 3 to 40 parts by mass, more preferably 5 to 35 parts by mass, and even more preferably 10 to 30 parts by mass, relative to 100 parts by mass of the polyol. By blending the amount of the chlorine-containing flame retardant at or above these lower limits, the effect of the inclusion of the chlorine-containing flame retardant is easily exhibited. On the other hand, by blending the amount at or below the upper limits, foaming is not inhibited by the chlorine-containing flame retardant.

[0061] <Antimony-containing flame retardants> Examples of antimony-containing flame retardants include antimony oxide, antimony salts, and pyroantimony salts. Examples of antimony oxide include antimony trioxide and antimony pentoxide. Examples of antimony salts include sodium antimonate and potassium antimonate. Examples of pyroantimonate salts include sodium pyroantimonate and potassium pyroantimonate. The antimony-containing flame retardant may be used alone or in combination of two or more. The preferred antimony-containing flame retardant for use in the present invention is antimony trioxide.

[0062] The amount of antimony-containing flame retardant blended is not particularly limited, but is preferably 1 to 40 parts by mass, more preferably 2 to 35 parts by mass, and even more preferably 3 to 30 parts by mass, per 100 parts by mass of polyol. By blending the amount of antimony-containing flame retardant at or above these lower limits, the effect of the antimony-containing flame retardant is more easily exerted, and flame retardancy is improved. On the other hand, by blending the amount at or below the upper limits, foaming is not inhibited by the antimony-containing flame retardant.

[0063] <Metal hydroxide> Examples of metal hydroxides used in the present invention include magnesium hydroxide, calcium hydroxide, aluminum hydroxide, iron hydroxide, nickel hydroxide, zirconium hydroxide, titanium hydroxide, zinc hydroxide, copper hydroxide, vanadium hydroxide, tin hydroxide, etc. The metal hydroxides may be used alone or in combination of two or more.

[0064] The amount of metal hydroxide blended is, for example, 0.1 to 50 parts by mass, preferably 0.2 to 30 parts by mass, more preferably 0.3 to 20 parts by mass, and even more preferably 0.5 to 15 parts by mass, relative to 100 parts by mass of polyol. By blending the amount of metal hydroxide at or above these lower limits, the effect of containing the metal hydroxide is easily exerted, and flame retardancy is improved. On the other hand, by blending the amount at or below the upper limits, foaming is not inhibited by the metal hydroxide.

[0065] Of the solid flame retardants mentioned above, red phosphorus-based flame retardants, boron-containing flame retardants, bromine-containing flame retardants, etc. are preferred, and among these, it is more preferred that the solid flame retardant contains at least a red phosphorus-based flame retardant. It is also preferable to use a combination of multiple solid flame retardants. In this case, it is preferable to use a red phosphorus-based flame retardant, a boron-containing flame retardant, and a bromine-containing flame retardant in combination. By using these in combination, it is easier to further improve flame retardancy.

[0066] <Solid flame retardant blend amount> The amount of the solid flame retardant is not particularly limited, but is, for example, 10 to 150 parts by mass, preferably 20 to 100 parts by mass, and more preferably 40 to 80 parts by mass, relative to 100 parts by mass of the polyol. By adjusting the amount of the solid flame retardant to be equal to or greater than these lower limits, it is possible to impart appropriate flame retardancy to the polyurethane foam. By adjusting the amount of the solid flame retardant to be equal to or less than these upper limits, it becomes easier to fill the polyurethane composition inside the structure, making it easier to obtain a polyurethane foam with little density variation depending on the location.

[0067] Liquid flame retardant The liquid polyol agent may contain a liquid flame retardant. A liquid flame retardant is a flame retardant that is liquid at room temperature (23°C) and normal pressure (1 atmosphere). A specific example of a liquid flame retardant is a phosphate ester. Unlike solid flame retardants, liquid flame retardants are less likely to produce sediment during storage and are easier to handle.

[0068] The phosphate ester is preferably a monophosphate ester, a condensed phosphate ester, etc. Examples of the monophosphate ester include trialkyl phosphates such as trimethyl phosphate, triethyl phosphate, tributyl phosphate, and tri(2-ethylhexyl)phosphate, halogen-containing phosphate esters such as tris(β-chloropropyl)phosphate, trialkoxyphosphates such as tributoxyethyl phosphate, aromatic ring-containing phosphate esters such as tricresyl phosphate, trixylenyl phosphate, tris(isopropylphenyl)phosphate, cresyl diphenyl phosphate, and diphenyl(2-ethylhexyl)phosphate, and acidic phosphate esters such as monoisodecyl phosphate and diisodecyl phosphate.

[0069] Examples of the condensed phosphate ester include aromatic condensed phosphate esters such as trialkyl polyphosphate, resorcinol polyphenyl phosphate, bisphenol A polycresyl phosphate, and bisphenol A polyphenyl phosphate. Commercially available condensed phosphate esters include, for example, "CR-733S," "CR-741," and "CR747" manufactured by Daihachi Chemical Industry Co., Ltd., and "ADEKA STAB PFR" and "FP-600" manufactured by ADEKA Corporation.

[0070] The liquid flame retardant may be one of the above-mentioned compounds, or two or more of them may be used in combination. Among these, from the viewpoint of facilitating the production of polyurethane foam and improving the flame retardancy of the polyurethane foam, monophosphate ester is preferred, and tris(β-chloropropyl)phosphate is more preferred.

[0071] When a liquid flame retardant is contained, the blending amount thereof is preferably from 5 to 80 parts by mass, more preferably from 10 to 70 parts by mass, and even more preferably from 20 to 60 parts by mass, relative to 100 parts by mass of the polyol.

[0072] [Reaction retarder] The polyol liquid used in this embodiment preferably contains a reaction retarder, which controls the curing time when the polyurethane foam is formed, and enables the formation of a polyurethane foam that has excellent filling properties when filling hollow spaces in a structure and little density variation from place to place. The reaction retarder preferably contains an acid component, more preferably at least one selected from carboxylic acids and acid-blocking catalysts, and even more preferably at least one selected from hydroxycarboxylic acid compounds and amine-based acid-blocking catalysts. The reaction retarder containing an acid component makes it easier to control the curing time when a polyurethane foam is formed. The principle by which the curing time is controlled by the reaction retarder is not clear, but it is presumed that the acid component in the reaction retarder blocks the amine catalyst described below, slowing down the rate of the curing reaction between the polyol and polyisocyanate. The reaction retarder may be contained alone or in combination of two or more kinds.

[0073] As the carboxylic acid, a hydroxycarboxylic acid compound or a carboxylic acid having no hydroxyl group can be used, but it is preferable to use a hydroxycarboxylic acid compound, since the hydroxyl group of the hydroxycarboxylic acid compound reacts with the polyisocyanate described below, making it easier to inhibit the reaction. Hydroxycarboxylic acid compounds are compounds having a hydroxyl group and a carboxyl group, and specific examples thereof include aliphatic hydroxycarboxylic acid compounds such as lactic acid, glycolic acid, 2-hydroxybutyric acid, and 3-hydroxybutyric acid, and aromatic hydroxycarboxylic acid compounds such as salicylic acid, coumaric acid, mandelic acid, benzilic acid, atrolactic acid, ferulic acid, sinapic acid, vanillic acid, and 4-hydroxybenzoic acid. The hydroxycarboxylic acid compound may also be a reaction product obtained by esterification of a dicarboxylic acid component and a dihydric alcohol component. It is preferable that such a reaction product have one hydroxyl group and one carboxyl group. Examples of the dicarboxylic acid component include phthalic acid, phthalic anhydride, isophthalic acid, and terephthalic acid. Examples of the dihydric alcohol component include ethylene glycol, diethylene glycol, and triethylene glycol. The dicarboxylic acid component and the dihydric alcohol component may each be used alone or in combination of two or more. The hydroxycarboxylic acid compound preferably has one hydroxyl group, and more preferably has one hydroxyl group and one carboxyl group.

[0074] As the carboxylic acid without a hydroxyl group, an aliphatic carboxylic acid or a carboxylic acid having an aromatic ring can be used. The aliphatic carboxylic acid is not particularly limited and may be saturated or unsaturated, and may be linear or branched. Examples of the aliphatic carboxylic acid include an aliphatic carboxylic acid having an aliphatic hydrocarbon group having 1 to 10 carbon atoms, such as formic acid, acetic acid, propionic acid, butyric acid, and valeric acid. Examples of the carboxylic acid having an aromatic ring include a carboxylic acid having a monocyclic (non-polycyclic) aromatic ring and a carboxylic acid having a polycyclic aromatic ring. Examples of carboxylic acids having a monocyclic (non-polycyclic) aromatic ring include benzoic acid, phthalic acid (orthophthalic acid, isophthalic acid, terephthalic acid), etc. Examples of carboxylic acids having a polycyclic aromatic ring include naphthoic acid, etc. Of the above-mentioned carboxylic acids not having a hydroxyl group, it is preferable to use an aliphatic carboxylic acid having an aliphatic hydrocarbon group having 1 to 10 carbon atoms, and it is more preferable to use formic acid.

[0075] As mentioned above, an acid-blocked catalyst can also be used as a reaction retarder. The acid-blocked catalyst has low activity at low temperatures and increases in activity with increasing temperature.

[0076] As the acid blocking catalyst, it is preferable to use an amine-based acid blocking catalyst in which an amino compound is blocked with a carboxylic acid. As the carboxylic acid, the above-mentioned compounds can be suitably used, but it is preferable to use formic acid. In the early stages of the curing reaction between polyol and polyisocyanate, the acid-blocked catalyst blocks the activity of catalytic compounds such as amines, thereby slowing the reaction rate. After that, as the temperature rises due to the heat of the curing reaction, the acid block is removed, allowing the intrinsic activity of catalytic compounds such as amines to be expressed and accelerate the curing reaction.

[0077] Examples of the amino compound include aliphatic amines and aromatic amines. The amine compound is preferably a tertiary amine, and more preferably a tertiary aliphatic amine. Examples of the amino compound include those having about 6 to 18 carbon atoms. Specific examples of the amino compound that can be used include triethylamine, N-methylmorpholine bis(2-dimethylaminoethyl) ether, N,N,N',N",N"-pentamethyldiethylenetriamine, N,N,N'-trimethylaminoethyl-ethanolamine, bis(2-dimethylaminoethyl) ether, N-methyl-N',N'-dimethylaminoethylpiperazine, N,N-dimethylcyclohexylamine, diazabicycloundecene, diazabicyclononene, trimethylaminoethylpiperazine, tripropylamine, and bisdiethylaminoethyl ether. Among these, tertiary aliphatic amines having multiple nitrogen atoms are preferred, and among these, it is preferable to use at least one selected from N,N,N',N",N"-pentamethyldiethylenetriamine, diazabicycloundecene, diazabicyclononene, triethylenediamine, and bisdiethylaminoethyl ether, and it is more preferable to use N,N,N',N",N"-pentamethyldiethylenetriamine.

[0078] In the present invention, it is preferable to use at least one selected from a hydroxycarboxylic acid compound and an amine-based acid blocking catalyst as the reaction retarder, more preferably at least one selected from a hydroxycarboxylic acid compound and a formic acid blocking catalyst, and even more preferably a hydroxycarboxylic acid compound. The use of these substances as reaction retarders makes it easier to suppress density variations in polyurethane foams and to impart excellent flame retardancy to the polyurethane foams. Furthermore, the overall molecular weight of the reaction retarder increases, making it easier to improve the storage stability of the polyol liquid.

[0079] The content of the reaction retarder is preferably 0.1 to 10 parts by mass, more preferably 0.3 to 7 parts by mass, and even more preferably 0.5 to 4 parts by mass, per 100 parts by mass of polyol. When the content of the reaction retarder is equal to or greater than the above-mentioned lower limit, excellent filling properties are easily imparted to the polyol liquid. Furthermore, when the content of the reaction retarder is equal to or less than the above-mentioned upper limit, the rate of the curing reaction between the polyol and the polyisocyanate is ensured to be at least constant, thereby making the density of the polyurethane foam filled therein appropriate and making it easier to impart excellent flame retardancy to the polyurethane foam.

[0080] [Foaming agent] The polyol liquid used in this embodiment preferably contains a foaming agent. The foaming agent can be used to mix the polyol liquid and the polyisocyanate liquid and foam them to form a polyurethane foam. The foaming agent is contained in at least one of the polyol liquid and the polyisocyanate liquid described below, but is preferably contained in the polyol liquid. The blowing agent is not particularly limited, but examples thereof include organic blowing agents such as hydrocarbon compounds, chlorinated aliphatic hydrocarbon compounds, hydrofluorocarbons, hydrochlorofluorocarbon compounds, and hydrofluoroolefins; inorganic blowing agents such as nitrogen gas, oxygen gas, argon gas, and carbon dioxide gas; and water. Of these, it is preferable to use organic blowing agents and water.

[0081] Examples of the hydrocarbon compound include propane, butane, pentane, hexane, heptane, cyclopropane, cyclobutane, cyclopentane, cyclohexane, and cycloheptane. Examples of the chlorinated aliphatic hydrocarbon compounds include dichloroethane, propyl chloride, isopropyl chloride, butyl chloride, isobutyl chloride, pentyl chloride, and isopentyl chloride. Examples of the hydrofluorocarbon include CHF3, CH2F2, and CH3F.

[0082] Examples of the hydrochlorofluorocarbon compounds include dichloromonofluoroethane (for example, HCFC141b (1,1-dichloro-1-fluoroethane), HCFC22 (chlorodifluoromethane), and HCFC142b (1-chloro-1,1-difluoroethane)), HFC-245fa (1,1,1,3,3-pentafluoropropane), and HFC-365mfc (1,1,1,3,3-pentafluorobutane).

[0083] Examples of the hydrofluoroolefin include fluoroalkenes having 3 to 6 carbon atoms. The hydrofluoroolefin may also be a hydrochlorofluoroolefin having a chlorine atom, and therefore may be a chlorofluoroalkene having 3 to 6 carbon atoms. The hydrofluoroolefin preferably has 3 or 4 carbon atoms. More specific examples include trifluoropropene, tetrafluoropropenes such as HFO-1234, pentafluoropropenes such as HFO-1225, chlorotrifluoropropenes such as HFO-1233, chlorodifluoropropene, chlorotrifluoropropene, and chlorotetrafluoropropene. More specifically, 1,3,3,3-tetrafluoropropene (HFO-1234ze), 1,1,3,3-tetrafluoropropene, 1,2,3,3,3-pentafluoropropene (HFO-1225ye), 1,1,1-trifluoropropene, 1,1,1,3,3-pentafluoropropene (HFO-1225zc), 1,1,1,3,3,3-hexafluorobut-2-ene, 1,1,2,3,3-pentafluoropropene (HFO-1225yc), 1,1,1,2,3-pentafluoropropene (HFO-1225yez), (E)-1-chloro-3,3,3-trifluoropropene (HFO-1233zd(E)), Examples include (Z)-1-chloro-3,3,3-trifluoropropene (HFO-1233zd(Z)), (Z)-1,1,1,4,4,4-hexafluorobut-2-ene (HFO-1336mzz(Z)), (E)-1,1,1,4,4,4-hexafluorobut-2-ene (HFO-1336mzz(E)), 2,3,3,3-tetrafluoropropene (HFO-1234yf), trifluoroethylene (HFO-1123), (E)-1-chloro-3,3,3-trifluoropropene (HCFO-1233zd(E)), and (Z)-2,3,3,3-tetrafluoro-1-chloropropene (HCFO-1224yd(Z)).

[0084] From the viewpoints of good foam formation and reducing the environmental load, it is preferable to use a hydrofluoroolefin as the foaming agent.

[0085] The content of the blowing agent is preferably 15 to 90 parts by mass, more preferably 25 to 80 parts by mass, and even more preferably 30 to 70 parts by mass, per 100 parts by mass of the polyol. When the content of the blowing agent is equal to or greater than the lower limit, foaming is promoted, fluidity is increased, and the density of the resulting polyurethane foam can be reduced. On the other hand, when the content of the blowing agent is equal to or less than the upper limit, excessive foaming can be suppressed.

[0086] As the blowing agent, it is preferable to use at least a hydrofluoroolefin, and it is also preferable to use a hydrofluoroolefin in combination with water. The content of hydrofluoroolefin as a blowing agent is preferably 10 to 85 parts by mass, more preferably 15 to 75 parts by mass, and even more preferably 20 to 70 parts by mass. The content of water as a blowing agent is preferably 0.2 to 15 parts by mass, more preferably 0.4 to 10 parts by mass, and even more preferably 0.6 to 5 parts by mass.

[0087] [Foam stabilizer] The polyol liquid preferably contains a foam stabilizer, which improves the foamability of the polyurethane composition obtained from the polyol liquid and the polyisocyanate liquid. Examples of the foam stabilizer include surfactants such as polyoxyalkylene-based foam stabilizers (e.g., polyoxyalkylene alkyl ethers) and silicone-based foam stabilizers (e.g., organopolysiloxanes). Among these, silicone-based foam stabilizers are preferred. These foam stabilizers may be used alone or in combination of two or more. The amount of foam stabilizer blended is preferably 0.1 to 10 parts by mass, more preferably 0.5 to 8 parts by mass, and even more preferably 1 to 5 parts by mass, per 100 parts by mass of polyol. When the amount of foam stabilizer blended is equal to or greater than these lower limits, the polyurethane composition becomes easier to foam, making it easier to obtain a homogeneous polyurethane foam. When the amount of foam stabilizer blended is equal to or less than these upper limits, a good balance between production costs and the obtained effects is achieved.

[0088] [Settling inhibitor] The polyol liquid preferably contains a settling inhibitor. The settling inhibitor inhibits the precipitation of the solid flame retardant dispersed in the polyol liquid and the inorganic filler described below during long-term storage at room temperature or low temperature. Furthermore, it also prevents caking due to the settled solid flame retardant and the inorganic filler described below. Even if the solid flame retardant and the inorganic filler described below settle after long-term storage, they can be easily and uniformly dispersed by stirring with a stirrer or the like. Settling inhibitors generally become solid at room temperature and normal pressure, and usually become solids (insolubles) in the liquid.

[0089] The settling inhibitor is not particularly limited. Specific examples of the settling inhibitor include powdered silica, organic clay, carbon black, hydrogenated castor oil wax, fatty acid amide wax, etc. One or more of these may be used. Examples of powdered silica that can be used include fumed silica, colloidal silica, and silica gel. Of these, fumed silica is preferred, and hydrophobic fumed silica is particularly preferred. Examples of fumed silica that can be used include Aerosil (registered trademark) from Nippon Aerosil Co., Ltd. As the organic clay, organophilic phyllosilicates and the like can be used. The carbon black that can be used is produced by a furnace method, a channel method, a thermal method, etc. The carbon black may be appropriately selected from commercially available products. Hydrogenated castor oil wax, fatty acid amide wax, etc. form a swollen gel structure in liquid. These agents are generally commercially available under names such as thixotropic agents, thickeners, anti-settling agents, and anti-sagging agents, and commercially available products can be appropriately selected and used.

[0090] The preferred anti-settling agent is a thickening agent, and more preferably, the anti-settling agent contains Si as an element. Specific examples of the thickening agent include fumed silica and organophilic phyllosilicates, and more preferably, fumed silica.

[0091] When a settling inhibitor is contained, its content is not particularly limited, but is, for example, 0.1 to 20 parts by mass, preferably 0.5 to 10 parts by mass, and more preferably 1 to 5 parts by mass, relative to 100 parts by mass of polyol. By setting the content of the settling inhibitor to at least the above-mentioned lower limit, the polyol solution is thickened, and settling of the solid flame retardant and the inorganic filler described below is suppressed, thereby improving their dispersibility. Furthermore, by setting the content of the settling inhibitor to at most the above-mentioned upper limit, deterioration in handleability due to an excessive increase in the viscosity of the solution is prevented.

[0092] [Other ingredients] The polyol liquid may contain one or more additives selected from phenolic, amine, sulfur-based and other antioxidants, inorganic fillers other than solid flame retardants and anti-settling agents, heat stabilizers, metal inhibitors, antistatic agents, stabilizers, crosslinking agents, lubricants, softeners, pigments, tackifying resins, tackifiers such as polybutene and petroleum resins, etc., as needed, within the scope of the present invention.

[0093] <Polyisocyanate liquid> The polyisocyanate liquid contains a polyisocyanate. As the polyisocyanate, any known polyisocyanate used in the formation of polyurethane foam can be used, such as an aromatic polyisocyanate, an alicyclic polyisocyanate, or an aliphatic polyisocyanate. Examples of aromatic polyisocyanates include phenylene diisocyanate, tolylene diisocyanate, xylylene diisocyanate, diphenylmethane diisocyanate, dimethyldiphenylmethane diisocyanate, triphenylmethane triisocyanate, naphthalene diisocyanate, and polymethylene polyphenyl polyisocyanate.

[0094] Examples of alicyclic polyisocyanates include cyclohexylene diisocyanate, methylcyclohexylene diisocyanate, isophorone diisocyanate, dicyclohexylmethane diisocyanate, and dimethyldicyclohexylmethane diisocyanate.

[0095] Examples of the aliphatic polyisocyanate include methylene diisocyanate, ethylene diisocyanate, propylene diisocyanate, tetramethylene diisocyanate, and hexamethylene diisocyanate.

[0096] Among these, from the viewpoints of ease of use and availability, aromatic polyisocyanates are preferred, and diphenylmethane diisocyanate is more preferred. One type of polyisocyanate may be used alone, or two or more types may be used in combination.

[0097] Isocyanate Index The isocyanate index of the polyurethane composition is not particularly limited, but is preferably 200 to 600, and more preferably 300 to 550. If the isocyanate index is equal to or greater than the lower limit, the amount of polyisocyanate relative to the polyol becomes excessive, facilitating the formation of isocyanurate bonds due to the trimerization of the polyisocyanate, resulting in improved flame retardancy of the polyurethane foam. Furthermore, if the isocyanate index is equal to or greater than the lower limit, it becomes easier to produce a polyurethane foam having isocyanurate bonds, i.e., a polyurethane foam that combines high levels of flame retardancy and thermal insulation. Furthermore, if the isocyanate index is equal to or less than the upper limit, the resulting polyurethane foam will have a good balance between flame retardancy and production costs.

[0098] The isocyanate index can be calculated by the following method. Isocyanate Index = number of equivalents of polyisocyanate ÷ (number of equivalents of polyol + number of equivalents of water) × 100 Here, each equivalent number can be calculated as follows: Polyisocyanate equivalent number = Amount of polyisocyanate used (g) × NCO content (mass%) / Molecular weight of NCO (mol) × 100 Equivalent weight of polyol = OHV × amount of polyol used (g) ÷ molecular weight of KOH (mmol) OHV is the hydroxyl value of the polyol (mg KOH / g). Equivalents of water = Amount of water used (g) / Molecular weight of water (moles) × Number of OH groups in water In the above formulas, the molecular weight of NCO is 42 (mol), the molecular weight of KOH is 56,100 (mmol), the molecular weight of water is 18 (mol), and the number of OH groups in water is 2.

[0099] When mixing the polyol liquid and the polyisocyanate liquid, the volume ratio of the two (polyol liquid / polyisocyanate liquid) may be set within the range of, for example, 1 / 1.4 to 1.4 / 1, preferably 1 / 1.2 to 1.2 / 1.

[0100] [Method for producing liquid polyol, polyurethane composition, and polyurethane foam] The method for producing the liquid polyol used in this embodiment and the polyurethane composition containing the same is not particularly limited, but preferably includes the following steps (1) to (3): Then, a polyurethane foam may be formed from the polyurethane composition obtained through steps (1) to (3). Step (1): A step of mixing the components constituting the polyol liquid, except for the catalyst and the reaction retarder, to obtain a mixed liquid. Step (2): A step of adding and mixing a catalyst and a reaction retarder to the mixture obtained in step (1) to obtain a polyol liquid. Step (3): A step of mixing the polyol liquid obtained in step (2) with the polyisocyanate liquid to obtain a polyurethane composition.

[0101] The liquid polyol and polyurethane composition used in this embodiment typically contain a blowing agent. Even in such cases, by producing them using the production method including the above steps (1) to (3), the two-stage foaming behavior caused by the trimerization catalyst and the resinification catalyst can be suppressed, and uniform and sufficient adhesion can be obtained within the elongated hollow portion of the rib, thereby satisfying the filling performance of closed spaces. The detailed procedures for each step will be described below.

[0102] In step (1), the components constituting the polyol liquid other than the catalyst and the reaction retarder, i.e., the polyol and filler, as well as any liquid flame retardant, blowing agent, foam stabilizer, etc., may be mixed. In step (2), when the catalyst and the reaction retarder are added to the mixed solution obtained in step (1), they may be added in a mixed state or may be added separately. The catalyst and the reaction retarder are preferably added immediately before mixing the polyisocyanate liquid with the polyol liquid. There are no particular limitations on the mixing method in steps (1) and (2). For example, the components can be mixed at room temperature using a mixer such as a Homodisper for about 30 seconds to 20 minutes.

[0103] The mixing method in step (3) is not particularly limited, and the polyol liquid agent and the polyisocyanate liquid agent obtained in step (2) may be mixed by a known method. Specifically, the mixture can be obtained using known devices such as a high-pressure foaming machine, a low-pressure foaming machine, a spray foaming machine, or a hand mixer.

[0104] The polyurethane composition obtained as described above may be filled into the hollow portion of the flat deck using a spray gun, etc. More specifically, it is preferable to use a foaming device equipped with a spray gun, mix a polyol liquid agent and a polyisocyanate liquid agent in the foaming device, and fill the spray gun with the mixture. The polyurethane composition filled by the spray gun is filled into the hollow space of the flat deck, and the polyol and polyisocyanate react with each other to foam, thereby forming a polyurethane foam. As described above, the polyurethane composition uses a specific polyol liquid, so the two-stage foaming behavior caused by the trimerization catalyst and resinification catalyst is suppressed in the formed polyurethane foam, and uniform and sufficient adhesion can be obtained within the elongated hollow space, thereby satisfying the filling performance of closed spaces. However, the above-described manufacturing method is merely an example, and the liquid polyol, polyurethane composition, and polyurethane foam may be manufactured by methods other than those described above, as long as the polyurethane composition is obtained by mixing the components constituting the polyurethane composition (i.e., polyol, polyisocyanate, catalyst, reaction retarder, flame retardant, and other optional components). For example, in the above description, in steps (1) and (2), components other than the catalyst and reaction retarder are mixed to obtain a mixed liquid, and then the catalyst and reaction retarder are added. However, the order of addition is not limited to this, and each component may be added and mixed simultaneously. Furthermore, in steps (1) and (2), components other than the catalyst and reaction retarder may be added to and mixed with the mixed liquid obtained by mixing the catalyst and reaction retarder to obtain a liquid polyol.

[0105] <Fire compartment structure> The fire compartment structure according to this embodiment will be described below. As shown in FIG. 5, the fire compartment structure according to this embodiment includes the flat deck 1 and a noncombustible material 20 filling the gaps between the ribs 30 on one surface 11D of the flat portion 11 of the flat deck 1. The flat deck 1 is arranged so that the one surface 11D of the flat portion 11 faces a partition material 31, such as gypsum board. Specifically, for example, the partition material 31 is arranged so that the upper end surface of the partition material 31 faces the bottom surface of the rib 12. In this state, the flat deck 1 and the partition material 31 can be attached with screws or the like. The gaps between the ribs 30, which are the gaps between the flat deck 1 and the partition material 31, are then filled with the noncombustible material 20, resulting in a fire compartment structure as shown in FIG. 5. By filling the gaps between the ribs 30 with the noncombustible material 20, fire resistance can be ensured. Furthermore, even on the outside of the rib 12, a non-combustible material (not shown) may be provided between the partition material 31 and the lower surface 11D of the flat deck 1 as needed. As the non-combustible material 20, a known non-combustible material capable of filling gaps, such as rock wool or glass wool, can be used.

[0106] In the fire compartment structure according to this embodiment, the flat deck 1 is laid across supporting materials such as beams of a building structure to form a floor structure, a roof structure, etc. The flat deck 1 is used, for example, as a formwork material, and when used as a formwork material, concrete (not shown) is poured onto the upper surface 11U.

[0107] As described above, in this embodiment, by filling the hollow portions 12a and connecting portions 12b of the ribs 12 with the filler 13, the cavities formed inside the ribs 12 prevent gaps from forming in the compartments, and it is possible to form compartments with good fire resistance, sound insulation, heat insulation, etc. Also, as described above, by making the filler 13 noncombustible, the fire resistance is further improved. Furthermore, by filling the gaps 30 between the ribs with the noncombustible material 20, the fire resistance can be further improved. In addition, in this embodiment, by inserting and fitting the claw portion 14 of another flat deck 1 that is arranged adjacently into the connecting portion 15, which is part of the connection portion 12b of the flat deck 1, it is possible to connect flat decks 1 that are arranged adjacent to each other, thereby improving workability.

[0108] (Other embodiments) Although the above description has been given with reference to an example in which the filler 13 is a foam, fillers other than foam may also be used, such as cement, mortar, putty, etc. When using a material other than foam, a filler 13 to be filled in the connecting portion 15, which is part of the connecting portion 12b of the flat deck 1, may be manufactured separately from the filler 13 to be filled in the hollow portion 12a of the flat deck 1, and the flat deck may be manufactured by filling it to a predetermined density. [Example]

[0109] The present invention will be explained in more detail below with reference to examples, but the present invention is not limited to these examples in any way.

[0110] The components used in each of the examples and comparative examples are as follows.

[0111] <Polyol> p-Phthalic acid-based polyester polyol (Kawasaki Chemical Industries, Ltd., product name: Maximol RLK-087, hydroxyl value 200 mg KOH / g)

[0112] <Reaction retarder> Hydroxycarboxylic acid compound (Kawasaki Chemical Industries, Ltd., product name: RAK253)

[0113] <Catalyst> Resinification catalyst: 1,2-dimethylimidazole (manufactured by Tosoh Corporation, product name: TOYOCAT-DM70) Trimerization catalyst: potassium 2-ethylhexanoate (manufactured by Air Products, product name: DABCO K-15), concentration 70 to 80% by mass

[0114] <Foam stabilizer> Silicone foam stabilizer (Toray Dow Corning, product name: SZ1642)

[0115] <Liquid flame retardant> Tris(β-chloropropyl)phosphate (manufactured by Daihachi Chemical Co., Ltd., product name: TMCPP)

[0116] <Solid flame retardant> Red phosphorus flame retardant (Rinkagaku Kogyo Co., Ltd., product name: Nova Excel 140) Zinc borate (Hayakawa Shoji Co., Ltd., product name: Firebrake ZB) Ethylenebis(pentabromophenyl) (Albemarle, product name: SAYTEX 8010)

[0117] <Settling inhibitor> Fumed silica (manufactured by Nippon Aerosil Co., Ltd., product name: Aerosil R976S)

[0118] <Foaming agent> HFO-1233zd(E) (manufactured by Central Glass Co., Ltd., product name: Solstice LBA) ·water

[0119] <Polyisocyanate> Polyisocyanate (MDI, manufactured by Sumitomo Chemical Co., Ltd., product name: Sumidur 44V20)

[0120] [Preparation of Polyurethane Composition] A polyol solution and a polyurethane composition were prepared according to the following procedure. (1) Of the components of the polyol liquid, 100 parts by mass of polyol, 3 parts by mass of foam stabilizer, 50 parts by mass of liquid flame retardant, 27 parts by mass of red phosphorus flame retardant as a solid flame retardant, 13 parts by mass of zinc borate, 27 parts by mass of ethylenebis(pentabromophenyl), 3 parts by mass of a settling inhibitor, 50 parts by mass of HFO-1233zd(E) as a foaming agent, and 1 part by mass of water were mixed. (2) A mixture obtained by mixing 2 parts by mass of a reaction retarder (hydroxycarboxylic acid compound), 5 parts by mass of a resinification catalyst (1,2-dimethylimidazole), and 7 parts by mass of a trimerization catalyst (potassium 2-ethylhexanoate) was added to the mixture obtained in (1) above to obtain a polyol liquid. (3) A polyurethane composition was prepared comprising the polyol liquid obtained in (2) above and a polyisocyanate liquid (268 parts by mass of polyisocyanate).

[0121] [Example 1] First, a flat deck, which had been bent to form a rib (cavity, connection) protruding from one side of the flat section and having a cavity inside, was heated to 80°C in a heating furnace. A heat source was then placed around the joint that functioned as a connecting part of the flat deck (see Figure 4(b)), and the steel plates that make up the joint (connecting part) were heated to the temperatures (steel plate temperature of the flat part, steel plate temperature of the pair of plate-shaped parts) shown in Table 1. Note that no heat source was placed around the joints that did not function as connecting parts. Then, 190 g (volume before foaming) of the polyurethane composition obtained by steps (1) to (3) above was injected into the inside of the rib (volume 3162 ml) through an injection port provided in the center of the bottom surface of the rib of the flat deck. During the injection, heating by the heat source was continued to maintain the temperature of the steel plates constituting the joint (connecting part) at the state shown in Table 1. The urethane resin composition injected into the inside of the rib was reacted and foamed to form a urethane foam as a filler for filling the inside of the rib.

[0122] [Examples 2 to 8] The same procedure as in Example 1 was carried out, except that the temperature of the steel plate constituting the connection part (joint part) when the urethane resin composition was injected from the injection port was set to the state shown in Table 1 using a heat source.

[0123] [Reference examples 1~2] First, a flat deck, which had been bent to form a rib (cavity, connection) protruding from one side of the flat section and having a cavity inside, was heated to 80°C in a heating furnace. Then, 190 g (volume before foaming) of the polyurethane composition obtained by steps (1) to (3) above was injected into the inside of the rib (volume 3162 ml) through an injection port provided in the center of the bottom surface of the rib of the flat deck. During injection, the temperature of the steel plates constituting the joint (connecting part) was measured and recorded in Table 1. The urethane resin composition injected into the inside of the rib was reacted and foamed to form a urethane foam as a filler for filling the inside of the rib. In Reference Examples 1 and 2, heating using a heat source was not performed before or during injection of the polyurethane composition.

[0124] The methods for measuring and evaluating the various physical properties in the present invention are as follows.

[0125] [density] The core portions of the polyurethane foam filled in the hollows and joints (connecting parts) of the ribs of the flat deck were cut out. The densities of the core portions were measured in accordance with JIS K 7222:2005. The results are shown in Table 1.

[0126] [Total heat generation] The polyurethane foam filled as a filler inside the hollows and joints (connecting parts) of the ribs of the flat deck was cut into a length of 10 cm, width of 10 cm and thickness of 5 cm to prepare a cone calorimeter test sample. Using the cone calorimeter test sample, a radiant heat intensity of 50 kW / m was measured in accordance with the test method of ISO-5660. 2 The total calorific value was measured after 20 minutes using a cone calorimeter. The results are shown in Table 1.

[0127] [Mating evaluation] The claws of the adjacent flat deck were placed on the filling of the connecting portion, and force was applied from the top of the claws to evaluate the degree of insertion based on the following criteria. A (Interlocking connection possible) The claws of adjacent flat decks can be fully interlocked. B (Difficult to fit) The claws of adjacent flat decks are difficult to fit together.

[0128] [Table 1]

[0129] As shown in Table 1, in each of the Examples and Reference Examples, the filler was filled not only in the hollow spaces inside the ribs but also in the connecting parts, so that good fire resistance could be maintained. Furthermore, in each example, by injecting a filler to fill the inside of the rib when the steel plate temperature at the connection portion (joint portion) was within a predetermined range, it was possible to adjust the density of the filler filling the connection portion to a predetermined range and fill the entire inside of the rib with the filler. Therefore, it was possible to insert and fit the claws of adjacent flat decks into the connection portion (joint portion). In contrast, in each reference example, the density of the filler filling the connection portion (joint portion) was not adjusted, so the claws of adjacent flat decks could not be inserted and fitted directly into the connection portion (joint portion), and measures such as removing some of the filler from the connection portion were required. [Explanation of symbols]

[0130] 1 Flat Deck 11 Flat section 11D Bottom surface (one side) 11U top 12 Ribs 12a Cavity 12b Connection 13 Filling 14 Claw 15 Connecting part 16 Inlet 20 Non-combustible materials 30 between ribs 31 Partition material 40 Warming furnace 41,42 Heat source

Claims

1. The device comprises a flat portion, a rib protruding from one surface of the flat portion, and a filler provided inside the rib, the rib has a hollow portion having a cavity therein and a connection portion connecting the hollow portion and the one surface, A flat deck, wherein the filler is filled inside the hollow portions and the connecting portions of the ribs.

2. The flat deck according to claim 1 , wherein any of the connection portions filled with the filler can be fitted with a claw portion of an adjacent flat deck.

3. The flat deck of claim 1 , wherein the filler is foam.

4. The flat deck of claim 1 , wherein the filler is an organic foam.

5. The flat deck of claim 4 , wherein the organic foam is polyurethane foam.

6. The density of the filling material in the hollow portion is 10 kg / m ３ More than 200kg / m ３ 2. The flat deck of claim 1, wherein:

7. The density of the filler in the connection portion is 10 kg / m ３ More than 100kg / m ３ 2. The flat deck of claim 1, wherein:

8. The filler has a radiant heat intensity of 50 kW / m in a heat generation test using a cone calorimeter tester in accordance with ISO 5660-1. ２ The total heat generation amount for 20 minutes after the start of heating is 8MJ / m ２ 2. The flat deck of claim 1, wherein:

9. The flat deck of claim 1 , wherein the rib has an inlet in a bottom portion for injecting the filler.

10. A flat deck according to any one of claims 1 to 9; and a non-combustible material filling the spaces between the ribs on one surface of the flat portion of the flat deck.

11. A method for manufacturing a flat deck comprising: a flat portion; a rib protruding from one surface of the flat portion; and a filler, wherein the rib has a hollow portion having a cavity therein and a connecting portion connecting the hollow portion to the one surface, A method for manufacturing a flat deck, comprising a step of filling the filler inside the rib while keeping the steel plate temperature at the connection portion at 60°C or higher and 150°C or lower.

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