Coating method and laminated material

Abstract

To provide a coating method for manufacturing a laminated material having an alkali metal silicate layer, where the coating method suppresses degree of swelling of the alkali metal silicate layer generated when the laminated material is heated.SOLUTION: A coating method includes applying an undercoat paint on a combustible material to form an undercoat layer, and applying an aqueous solution containing an alkali metal silicate on the undercoat layer to form an alkali metal silicate layer, where the undercoat paint contains a silane coupling agent.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to coating methods and laminate materials. [Background technology]

[0002] Coating methods for providing an alkali metal silicate layer on the outside of a combustible material to impart fire resistance to the material are known. For example, Patent Documents 1 to 5 disclose the following materials and methods.

[0003] Patent Document 1 discloses a coated substrate comprising a wood material, an intermediate layer containing a versatate vinyl ester copolymer provided on the wood material, and an alkali metal silicate layer provided on the intermediate layer.

[0004] Patent Document 2 discloses a coated substrate comprising a substrate, an alkali metal silicate layer provided on the substrate, and a top layer containing an acrylic urethane resin provided on the alkali metal silicate layer.

[0005] Patent Document 3 discloses a method for producing a coated substrate, which includes the steps of applying an aqueous solution containing amorphous silica and an alkali metal silicate to the surface of a substrate, and drying the applied aqueous solution to form an alkali metal silicate layer.

[0006] Patent Document 4 discloses a coated substrate comprising a combustible substrate, an intermediate layer containing silica as a main component provided on the combustible substrate, and an alkali metal silicate layer provided on the intermediate layer.

[0007] Patent Document 5 discloses a coated substrate comprising a combustible substrate and an alkali metal silicate layer containing fibers provided on the combustible substrate. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] Patent Publication No. 2021-074892 [Patent Document 2] Patent Publication No. 2021-074891 [Patent Document 3] Patent Publication No. 2021-074646 [Patent Document 4] Japanese Patent Application Laid-Open No. 2018-115294 [Patent Document 5] Japanese Patent Application Publication No. 2018-114724 Summary of the Invention [Problem to be solved by the invention]

[0009] In laminated materials that have an alkali metal silicate layer on the outside of a combustible material, gas and / or water vapor may be generated from the combustible material during a fire, causing the alkali metal silicate layer to swell. A certain degree of swelling of the alkali metal silicate layer is desirable because the swelled alkali metal silicate layer functions as an insulating layer and suppresses the combustion of the combustible material. However, if the alkali metal silicate layer swells too much, it may crack, and the alkali metal silicate layer will no longer perform its expected function of providing fire protection.

[0010] It is against this background that the present disclosure has been made. The present disclosure aims to provide a coating method for producing a laminated material having an alkali metal silicate layer, which coating method suppresses the degree of swelling of the alkali metal silicate layer that occurs when the laminated material is heated. An object of the present disclosure is to provide a laminate material having an alkali metal silicate layer, in which the alkali metal silicate layer does not swell excessively when heated. [Means for solving the problem]

[0011] Specific means for solving the above problems include the following aspects. <1> Applying a primer paint on the combustible material to form a primer layer; and applying an aqueous solution containing an alkali metal silicate onto the undercoat layer to form an alkali metal silicate layer. The undercoat paint contains a silane coupling agent. Painting method. <2> The content of the silane coupling agent in the undercoat paint is 0.1% by mass to 10% by mass. <1> The coating method described in <3> further comprising disposing fibers within the alkali metal silicate layer. <1> or <2> The coating method described in <4> Further, a topcoat paint is applied on the alkali metal silicate layer to form a topcoat layer. <1> ~ <3> 10. The coating method according to claim 9, wherein the coating is performed in a manner similar to that described above. <5> The topcoat paint contains an acrylic polyol and a polyisocyanate. <4> The coating method described in <6> The combustible material is a wood material. <1> ~ <5> 10. The coating method according to claim 9, wherein the coating is performed in a manner similar to that described above. <7> a flammable material; a primer layer disposed on the combustible material; an alkali metal silicate layer provided on the undercoat layer, The undercoat layer contains a reaction product of a silane coupling agent. Laminated material. <8> The alkali metal silicate layer has fibers therein. <7> The laminate material according to claim 1. <9> Further, a topcoat layer is provided on the alkali metal silicate layer. <7> or <8> The laminate material according to claim 1. <10> The topcoat layer contains an acrylic urethane resin. <9> The laminate material according to claim 1. <11> The combustible material is a wood material. <7> ~ <10> 10. The laminate material according to any one of the preceding items. [Effects of the Invention]

[0012] According to the present disclosure, there is provided a coating method for producing a laminate material having an alkali metal silicate layer, which coating method suppresses the degree of swelling of the alkali metal silicate layer that occurs when the laminate material is heated. According to the present disclosure, there is provided a laminate material comprising an alkali metal silicate layer, wherein the alkali metal silicate layer does not swell excessively when heated. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 is a schematic cross-sectional view showing an example of a layer structure of a laminate material according to the present disclosure. [Figure 2] FIG. 1 is a schematic cross-sectional view showing an example of a layer structure of a laminate material according to the present disclosure. [Figure 3] FIG. 1 is a schematic cross-sectional view showing an example of a layer structure of a laminate material according to the present disclosure. [Figure 4] FIG. 1 is a schematic cross-sectional view showing an example of a layer structure of a laminate material according to the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0014] The following describes embodiments of the present invention. These descriptions and examples are intended to illustrate the embodiments and are not intended to limit the scope of the present invention.

[0015] In the present disclosure, "A and / or B" is synonymous with "at least one of A and B." In other words, "A and / or B" means that it may be only A, only B, or a combination of A and B.

[0016] In the present disclosure, numerical ranges indicated using "to" include the numerical values ​​before and after "to" as the minimum and maximum values, respectively. In the numerical ranges described in stages in this disclosure, the upper or lower limit value described in one numerical range may be replaced with the upper or lower limit value of another numerical range described in stages. In the numerical ranges described in this disclosure, the upper or lower limit value of the numerical range may be replaced with the value shown in the examples.

[0017] In the present disclosure, the term "step" includes not only an independent step but also a step that cannot be clearly distinguished from other steps as long as the purpose of the step is achieved.

[0018] When embodiments of the present disclosure are described with reference to the drawings, the configuration of the embodiment is not limited to the configuration shown in the drawings. Furthermore, the sizes of the components in each drawing are conceptual, and the relative size relationships between the components are not limited to these.

[0019] In the present disclosure, each component may contain multiple corresponding substances. When referring to the amount of each component in a composition in the present disclosure, if multiple substances corresponding to each component are present in the composition, the total amount of the multiple substances present in the composition is meant unless otherwise specified.

[0020] In the present disclosure, the composition may contain multiple types of particles corresponding to each component. When multiple types of particles corresponding to each component are present in the composition, the particle size of each component means the value for a mixture of the multiple types of particles present in the composition, unless otherwise specified.

[0021] In the present disclosure, the term "(meth)acrylic" means either "acrylic" or "methacrylic."

[0022] <Painting method, laminate material> The coating method disclosed herein includes applying a primer paint onto a flammable material to form a primer layer, and applying an aqueous solution containing an alkali metal silicate onto the primer layer to form an alkali metal silicate layer, wherein the primer paint contains a silane coupling agent. Hereinafter, an aqueous solution containing an alkali metal silicate will be referred to as an "alkali metal silicate aqueous solution."

[0023] The laminate material of the present disclosure is a laminate material comprising a combustible material, a primer layer provided on the combustible material, and an alkali metal silicate layer provided on the primer layer, wherein the primer layer contains a reaction product of a silane coupling agent.

[0024] The coating method of the present disclosure produces the laminate material of the present disclosure. The coating method of the present disclosure is a coating method for forming an alkali metal silicate layer for the purpose of imparting fire retardancy to a flammable material. The laminate material of the present disclosure is a laminate material on which an alkali metal silicate layer is formed for the purpose of imparting fire retardancy to a flammable material.

[0025] The coating method of the present disclosure suppresses the degree of swelling of the alkali metal silicate layer that occurs when the laminate material is heated. The laminate material of the present disclosure does not experience excessive swelling of the alkali metal silicate layer when heated. The mechanism behind this is presumed to be as follows.

[0026] The coating method disclosed herein uses a primer coating containing a silane coupling agent to form a primer layer between a flammable material and an alkali metal silicate layer. The silane coupling agent chemically bonds the alkali metal silicate layer (inorganic material layer) to the underlayer (at least the primer layer, and in some cases the flammable material) (organic material layer). This is thought to enhance adhesion between the alkali metal silicate layer and the underlayer, preventing excessive swelling of the alkali metal silicate layer when the laminated material is heated.

[0027] The layer structure of the laminate material of the present disclosure will be described with reference to the drawings. 1 to 4 are schematic cross-sectional views of examples of laminated materials. Figures 1 to 4 are schematic cross-sectional views mainly for explaining the order in which layers are stacked, and the structure of each layer is omitted or simplified. In Figures 1 to 4, layers having similar functions are denoted by the same reference numerals.

[0028] The laminated material 101 shown in FIG. 1 has a structure in which an undercoat layer 20, an alkali metal silicate layer 30, and an overcoat layer 40 are laminated in this order on a combustible material 10.

[0029] The laminated material 102 shown in Fig. 2 has a structure in which an undercoat layer 20, an alkali metal silicate layer 30, and a topcoat layer 40 are laminated in this order on a combustible material 10. The alkali metal silicate layer 30 has a fiber sheet 50 therein. The fiber sheet 50 is arranged flat in the plane direction of the alkali metal silicate layer 30. The fiber sheet 50 may be a woven fabric as shown in Fig. 2, or a nonwoven fabric.

[0030] 3 has a structure in which an undercoat layer 20, an alkali metal silicate layer 30, and a topcoat layer 40 are laminated in this order on a combustible material 10. The alkali metal silicate layer 30 has fibers 60 therein. The fibers 60 are arranged inside the alkali metal silicate layer 30 while entangled with each other.

[0031] 4 has a structure in which an undercoat layer 20, an alkali metal silicate layer 30, and a topcoat layer 40 are layered in this order on a combustible material 10. The alkali metal silicate layer 30 has fibers 70 therein. The fibers 70 are dispersed and arranged inside the alkali metal silicate layer 30.

[0032] In the laminated materials 101 to 104, the undercoat layer 20 contacts the combustible material 10, the alkali metal silicate layer 30 contacts the undercoat layer 20, and the topcoat layer 40 contacts the alkali metal silicate layer 30.

[0033] The laminated materials 101 to 104 may or may not have the topcoat layer 40. In the laminated materials 101 to 104, the topcoat layer 40 may be replaced with an overlay layer formed by laminating a resin film. From the viewpoint of protecting the alkali metal silicate layer 30, the laminated materials 101 to 104 preferably have the topcoat layer 40 or an overlay layer.

[0034] The primer layer 20 is formed by applying a primer paint on the combustible material 10. Specifically, the formation of the primer layer 20 includes applying a primer paint on the combustible material 10 and drying the applied primer paint. The primer paint is applied using, for example, a brush, a roller, a spray, or the like. The applied primer paint may be dried naturally. The application and drying of the primer paint may be repeated multiple times.

[0035] The alkali metal silicate layer 30 is formed by applying an alkali metal silicate aqueous solution onto the undercoat layer 20. Specifically, the formation of the alkali metal silicate layer 30 includes applying the alkali metal silicate aqueous solution onto the undercoat layer 20 and drying the applied alkali metal silicate aqueous solution. The alkali metal silicate aqueous solution is applied using, for example, a brush, a roller, a spray, or the like. The applied alkali metal silicate aqueous solution may be dried by natural drying. The application and drying of the alkali metal silicate aqueous solution may be repeated multiple times.

[0036] The fiber sheet 50, the fiber 60, or the fiber 70 is disposed inside the alkali metal silicate layer 30. The fiber is disposed, for example, by placing the fiber on the undercoat layer 20 and then coating the fiber with an aqueous alkali metal silicate solution. The fiber can also be disposed, for example, by placing the fiber on at least one alkali metal silicate layer 30 and then coating the fiber with an aqueous alkali metal silicate solution to form a further alkali metal silicate layer 30. The fiber 70 can also be disposed, for example, by coating the undercoat layer 20 with an aqueous alkali metal silicate solution containing the fiber 70.

[0037] The topcoat layer 40 is formed by applying a topcoat paint on the alkali metal silicate layer 30. Specifically, the formation of the topcoat layer 40 includes applying a topcoat paint on the alkali metal silicate layer 30 and drying the applied topcoat paint. The topcoat paint is applied using, for example, a brush, a roller, a spray, or the like. The applied topcoat paint may be dried naturally. The application and drying of the topcoat paint may be repeated multiple times.

[0038] The laminated materials 101 to 104 can be used, for example, for building structures (e.g., pillars, beams, floors, walls, roofs), building finishing materials (e.g., ceiling materials, interior wall materials, exterior materials, stairs, fittings), interior materials for vehicles (e.g., automobiles, railroad cars, ships, aircraft), furniture materials, etc.

[0039] The layers and coatings that make up the laminate material are described in more detail below.

[0040] [Flammable materials] Combustible materials include wood materials and resin moldings.

[0041] Examples of wood materials include lumber products, logs, plywood, laminated lumber, LVL (Laminated Veneer Lumber), CLT (Cross Laminated Timber), structural panels, OSB (Oriented Strand Board), particle board, and fiberboard.

[0042] When an alkali metal silicate solution is directly applied to a wood material, the surface of the wood material is likely to turn black (a phenomenon known as alkali burn). Wood materials require a primer layer to prevent alkali burn and to improve the adhesion of the alkali metal silicate layer.

[0043] Examples of materials for the resin molded product include polyethylene, polypropylene, polystyrene, polyester, polyvinyl chloride, acrylic resin, fluororesin, polyamide, polycarbonate, polyurethane, natural rubber, ABS resin, chloroprene rubber, ethylene propylene rubber, and melamine resin. The resin molded product may be either a non-foamed product or a foamed product.

[0044] There is no limitation on the shape of the combustible material. Examples of the shape of the combustible material include a plate, sheet, pillar, rod, and pipe. When the combustible material is a plate or sheet, the thickness is, for example, 3 μm to 3.5 m.

[0045] [Primer paint, primer layer] The undercoat layer is preferably a layer containing a resin as a main component from the viewpoint of adhesion to the combustible material and adhesion to the alkali metal silicate layer. Therefore, the primer paint is preferably a paint containing a resin as a main component, or may be a paint containing a resin precursor that forms a resin during application as a main component.

[0046] Examples of resins contained in the undercoat paint and undercoat layer include modified epoxy resins, urethane resins, acrylic resins, and versatic acid vinyl ester copolymers.

[0047] The undercoat paint and undercoat layer may contain inorganic particles (for example, silica particles, alumina particles).

[0048] The primer coating contains a silane coupling agent. The silane coupling agent preferably has a reactive functional group that reacts with the resin contained in the primer coating and a hydroxyl group or a hydrolyzable group for linking to the alkali metal silicate layer. Examples of the reactive functional group include an amino group, an epoxy group, a (meth)acrylic group, a vinyl group, an isocyanate group, a mercapto group, a carboxy group, and an alkylene glycol. Examples of the hydrolyzable group include an alkoxy group (e.g., a methoxy group, an ethoxy group), and an acetoxy group. The type of reactive functional group of the silane coupling agent may be selected depending on the type of resin that is the main component of the undercoat paint.

[0049] The primer layer contains a reaction product of a silane coupling agent, which is presumably reacted with a resin contained in the primer coating during preparation of the primer coating and with an alkali metal silicate during formation of the alkali metal silicate layer.

[0050] The content of the silane coupling agent in the undercoat paint is preferably 0.1% by mass to 10% by mass relative to the total mass of the undercoat paint. When the content of the silane coupling agent is 0.1% by mass or more, the adhesion between the alkali metal silicate layer and the underlayer (at least the primer layer, and in some cases even the combustible material) is further improved. From this viewpoint, the content of the silane coupling agent is more preferably 0.5% by mass or more, even more preferably 0.8% by mass or more, and still more preferably 1% by mass or more. When the content of the silane coupling agent is 10% by mass or less, cracks are less likely to occur in the alkali metal silicate layer when the laminate material is heated. From this viewpoint, the content of the silane coupling agent is more preferably 8% by mass or less, even more preferably 5% by mass or less, and even more preferably 2% by mass or less.

[0051] The primer coating contains at least a solvent and / or a dispersion medium, a resin and / or a resin precursor, and a silane coupling agent. The concentration of the resin or resin precursor in the primer coating may be set depending on the application method from the viewpoint of work efficiency. The primer coating may contain additives such as defoamers, wetting agents, dispersants, stabilizers, thickeners, plasticizers, pigments, flame retardants, and matting agents.

[0052] From the viewpoint of increasing the transparency of the undercoat layer, the thickness of the undercoat layer is preferably 150 μm or less, more preferably 120 μm or less, and even more preferably 90 μm or less. The thickness of the undercoat layer is preferably 15 μm or more, more preferably 30 μm or more, and even more preferably 45 μm or more, from the viewpoint of further improving adhesion to the alkali metal silicate layer and obtaining a sealing effect.

[0053] The amount of primer coating to be applied is determined depending on the concentration of the primer coating and the thickness of the primer layer. For example, the amount of primer coating to be applied is 50 g / m 2 ~500g / m 2 is.

[0054] [Alkali metal silicate aqueous solution, alkali metal silicate layer] The alkali metal silicate aqueous solution and the alkali metal silicate layer contain an alkali metal silicate. The composition formula of the alkali metal silicate is MO·nSiO, where M is Na, K, Li, or a combination thereof, and n is the molar ratio of MO to SiO. When M is Na, n is preferably 2.0 to 3.8, when M is K, n is preferably 1.8 to 3.7, and when M is Li, n is preferably 3.5 to 7.5.

[0055] The alkali metal silicate preferably contains Na2O·nSiO2 (i.e., sodium silicate), where n=2.0 to 3.8 is preferred, and n=2.0 to 3.3 is more preferred.

[0056] The mass proportion of sodium silicate in the total alkali metal silicate contained in the alkali metal silicate layer is preferably 20 mass% or more, more preferably 30 mass% or more, and even more preferably 40 mass% or more, from the viewpoint of the formability of the layer and the fire resistance of the laminated material.

[0057] From the viewpoint of improving the water resistance of the alkali metal silicate layer, the alkali metal silicate preferably contains Na2O·nSiO2 (ie, sodium silicate) and Li2O·nSiO2 (ie, lithium silicate).

[0058] When the alkali metal silicate layer contains sodium silicate and lithium silicate, the mass ratio of lithium silicate to sodium silicate (lithium silicate / sodium silicate) is preferably 0.1 to 1.5, more preferably 0.2 to 1.4, and even more preferably 0.3 to 1.2, from the viewpoint of the balance between the gloss and water resistance of the layer.

[0059] The alkali metal silicate aqueous solution and the alkali metal silicate layer may contain phosphate, borate, or the like.

[0060] The alkali metal silicate aqueous solution and the alkali metal silicate layer may contain amorphous silica. The amorphous silica may be fused quartz glass or synthetic silica glass. The fused quartz glass may be produced by electrical melting or flame melting. The synthetic silica glass may be dry silica or wet silica. The particle size of the amorphous silica is, for example, 1 μm to 15 μm. The content of amorphous silica is, for example, 3 mass % to 160 mass % relative to the total alkali metal silicate.

[0061] From the viewpoint of fire resistance of the laminated material, the thickness of the alkali metal silicate layer is preferably 30 μm or more, more preferably 90 μm or more, and even more preferably 150 μm or more. The thickness of the alkali metal silicate layer is preferably 900 μm or less, more preferably 600 μm or less, and even more preferably 450 μm or less, from the viewpoint of the transparency of the layer and the workability when the laminated material is used as furniture or building material.

[0062] The dry mass of the alkali metal silicate layer is 50 g / m² from the viewpoint of the fire resistance of the laminated material. 2 It is preferable that the weight is 150 g / m or more. 2 More preferably, 250 g / m 2 The above is more preferable. The dry mass of the alkali metal silicate layer is set to 1500 g / m from the viewpoint of the transparency of the layer and the workability when the laminated material is used as furniture or building material. 2 It is preferable that the thickness is 1000 g / m or less. 2 Less than 750 g / m is more preferable. 2 The following is even more preferred:

[0063] The amount of the alkali metal silicate aqueous solution to be applied is determined depending on the concentration of the alkali metal silicate aqueous solution and the thickness or mass of the alkali metal silicate layer. 2 ~3000g / m 2 is.

[0064] [fiber] From the viewpoint of achieving superior fire resistance, the laminate material of the present disclosure preferably has fibers inside the alkali metal silicate layer. The fibers present inside the alkali metal silicate layer suppress the occurrence of cracks in the layer, suppress peeling and falling off of the layer, and maintain the thickness of the layer, thereby further enhancing the fire resistance of the laminate material.

[0065] The fibers are preferably highly heat-resistant fibers that do not melt even at high temperatures. Examples of fibers include glass fibers, carbon fibers, ceramic fibers (e.g., alumina fibers, silica fibers), resin fibers (e.g., aramid fibers, polypropylene fibers), and metal fibers (e.g., carbon steel fibers, stainless steel fibers, plated steel fibers).

[0066] In the embodiment shown in Fig. 2, the fiber sheet may be a woven fabric (for example, plain weave) or a nonwoven fabric. The thickness of the fiber sheet is, for example, 0.003 mm to 2 mm. From the viewpoint of suppressing diffuse reflection of the alkali metal silicate layer, the fiber sheet is preferably a woven fabric (glass cloth) or a nonwoven fabric (glass mat, etc.) of glass fiber. The basis weight of the woven fabric and nonwoven fabric of glass fiber is, for example, 1 g / m 2 ~1000g / m 2 is.

[0067] In the embodiment shown in FIG. 3 or 4, the fiber diameter is, for example, 0.003 mm to 1 mm, and the fiber length is, for example, 0.1 mm to 100 mm. In the embodiment shown in FIG. 3 or 4, the fibers preferably account for 0.1% to 20% by mass of the total mass of the alkali metal silicate layer.

[0068] [Top coat paint, top coat layer] The laminate material of the present disclosure preferably includes a topcoat layer on the alkali metal silicate layer to protect the alkali metal silicate layer from water and the like.

[0069] From the viewpoint of adhesion to the alkali metal silicate layer, the topcoat layer is preferably a layer containing a resin as a main component. Therefore, the top coat paint is preferably a paint containing a resin as a main component, or may be a paint containing a resin precursor that forms a resin during application as a main component.

[0070] Examples of resins contained in the topcoat paint and topcoat layer include alkyd resins, acrylic resins, urethane resins, acrylic silicone resins, fluororesins, silicone resins, epoxy resins, vinylidene chloride copolymers, and vinyl chloride resins.

[0071] The topcoat layer preferably contains an acrylic urethane resin from the viewpoints of excellent water resistance and resistance to peeling. The acrylic urethane resin is preferably a resin obtained by reacting at least an acrylic polyol with a polyisocyanate. Therefore, the topcoat paint preferably contains an acrylic polyol and a polyisocyanate. The acrylic urethane resin may be a resin obtained by reacting a small amount of a polyol other than the acrylic polyol in addition to the acrylic polyol and the polyisocyanate.

[0072] Acrylic polyol is an acrylic resin having two or more hydroxyl groups in the molecule. Examples of acrylic polyol include polymers of (meth)acrylic acid esters and hydroxyl group-containing polymerizable unsaturated monomers.

[0073] Examples of (meth)acrylic acid esters include (meth)acrylic acid alkyl esters such as methyl (meth)acrylate, ethyl (meth)acrylate, butyl (meth)acrylate, sec-butyl (meth)acrylate, isobutyl (meth)acrylate, tert-butyl (meth)acrylate, hexyl (meth)acrylate, octyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, lauryl (meth)acrylate, stearyl (meth)acrylate, cyclohexyl (meth)acrylate, isobornyl (meth)acrylate, adamantyl (meth)acrylate, and benzyl (meth)acrylate, and (meth)acrylic acid phenyl alkyl esters. These may be used alone or in combination of two or more.

[0074] Examples of hydroxyl group-containing polymerizable unsaturated monomers include (meth)acrylic acid hydroxyalkyl esters such as 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate, 2-hydroxybutyl (meth)acrylate, 3-hydroxybutyl (meth)acrylate, 4-hydroxybutyl (meth)acrylate, and 3-chloro-2-hydroxybutyl (meth)acrylate; unsaturated bond-containing polyhydroxyalkyl esters, which are dihydroxyalkyl esters of polycarboxylic acids such as maleic acid, fumaric acid, and itaconic acid; (poly)alkylene glycol mono(meth)acrylates such as (poly)ethylene glycol mono(meth)acrylate and (poly)propylene glycol mono(meth)acrylate; hydroxyalkyl vinyl ethers such as hydroxybutyl vinyl ether; and alcohols such as allyl alcohol and methacrylic alcohol. These may be used alone or in combination of two or more.

[0075] The hydroxyl value of the acrylic polyol is preferably 60 mgKOH / g or more, more preferably 80 mgKOH / g or more, and even more preferably 100 mgKOH / g or more, from the viewpoint of improving the water resistance of the acrylic urethane resin. The glass transition temperature of the acrylic polyol is, for example, 10° C. to 120° C. The glass transition temperature is a value measured using a differential scanning calorimeter.

[0076] Polyisocyanate is a compound having two or more isocyanate groups in the molecule. Examples of polyisocyanates include aliphatic polyisocyanates such as hexamethylene diisocyanate; aromatic polyisocyanates such as tolylene diisocyanate and diphenylmethane diisocyanate; and alicyclic polyisocyanates such as isophorone diisocyanate. The mass proportion of isocyanate groups in the polyisocyanate molecules is, for example, 10 mass % to 25 mass %.

[0077] When the topcoat layer contains an acrylic urethane resin, the content of the acrylic urethane resin in the topcoat layer is preferably 80% by mass or more, more preferably 90% by mass or more, and even more preferably 95% by mass or more, based on the total mass of the topcoat layer. The content of the acrylic urethane resin in the topcoat layer may be 100% by mass.

[0078] The top coat paint contains at least a solvent and / or a dispersion medium, and a resin and / or a resin precursor. The concentration of the resin or resin precursor in the top coat paint may be set in accordance with the application method from the viewpoint of work efficiency. The topcoat may contain additives such as defoamers, wetting agents, dispersants, stabilizers, thickeners, plasticizers, pigments, flame retardants, and matting agents.

[0079] The thickness of the topcoat layer is, for example, 15 μm to 150 μm.

[0080] The amount of topcoat paint to be applied is determined according to the concentration of the topcoat paint and the thickness of the topcoat layer. 2 ~500g / m 2 is.

[0081] The topcoat layer may be replaced with a topcoat layer formed by laminating a preformed resin film. Materials constituting the resin film include the resins contained in the topcoat layer described above. The alkali metal silicate layer and the resin film may be laminated together using an adhesive or by thermocompression bonding of the resin film. [Example]

[0082] The coating method and laminate material of the present disclosure will be described in more detail below with reference to examples. The materials, amounts used, ratios, processing procedures, etc. shown in the following examples can be changed as appropriate without departing from the spirit of the present disclosure. Therefore, the scope of the coating method and laminate material of the present disclosure should not be interpreted as being limited by the specific examples shown below.

[0083] In the following description, synthesis, processing, manufacturing, testing, etc. were carried out at room temperature (25°C ± 3°C) unless otherwise specified.

[0084] <Examples 1 and 2> [Preparation of primer paint] A silane coupling agent was added to a Versatic acid vinyl ester copolymer acrylic emulsion (trade name: DSV.4176, VANORA) while stirring. Silane coupling agent A below was used as the silane coupling agent. The content of the silane coupling agent in the primer paint was 1% by mass or 2% by mass.

[0085] Silane coupling agent A: A water-based silane coupling agent containing alkylene glycol (product name: X-12-1098, Shin-Etsu Chemical Co., Ltd.)

[0086] Example 1: The content of silane coupling agent A in the primer paint is 1% by mass Example 2: The content of silane coupling agent A in the primer paint is 2% by mass

[0087] [Preparation of alkali metal silicate aqueous solution] An aqueous solution of sodium silicate (water glass No. 3: n = 3.1 to 3.3, sodium silicate concentration 38.5 mass% to 40.0 mass%) and an aqueous solution of lithium silicate (trade name: Lithium Silicate 45, SiO2 / Li2O molar ratio 4.5, lithium silicate concentration 22 mass%) were mixed in a mass ratio of sodium silicate aqueous solution:lithium silicate aqueous solution = 2:1 to obtain an aqueous solution of alkali metal silicate.

[0088] [Preparation of topcoat paint] A topcoat paint was obtained by mixing 100 parts by mass of an aqueous acrylic polyol (trade name: Burnock WE-306, solvent: water, solid content 44% to 46% by mass, DIC Corporation) and 25 parts by mass of a polyisocyanate (trade name: Burnock DNW-5000, solvent: diethylene glycol dimethyl ether, solid content 79% to 81% by mass, DIC Corporation).

[0089] [Laminated material manufacturing] The primer was applied to the CLT using a brush, and then left to dry naturally for 24 hours to form a primer layer. The amount of primer applied was 130 g / m 2 It was decided. An aqueous solution of alkali metal silicate was applied onto the undercoat layer using a brush, and then allowed to stand for 24 hours to dry naturally, forming an alkali metal silicate layer. The amount of the aqueous solution of alkali metal silicate applied was 1000 g / m 2 It was decided. A topcoat was applied to the alkali metal silicate layer using a brush and left to stand for 24 hours to harden the acrylic urethane resin, forming a topcoat layer. The amount of topcoat applied was 135 g / m 2 It was decided.

[0090] [Adhesion evaluation] The laminated material obtained above was used as a test specimen, and the adhesion of the topcoat layer was evaluated in accordance with JIS K5600-5-6:1999 "General test methods for paints - Part 5: Mechanical properties of coatings - Section 6: Adhesion (cross-cut method)." Cross-cuts were made at 2 mm intervals, and the degree of peeling of the topcoat layer was classified as follows:

[0091] G0: The edges of the cut are completely smooth and there is no peeling on any of the grids. G1: Small peeling of the coating at the intersection of the cuts. G2: The coating is peeling along the edges of the cuts and / or at the intersections.

[0092] In both Examples 1 and 2, the degree of peeling of the topcoat layer was G0.

[0093] The following confirmation was also carried out for Examples 1 and 2. Visual inspection of the primer layer formed on the glass plate confirmed that the primer layer was not cloudy. Silane coupling agent A had good compatibility with the versatate vinyl ester copolymer acrylic emulsion, the main ingredient of the primer paint. Visual inspection of the primer layer formed on the CLT and the alkali metal silicate layer formed on top of that confirmed that there were no painting defects in either the primer layer or the alkali metal silicate layer.

[0094] <Example 3 and Comparative Example 1> [Preparing paint] In Example 3, the same primer paint, alkali metal silicate aqueous solution, and top coat paint were used as in Example 1. That is, the primer paint in Example 3 contains 1 mass % of silane coupling agent A. In Comparative Example 1, the same paint as in Example 3 was used, except that the undercoat paint did not contain a silane coupling agent.

[0095] [Laminated material manufacturing] The primer was applied to the top surface of a 10cm x 10cm x 36mm CLT board using a brush, and then left to dry naturally for 24 hours to form a primer layer. The amount of primer applied was 130g / m 2 It was decided. On top of the primer layer, a glass fiber sheet (product name: Surface Mat FC-30S, basis weight 30 g / m 2A 0.23 mm thick sheet of aluminum foil (Central Glass Fiber Co., Ltd.) was placed on the surface, and an aqueous solution of alkali metal silicate was applied thereon using a brush. The resulting solution was left to stand for 24 hours and allowed to dry naturally, forming an alkali metal silicate layer. The amount of the aqueous solution of alkali metal silicate applied was 1000 g / m. 2 It was decided. A topcoat was applied to the alkali metal silicate layer using a brush and left to stand for 24 hours to harden the acrylic urethane resin, forming a topcoat layer. The amount of topcoat applied was 135 g / m 2 It was decided.

[0096] [Pyrogenicity test] The laminated material obtained above was used as a test specimen and a heat generation test was carried out using a cone calorimeter in accordance with ISO5660-1:2002 and the "Fire Resistance Performance Testing and Evaluation Procedures" (General Building Research Corporation of Japan). The test continued for 20 minutes, and the total heat generation amount and heat generation rate were recorded at 5, 10, and 20 minutes after the start of the test. The thickness of the test specimen was measured before and after the test, and the difference was taken as the swelling of the test specimen. The fire resistance of the laminated material was classified as follows depending on whether it met the pass criteria shown in Table 1 at 5, 10 and 20 minutes. Table 2 shows the test results.

[0097] G1: Meets the passing criteria at 20 minutes. Equivalent to non-combustible material. G2: Meets the pass criteria at 10 minutes, but does not meet the pass criteria at 20 minutes. Equivalent to semi-noncombustible material. G3: Meets the pass criteria at 5 minutes, but does not meet the pass criteria at 10 minutes. Equivalent to flame-retardant material.

[0098] [Table 1]

[0099] [Table 2]

[0100] The fire resistance of Example 3 (an example in which the primer paint contained a silane coupling agent) was equal to or better than that of Comparative Example 1 (an example in which the primer paint did not contain a silane coupling agent).

[0101] The average swelling value was 7.81 mm in Comparative Example 1. In contrast, the average swelling value was 6.60 mm in Example 3. By including a silane coupling agent in the primer paint, the degree of swelling of the alkali metal silicate layer that occurs when the laminate material is heated can be suppressed. [Explanation of symbols]

[0102] 101, 102, 103, 104 Laminated materials 10 Flammable materials 20 Primer layer 30 Alkali metal silicate layer 40 Topcoat 50 Fiber Sheet 60, 70 fibers

Claims

1. Applying a primer paint on the combustible material to form a primer layer; and applying an aqueous solution containing an alkali metal silicate onto the undercoat layer to form an alkali metal silicate layer. The undercoat paint contains a silane coupling agent. Painting method.

2. The content of the silane coupling agent in the undercoat paint is 0.1% by mass to 10% by mass. The coating method according to claim 1.

3. further comprising disposing fibers within the alkali metal silicate layer. The coating method according to claim 1.

4. Further, a topcoat paint is applied on the alkali metal silicate layer to form a topcoat layer. The coating method according to claim 1.

5. The topcoat paint contains an acrylic polyol and a polyisocyanate. The coating method according to claim 4.

6. The combustible material is a wood material. The coating method according to any one of claims 1 to 5.

7. a flammable material; a primer layer disposed on the combustible material; an alkali metal silicate layer provided on the undercoat layer, The undercoat layer contains a reaction product of a silane coupling agent. Laminated material.

8. The alkali metal silicate layer has fibers therein. The laminate material of claim 7.

9. Further, a topcoat layer is provided on the alkali metal silicate layer. The laminate material of claim 7.

10. The topcoat layer contains an acrylic urethane resin. The laminate material of claim 9.

11. The combustible material is a wood material. The laminate material according to any one of claims 7 to 10.

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