Corner material and covering structure

Abstract

As a substitute for concrete, organic substrates such as wood substrates and plastic substrates are used in various structures. However, when the organic substrate is exposed to a high temperature, combustion, deformation, a decrease in strength, and the like easily occur. Therefore, fire resistance is required against fire occurring at the time of a disaster or the like.SOLUTION: The corner material having fire resistance includes a binder and a heat absorbing layer formed of sodium tetraborate, and has a seamless structure.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a corner material having a seamless structure and including a heat absorption layer, and to a covered structure covered with the corner material. [Background technology]

[0002] BACKGROUND ART Conventionally, concrete has been widely used for the structural framework (columns, beams, floors, and foundations) of buildings, and civil engineering structures such as tunnels and bridges.

[0003] Although such concrete structures are generally said to have a service life of about 50 years, they can be damaged and deteriorated earlier in disasters such as earthquakes.In addition, because concrete itself has a large mass, there are concerns that it could become a factor in human casualties in the event of a disaster.

[0004] Organic substrates such as wood and plastic are used as substitutes for concrete in various structures. In particular, wood substrates such as CLT (Cross Laminated Timber) and fiber-reinforced plastic substrates have attracted attention for their use in various structural components due to their excellent specific strength.

[0005] However, organic substrates are prone to burning, deformation, loss of strength, etc. when exposed to high temperatures, so fire resistance is required to protect them from fires that may occur during disasters.

[0006] For example, if organic base materials are used in the structural framework of a building, the heat generated in the event of a fire can cause the organic base materials to burn or deform, significantly reducing their strength and potentially causing the building to collapse.

[0007] In addition, in the case of a fire, the corners of a building's structural frame are subject to heat from two sides, making the temperature more likely to rise, raising concerns that the effects of combustion or deformation may become greater.

[0008] In Patent Document 1, the fire resistance of wood materials is improved by using a laminate of gypsum board, panel insulation material (such as phenolic foam), and non-combustible material (such as calcium silicate board) in the wood materials. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] Patent Publication No. 2019-150389 Summary of the Invention [Problem to be solved by the invention]

[0010] However, the laminate specifically disclosed in Patent Document 1 uses inorganic non-combustible materials such as gypsum board and calcium silicate board, and the overall thickness of the laminate needs to be increased to ensure sufficient non-combustibility. Furthermore, when the laminate is attached to the corners of pillars or the like, work to fill the gaps at the corner joints is required, which can lead to poor workability and construction. Furthermore, even if the gaps at the corner joints are filled, heat can easily penetrate into the pillar, posing a risk of combustion, which is a problem.

[0011] Therefore, the problem that the present invention aims to solve is to provide a corner material that is thin and has excellent workability, safety, and fire resistance by using a corner material that includes a heat-absorbing layer made from a specific raw material and has a seamless structure, and to provide a covered structure in which the corner portions of a core material made from an organic base material are covered with the corner material. [Means for solving the problem]

[0012] Therefore, the inventors conducted extensive research to solve the above problems, and as a result, they discovered that a corner material with fire resistance, which includes a heat-absorbing layer formed from specific raw materials and has a seamless structure, is thin, has excellent workability, safety, and fire resistance, and is particularly able to suppress the penetration of heat through the joints that are unique to corners, thereby completing the present invention.

[0013] That is, the present invention has the following features. 1. A corner material having fire resistance, comprising a binder and a heat absorption layer formed by sodium tetraborate, and having a seamless structure. 2. The corner material described in 1., wherein the binder is an organic binder and the sodium tetraborate includes sodium tetraborate decahydrate. 3. A covered structure in which the corner portions of a core material formed from an organic base material are covered with the corner material described in 1. or 2. 4. The covered structure according to 3, wherein the organic substrate is a wood substrate and / or a plastic substrate. [Effects of the Invention]

[0014] The corner material of the present invention is thin and has excellent workability, safety, and fire resistance, and is particularly useful in that it can prevent heat from entering through the joints that are unique to corners. [Brief explanation of the drawings]

[0015] [Figure 1] (1) An example of a schematic diagram showing the corner material of the present invention. (2) An enlarged view of the XX' portion of the schematic diagram of (1). [Figure 2] 1 is a schematic diagram (cross-sectional view) showing an example of a corner material of the present invention. [Figure 3] 1 is a schematic diagram showing an example of a coated structure of the present invention. [Figure 4] 1 is a schematic diagram showing an example of a coated structure of the present invention. [Figure 5] 1 is a schematic diagram showing an example of a coated structure of the present invention. [Figure 6]1 is a schematic diagram showing an example of a coated structure of the present invention. [Figure 7] 1 is a schematic diagram showing an example of a coated structure of the present invention. [Figure 8] 1 is a schematic diagram showing an example of a coated structure of the present invention. [Figure 9] 1 is a schematic diagram showing an example of a coated structure of the present invention. [Figure 10] 1 is a schematic diagram showing an example of a coated structure of the present invention. [Figure 11] 1 is a schematic diagram showing an example of a coated structure of the present invention. [Figure 12] 1 is a schematic diagram showing an example of a coated structure of the present invention. [Figure 13] FIG. 1 is a schematic diagram showing a test apparatus and a test specimen used in a fire resistance test. [Explanation of symbols]

[0016] 1: Organic base material 2: Corner material 3: Endothermic layer 4: Decorative layer 5: Non-combustible material layer 6: Thermal foam layer L: Length of the corner material in the longitudinal direction H: Length of one side of the cross section of the corner material T: Thickness of corner material A: Cone heater B: Load cell C: Test specimen D: Thermocouple DETAILED DESCRIPTION OF THE INVENTION

[0017] Hereinafter, an embodiment of the present invention will be described.

[0018] [Corner material] The present invention relates to a corner material having fire resistance, which comprises a binder and a heat absorption layer formed by sodium tetraborate, and has a seamless structure.

[0019] [Endothermic layer] The corner material of the present invention is a corner material including a heat-absorbing layer, the heat-absorbing layer being formed from a binder and sodium tetraborate. By using the binder, the sodium tetraborate can be fixed, and a heat-absorbing layer with excellent heat absorption properties can be formed.

[0020] The heat-absorbing layer can be one that exhibits heat absorption when the temperature rises. When a corner material including such a heat-absorbing layer is applied to the corner portion of a core material formed from an organic substrate (described later), it can suppress heat penetration into the corner portion when the temperature rises, such as during a fire, and plays a role in maintaining the shape of the organic substrate. As a result, a covering structure in which the corner portion of a core material formed from the organic substrate is covered with the corner material is useful because the heat-absorbing effect of the heat-absorbing layer improves fire resistance and other properties.

[0021] (binder) The binder may be an organic binder or an inorganic binder, and from the viewpoint of manufacturability and processability, an organic binder is preferred.

[0022] (organic binder) Examples of the organic binder include polyether resin, polyester resin, unsaturated polyester resin, vinyl acetate resin, alkyd resin, epoxy resin, acrylic resin, acrylic silicone resin, urethane resin, phenol resin, melamine resin, polycarbonate resin, fluororesin, acrylic-vinyl acetate resin, acrylic-urethane resin, acrylic-epoxy resin, acrylic-silicone resin, silicone-modified acrylic resin, and ethylene-vinyl acetate resin. Among these, from the viewpoint of manufacturability and processability, preferred are those obtained from polyol and isocyanate (the urethane resin obtained by reaction and curing), or those obtained from unsaturated polyester and unsaturated monomer (the unsaturated polyester resin obtained by reaction and curing).

[0023] (Polyol) Examples of the polyol include polyester polyol, polyether polyol, polycarbonate polyol, polylactone polyol, polybutadiene polyol, polypentadiene polyol, castor oil, and castor oil-based polyols, and one or more of these can be used.

[0024] Examples of the polyester polyol include aromatic polyester polyol, aliphatic polyester polyol, and aromatic / aliphatic polyester polyol.

[0025] Specifically, the aliphatic polyester polyol is a polyol having an aliphatic hydrocarbon in one molecule, and examples thereof include condensation polyester polyols obtained by reacting a saturated aliphatic polybasic acid such as succinic acid, adipic acid, azelaic acid, or sebacic acid with a polyhydric alcohol, and condensation polyester polyols obtained by reacting an unsaturated aliphatic polybasic acid such as maleic acid or fumaric acid with a polyhydric alcohol.

[0026] The aromatic polyester polyol is a polyol having an aromatic hydrocarbon in one molecule, and examples thereof include condensation polyester polyols obtained by reacting an aromatic polybasic acid such as orthophthalic acid, isophthalic acid, terephthalic acid, or phthalic anhydride with a polyhydric alcohol, and phthalic acid-based polyester polyols obtained by decomposing phthalic acid-based polyester molded products such as polyethylene terephthalate. Examples of polyhydric alcohols include dihydric or higher alcohols and derivatives thereof, dihydric or higher phenols, and polyols.

[0027] The aromatic / aliphatic polyester polyol is a polyol having an aliphatic hydrocarbon and an aromatic hydrocarbon in one molecule, and examples thereof include condensation polyester polyols obtained by reacting an aromatic polybasic acid or an aliphatic polybasic acid with a polyhydric alcohol.

[0028] Examples of the polyether polyol include aromatic polyether polyol, phosphorus-containing polyether polyol, glycerin-based polyether polyol, and amino group-containing polyether polyol.

[0029] Examples of the aromatic polyether polyols include bisphenol A-type polyether polyols obtained by adding an alkylene oxide (e.g., ethylene oxide, propylene oxide, etc.) to bisphenol A as an initiator, and aromatic amine-based polyether polyols obtained by adding an alkylene oxide to an aromatic amine (e.g., toluenediamine, diethyltoluenediamine, 4,4'-diaminodiphenylmethane, p-phenylenediamine, o-phenylenediamine, naphthalenediamine, triethanolamine, Mannich condensation products, etc.) as an initiator.

[0030] Examples of the phosphorus-containing polyether polyol include dialkyl-N,N-bis(2-hydroxyethyl)aminomethylphosphonate, which is a diol having a phosphate ester structure.

[0031] Examples of the glycerin-based polyether polyol include polyether polyols obtained by adding alkylene oxide to glycerin as an initiator.

[0032] Examples of the amino group-containing polyether polyol include those obtained by adding alkylene oxide to a low molecular weight amine (for example, ethylenediamine, propylenediamine, butylenediamine, hexamethylenediamine, neopentyldiamine, etc.) as an initiator.

[0033] The castor oil-based polyol is a polymer derived from castor oil or castor oil fatty acid, and examples thereof include alkylene oxide adducts of castor oil or castor oil fatty acid, epoxidized products of castor oil or castor oil fatty acid, halides of castor oil or castor oil fatty acid, transesterification products of castor oil or castor oil fatty acid with polyhydric alcohols, and hydrogenated products thereof. In the present invention, castor oil-based polyols and / or castor oil are particularly preferred, and it is even more preferred that the polyol contains castor oil.

[0034] In particular, in the present invention, the polyol is preferably one containing a castor oil-based polyol and / or castor oil, and more preferably one containing castor oil.

[0035] The mixing ratio (mass ratio of solid contents) of the castor oil-based polyol to the castor oil is preferably 0:100 to 50:50, and more preferably 0:100 to 30:70.

[0036] The hydroxyl value of the polyol in the present invention is not particularly limited, but is preferably 50 mgKOH / g or more and 500 mgKOH / g or less. The hydroxyl value is expressed as the number of milligrams of potassium hydroxide equivalent to the moles of hydroxyl groups contained in 1 g of sample, and is measured based on JIS K 1557-1:2007 Plastics - Test methods for polyurethane raw polyols - Part 1: Determination of hydroxyl value. The hydroxyl value of a polyol is the value measured for a mixture of all polyols.

[0037] (Isocyanate) The isocyanate has two or more isocyanate groups in one molecule and reacts with the polyol to form a molded product, and various isocyanates known in the polyurethane technical field can be used.

[0038] Examples of the isocyanate include aliphatic diisocyanates, alicyclic diisocyanates, aromatic diisocyanates, araliphatic diisocyanates, and derivatives thereof obtained by allophanating, biureting, dimerizing (uretidione), trimerizing (isocyanurate), adducting, carbodiimide reaction, etc., mixtures thereof, and copolymers of these with copolymerizable monomers. These can be used alone or in combination of two or more.

[0039] Examples of the aliphatic diisocyanate include 1,3-trimethylene diisocyanate, 1,4-tetramethylene diisocyanate, 1,3-pentamethylene diisocyanate, 1,5-pentamethylene diisocyanate, 1,6-hexamethylene diisocyanate (HMDI), 1,2-propylene diisocyanate, 1,2-butylene diisocyanate, 2,3-butylene diisocyanate, and 1,3-butylene diisocyanate. anate, 2-methyl-1,5-pentamethylene diisocyanate, 3-methyl-1,5-pentamethylene diisocyanate, 2,4,4-trimethyl-1,6-hexamethylene diisocyanate, 2,2,4-trimethyl-1,6-hexamethylene diisocyanate, 2,6-diisocyanate methyl caproate, lysine diisocyanate, dimer acid diisocyanate, norbornene diisocyanate, and the like.

[0040] Examples of the alicyclic diisocyanate include 1,3-cyclopentane diisocyanate, 1,4-cyclohexane diisocyanate, 1,3-cyclohexane diisocyanate, 3-isocyanatomethyl-3,5,5-trimethylcyclohexyl isocyanate, 4,4'-methylenebis(cyclohexyl isocyanate), methyl-2,4-cyclohexane diisocyanate, methyl-2,6-cyclohexane diisocyanate, 1,3-bis(isocyanatomethyl)cyclohexane, 1,4-bis(isocyanatomethyl)cyclohexane, isophorone diisocyanate (IPDI), norbornane diisocyanate, dicyclohexylmethane diisocyanate, hydrogenated diphenylmethane diisocyanate, and hydrogenated xylylene diisocyanate.

[0041] Examples of the aromatic diisocyanate include m-phenylene diisocyanate, p-phenylene diisocyanate, 2,4-tolylene diisocyanate (TDI), 2,6-tolylene diisocyanate (TDI), naphthylene-1,4-diisocyanate, naphthylene-1,5-diisocyanate, 4,4'-diphenyl diisocyanate, 4,4'-diphenylmethane diisocyanate (MDI), 2,4'-diphenylmethane diisocyanate, Examples of the isocyanate include 4,4'-diphenyl ether diisocyanate, 2-nitrodiphenyl-4,4'-diisocyanate, 2,2'-diphenylpropane-4,4'-diisocyanate, 3,3'-dimethyldiphenylmethane-4,4'-diisocyanate, 4,4'-diphenylpropane diisocyanate, 3,3'-dimethoxydiphenyl-4,4'-diisocyanate, dianisidine diisocyanate, and tetramethylene xylylene diisocyanate.

[0042] Examples of the aromatic aliphatic diisocyanate include 1,3-xylylene diisocyanate (XDI), 1,4-xylylene diisocyanate (XDI), ω,ω'-diisocyanato-1,4-diethylbenzene, 1,3-bis(1-isocyanato-1-methylethyl)benzene, 1,4-bis(1-isocyanato-1-methylethyl)benzene, and 1,3-bis(α,α-dimethylisocyanatomethyl)benzene.

[0043] In the present invention, it is particularly preferable to use aliphatic diisocyanates such as HMDI and its derivatives, and aromatic diisocyanates such as MDI and its derivatives. Furthermore, in the present invention, it is preferable to use trimerized (isocyanurated) aliphatic diisocyanates or aromatic diisocyanates, and it is particularly preferable to use trimerized (isocyanurated) aliphatic diisocyanates in the present invention.

[0044] In the present invention, the isocyanate index is preferably from 100 to 500 (more preferably from 105 to 400, and even more preferably from 110 to 300). By mixing the polyol and the isocyanate in such a range, a urethane resin having excellent heat resistance and a heat-absorbing layer using the urethane resin can be obtained. The isocyanate index is expressed as 100 times the value obtained by dividing the number of equivalents of isocyanate groups in an isocyanate by the total number of equivalents of active hydrogen in the active hydrogen-containing component (polyol). In addition, the water released from the hydrate of sodium tetraborate, which will be described later, is not counted as an active hydrogen-containing component used in the isocyanate index.

[0045] (unsaturated polyester) Examples of the unsaturated polyester include those produced by an esterification reaction between a polyhydric alcohol and a polybasic acid.

[0046] Examples of the polyhydric alcohol include alkylene glycols such as ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, dipropylene glycol, and neopentyl glycol, trimethylolethane, trimethylolpropane, glycerin, pentaerythritol, 1,6-hexanediol, ester glycol, 1,4-cyclohexanedimethanol, and 1,3-butanediol, and these can be used alone or in combination of two or more.

[0047] Examples of the polybasic acid include unsaturated polybasic acids such as maleic acid, maleic anhydride, fumaric acid, itaconic acid, itaconic anhydride, and citraconic acid. Phthalic acid (orthophthalic acid), isophthalic acid, terephthalic acid, phthalic anhydride, tetrahydrophthalic acid, tetrahydrophthalic anhydride, hexahydrophthalic acid, hexahydrophthalic anhydride, cyclohexanedicarboxylic acid, oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, azelaic acid, sebacic acid, trimellitic acid, and pyromellitic acid can also be used in combination, and one or more of these can be used.

[0048] (unsaturated monomer) Examples of the unsaturated monomer include (meth)acrylic acid ester monomers such as methyl (meth)acrylate, and aromatic monomers such as styrene, methylstyrene, and divinylbenzene, and one or more of these can be used.

[0049] In the present invention, the mixing ratio of the unsaturated polyester and the unsaturated monomer is preferably 10 to 200 parts by mass, more preferably 20 to 180 parts by mass, of the unsaturated monomer relative to 100 parts by mass of the unsaturated polyester. By mixing the unsaturated polyester and the unsaturated monomer in such a range and optionally adding an initiator, an unsaturated polyester resin having excellent heat resistance and a heat-absorbing layer using the unsaturated polyester resin can be obtained.

[0050] (inorganic binder) Examples of the inorganic binder include cement, gypsum, glass, water glass, and silicone resin.

[0051] (Sodium tetraborate) The sodium tetraborate is a component that imparts endothermic properties. From the viewpoint of endothermic properties, the sodium tetraborate is preferably a hydrate of sodium tetraborate, more preferably sodium tetraborate pentahydrate or sodium tetraborate decahydrate. Among these, sodium tetraborate decahydrate is particularly preferred from the viewpoint of excellent endothermic properties, since a large amount of hydration water is liberated from the hydrate and the temperature at which it is liberated is relatively low (about 60°C).

[0052] The sodium tetraborate pentahydrate is a substance that releases water of hydration at temperatures around 100 to 150°C, and the sodium tetraborate decahydrate is a substance that releases water of hydration at temperatures around 60°C. When the organic binder is a urethane resin, the sodium tetraborate hydrate is a component that can contribute to manufacturability and processability by mixing the polyol and the isocyanate, whereby free water from the sodium tetraborate hydrate reacts with the isocyanate to generate carbon dioxide and foam.

[0053] The content of the sodium tetraborate is preferably 5% by mass to 90% by mass (more preferably 10% by mass to 80% by mass, and even more preferably 20% by mass to 70% by mass) of the entire heat-absorbing layer. Within this range, a heat-absorbing layer having sufficient heat-absorbing properties can be obtained.

[0054] The content of the sodium tetraborate in the heat absorption layer is 2.0 kg / m 2 or more (more preferably 2.5 kg / m 2 More than 20.0kg / m 2 or less, more preferably 3.0 kg / m 2 More than 15.0kg / m 2 Within this range, it is possible to obtain a heat absorbing layer that has sufficient heat absorbing properties.

[0055] The amount of sodium tetraborate mixed is preferably 5 parts by mass or more and 2000 parts by mass or less (more preferably 10 parts by mass or more and 1800 parts by mass or less, and even more preferably 20 parts by mass or more and 1500 parts by mass or less) per 100 parts by mass of the organic binder.

[0056] When the organic binder is a urethane resin, it is particularly preferable that the amount of sodium tetraborate mixed is 30 parts by mass or more and 2000 parts by mass or less (more preferably 50 parts by mass or more and 1800 parts by mass or less, and even more preferably 100 parts by mass or more and 1500 parts by mass or less) per 100 parts by mass of the polyol.

[0057] When the organic binder is an unsaturated polyester resin, it is particularly preferable that the amount of sodium tetraborate mixed is 40 parts by mass or more and 2000 parts by mass or less (more preferably 80 parts by mass or more and 1800 parts by mass or less, and even more preferably 120 parts by mass or more and 1500 parts by mass or less) per 100 parts by mass of the unsaturated polyester.

[0058] The heat-absorbing layer can be obtained by mixing other additives in addition to the above-mentioned components, such as fillers, flame retardants, foaming agents, foam stabilizers, viscosity modifiers, curing accelerators, initiators, metal hydrates, colorants, dyes, film-forming aids, leveling agents, wetting agents, plasticizers, antifreeze agents, pH adjusters, preservatives, antifungal agents, anti-algae agents, antibacterial agents, dispersants, surfactants, adsorbents, fibers, carbonizing agents, and solvents.

[0059] Examples of the filler include heavy calcium carbonate, kaolin, diatomaceous earth, white carbon, clay, talc, barite powder, precipitated barium sulfate, barium carbonate, silica sand, vermiculite, ceramic beads, glass beads, silica gel, gypsum dihydrate, perlite, expanded vermiculite, pumice, vermiculite, crushed ALC, hollow ceramic beads, hollow glass beads, shirasu balloons, charcoal, bamboo charcoal, seed shell charcoal, smoked seed shell charcoal, styrene resin foam, ethylene vinyl acetate resin foam, and polyvinyl chloride resin foam, and one or more of these may be used.

[0060] The amount of the filler to be mixed may be 10 to 500 parts by mass (or even 20 to 400 parts by mass) relative to 100 parts by mass of the organic binder.Within this range, excellent strength can be exhibited.

[0061] When the organic binder is a urethane resin, the amount of the filler to be mixed may be 30 to 500 parts by mass (or even 50 to 400 parts by mass) relative to 100 parts by mass of the polyol.Within this range, excellent strength can be exhibited.

[0062] When the organic binder is an unsaturated polyester resin, the amount of the filler to be mixed may be 40 parts by mass or more and 500 parts by mass or less (even 80 parts by mass or more and 400 parts by mass or less) per 100 parts by mass of the unsaturated polyester.

[0063] In particular, in the present invention, the filler has a bulk density of 0.01 g / cm 3 More than 1g / cm 3 A lightweight filler having a mass of less than 10 ... Furthermore, in the present invention, one or more non-combustible lightweight fillers selected from perlite, expanded vermiculite, pumice, vermiculite, crushed ALC, hollow ceramic beads, hollow glass beads, charcoal, bamboo charcoal, seed shell charcoal, and smoked seed shell charcoal can be used.

[0064] The amount of the lightweight filler to be mixed may be 300 parts by mass or less (even 250 parts by mass or less) per 100 parts by mass of the organic binder. The amount of the lightweight filler in this range is advantageous in terms of lightness and strength. Furthermore, if the lightweight filler is a non-flammable lightweight filler, it is also advantageous in terms of heat resistance.

[0065] When the organic binder is a urethane resin, the amount of the lightweight filler mixed may be 300 parts by mass or less (even 250 parts by mass or less) per 100 parts by mass of the polyol. The lightweight filler in this range is advantageous in terms of lightness and strength. Furthermore, when the lightweight filler is a non-flammable lightweight filler, it is also advantageous in terms of heat resistance.

[0066] When the organic binder is an unsaturated polyester resin, the amount of the lightweight filler mixed may be 300 parts by mass or less (even 250 parts by mass or less) per 100 parts by mass of the unsaturated polyester. The lightweight filler in this range is advantageous in terms of lightness and strength. Furthermore, when the lightweight filler is a non-flammable lightweight filler, it is also advantageous in terms of heat resistance.

[0067] The bulk density of the filler is a value measured by supplying lightweight colored particles to a cylindrical container and applying up and down vibration (tapping vibration) until the bulk change of the lightweight colored particles in the container is completed.

[0068] The average particle size of the filler is not particularly limited, but may be from 50 μm to 1000 μm, and can be measured using a laser diffraction particle size distribution analyzer.

[0069] Examples of the flame retardant include phosphorus-based flame retardants, halogen-based flame retardants, boron-based flame retardants, metal hydroxide-based flame retardants, nitrogen-based flame retardants, and silicon-based flame retardants, and one or more of these can be used.

[0070] Examples of the phosphorus-based flame retardant include phosphate ester compounds, phosphate compounds, polyphosphate compounds, phosphite compounds, phosphonate compounds, phosphonite compounds, phosphinate compounds, phosphinite compounds, red phosphorus, phosphorus trichloride, and phosphorus pentachloride.

[0071] Specific examples of the phosphate ester compounds include trimethyl phosphate, triethyl phosphate, tributyl phosphate, trioctyl phosphate, triphenyl phosphate, trisnonylphenyl phosphate, tributoxyethyl phosphate, tricresyl phosphate, cresyl phenyl phosphate, cresyl diphenyl phosphate, octyl diphenyl phosphate, trixylenyl phosphate, diisopropyl phenyl phosphate, tris(2-ethylhexyl) phosphate, resorcinol bisdiphenyl phosphate, bisphenol A bis(diphenyl phosphate), resorcinol bisdixylenyl phosphate, tris(chloroethyl) phosphate, tris(chloropropyl) phosphate, tris(dichloropropyl) phosphate, bis(2, 3-dibromopropyl)-2,3-dichloropropyl phosphate, tris(2,3-dibromopropyl)phosphate, bis(chloropropyl)monoctyl phosphate, hydroquinonyl diphenyl phosphate, phenyl nonyl phenyl hydroquinonyl phosphate, phenyl dinonyl phenyl phosphate, diphenyl-4-hydroxy-2,3,5,6-tetrabromobenzyl phosphonate, dimethyl-4-hydroxy-3,5-dibromobenzyl phosphonate, diphenyl-4-hydroxy-3,5-dibromobenzyl phosphonate, trialkyl polyphosphate, resorcinol polyphenyl phosphate, bisphenol A polycresyl phosphate, resorcinol poly(di-2,6-xylyl)phosphate, hydroquinone poly(2,6-xylyl)phosphate, and the like.

[0072] Examples of the phosphate compound include aluminum phosphate, sodium phosphate, potassium phosphate, calcium phosphate, zinc phosphate, ammonium phosphate, aluminum phosphite, sodium phosphite, potassium phosphite, calcium phosphite, zinc phosphite, ammonium phosphite, aluminum hypophosphite, sodium hypophosphite, potassium hypophosphite, calcium hypophosphite, zinc hypophosphite, ammonium hypophosphite, aluminum metaphosphate, sodium metaphosphate, potassium metaphosphate, calcium metaphosphate, and zinc metaphosphate.

[0073] Examples of the polyphosphate compounds include ammonium polyphosphate, ammonium amide polyphosphate, melamine polyphosphate, piperazine polyphosphate, melem polyphosphate, melam polyphosphate, melon polyphosphate, and aluminum polyphosphate.

[0074] Examples of the phosphonate compound include methylphosphonic acid, dimethyl methylphosphonate, diethyl methylphosphonate, ethylphosphonic acid, propylphosphonic acid, butylphosphonic acid, 2-methylpropylphosphonic acid, t-butylphosphonic acid, 2,3-dimethyl-butylphosphonic acid, octylphosphonic acid, phenylphosphonic acid, and dioctyl phenylphosphonate.

[0075] Examples of the phosphinate compound include dimethylphosphinic acid, methylethylphosphinic acid, methylpropylphosphinic acid, diethylphosphinic acid, dioctylphosphinic acid, phenylphosphinic acid, diethylphenylphosphinic acid, diphenylphosphinic acid, and bis(4-methoxyphenyl)phosphinic acid.

[0076] Examples of the halogen-based flame retardants include those containing fluorine, chlorine, bromine, iodine, and antimony, and examples thereof include halogen oxides, halogenated phosphazenes, halogenated alkanes, halogenated indanes, halogenated phosphate esters, and halogenated polystyrenes.

[0077] Examples of the boron-based flame retardant include boron oxide, boric acid, lithium borate, sodium borate (excluding sodium tetraborate), potassium borate, cesium borate, magnesium borate, calcium borate, barium borate, zirconium borate, zinc borate, aluminum borate, and ammonium borate.

[0078] Examples of the metal hydroxide flame retardant include aluminum hydroxide, magnesium hydroxide, calcium hydroxide, iron hydroxide, nickel hydroxide, zirconium hydroxide, zinc hydroxide, titanium hydroxide, copper hydroxide, tin hydroxide, and vanadium hydroxide.

[0079] The amount of the flame retardant mixed is preferably 5 to 1000 parts by mass (more preferably 10 to 500 parts by mass, even more preferably 15 to 200 parts by mass, still more preferably 20 to 100 parts by mass, and most preferably 25 to 80 parts by mass) relative to 100 parts by mass of the organic binder. By using the flame retardant in this range, dispersibility can be improved and heat resistance can be further enhanced.

[0080] When the organic binder is a urethane resin, the amount of the flame retardant mixed is preferably 10 to 1,000 parts by mass (more preferably 15 to 500 parts by mass, even more preferably 20 to 200 parts by mass, still more preferably 25 to 100 parts by mass, and most preferably 30 to 80 parts by mass) relative to 100 parts by mass of the polyol. By using the flame retardant in this range, it is possible to improve dispersibility and heat resistance. In particular, it is preferable to use a castor oil-based polyol and / or castor oil (more preferably castor oil) as the polyol in the above-mentioned mixing ratio.

[0081] When the organic binder is an unsaturated polyester resin, the amount of the flame retardant mixed is preferably 10 to 1,000 parts by mass (more preferably 15 to 500 parts by mass, even more preferably 20 to 200 parts by mass, still more preferably 25 to 100 parts by mass, and most preferably 30 to 80 parts by mass) relative to 100 parts by mass of the unsaturated polyester. By using the flame retardant in this range, dispersibility can be improved and heat resistance can be further enhanced. In particular, it is preferable to use as the unsaturated polyester a product produced by an esterification reaction between a polyhydric alcohol selected from ethylene glycol and propylene glycol and a polybasic acid selected from maleic acid, maleic anhydride, fumaric acid, and isophthalic acid, and as the unsaturated monomer a (meth)acrylic acid ester monomer and / or an aromatic monomer in the above-mentioned mixing ratio.

[0082] In the present invention, it is preferable to use the flame retardant in combination with the sodium tetraborate, which can further improve heat resistance, and in particular, by using a liquid flame retardant in combination, it is possible to control the dispersion stability of the sodium tetraborate and the viscosity of the composition, thereby obtaining a heat absorbing layer with better heat resistance.

[0083] The foaming agent is not particularly limited, but examples thereof include hydrofluoroolefin, hydrochlorofluoroolefin, water, liquefied carbon dioxide gas, etc., and one or more of these can be used.

[0084] Examples of the hydrofluoroolefin (HFO) include pentafluoropropenes such as 1,2,3,3,3-pentafluoropropene (HFO1225ye), tetrafluoropropenes such as 1,3,3,3-tetrafluoropropene (HFO1234ze), 2,3,3,3-tetrafluoropropene (HFO1234yf), and 1,2,3,3-tetrafluoropropene (HFO1234ye), and 3,3,3-trifluoropropene. Examples of suitable fluorocarbons include trifluoropropenes such as (HFO1243zf), tetrafluorobutene (HFO1345), pentafluorobutene (HFO1354), hexafluorobutene (HFO1336), heptafluorobutene (HFO1327), heptafluoropentene (HFO1447), octafluoropentene (HFO1438), nonafluoropentene (HFO1429), and isomers thereof (cis isomer, trans isomer).

[0085] Examples of the hydrochlorofluoroolefin (HCFO) include 1-chloro-3,3,3-trifluoropropene (HCFO-1233zd), 2-chloro-3,3,3-trifluoropropene (HCFO-1233xf), dichlorotrifluoropropene (HCFO1223), and isomers thereof (cis isomer, trans isomer).

[0086] The blowing agent in the present invention is preferably one or more selected from hydrofluoroolefins, hydrochlorofluoroolefins, and water, and each blowing agent can be used in combination, for example, a hydrofluoroolefin and water, a hydrochlorofluoroolefin and water, or a hydrofluoroolefin, a hydrochlorofluoroolefin, and water.

[0087] In particular, when the organic binder is a urethane resin, the amount of the foaming agent mixed is preferably 200 parts by mass or less, more preferably 20 parts by mass or more and 180 parts by mass or less, and even more preferably 30 parts by mass or more and 150 parts by mass or less, per 100 parts by mass of the polyol.

[0088] Examples of the foam stabilizer include silicone-based foam stabilizers such as polyether-modified silicone compounds, fluorine-containing compound-based foam stabilizers, etc. These may be used alone or in combination of two or more.

[0089] Examples of the polyether-modified silicone compound include graft copolymers of polydimethylsiloxane and polyoxyethylene glycol or polyoxyethylene-propylene glycol.

[0090] In particular, when the organic binder is a urethane resin, the amount of the foam stabilizer mixed is preferably 40 parts by mass or less, more preferably 0.5 to 30 parts by mass, per 100 parts by mass of the polyol.

[0091] Examples of the viscosity adjuster include layered clay minerals such as smectite and vermiculite, amide wax, hydrophobic cellulose such as ethyl cellulose and cellulose nitrate, and polyolefins such as polyethylene and polypropylene, and one or more of these can be used. In the present invention, it is particularly preferable to use layered clay minerals, and it is particularly preferable to use layered clay minerals that have been organically treated with long-chain alkylammonium ions or the like (organic smectites (organic montmorillonite, organic bentonite, etc.), organic vermiculite, etc.).

[0092] In particular, when the organic binder is a urethane resin, the amount of the viscosity modifier mixed is preferably 60 parts by mass or less, more preferably 1.0 to 40 parts by mass, relative to 100 parts by mass of the polyol.

[0093] Examples of the curing accelerator include amines such as triethylamine, triethylenediamine, triethylamine, tetramethylbutanediamine, dimethylaminoethanol, dimer diamine, and dimer acid polyamidoamine; tin carboxylates such as dibutyltin dilaurate, dibutyltin diacetate, and tin octoate; metal carboxylates such as iron naphthenate, cobalt naphthenate, manganese naphthenate, zinc naphthenate, iron octoate, cobalt octoate, manganese octoate, and zinc octoate; carboxylates such as dibutyltin thiocarboxylate, dioctyltin thiocarboxylate, tributylmethylammonium acetate, and trioctylmethylammonium acetate; and aluminum compounds such as aluminum trisacetylacetate. One or more of these may be used.

[0094] In particular, when the organic binder is a urethane resin, the amount of the curing accelerator mixed is preferably 0.05 to 40 parts by mass, more preferably 0.1 to 30 parts by mass, relative to 100 parts by mass of the polyol.

[0095] Examples of the initiator include organic peroxides such as hydroperoxides, dialkyl peroxides, diacyl peroxides, ketone peroxides, peroxyesters, peroxyketals, and peroxydicarbonates, and azo compounds such as azobisisobutyronitrile, azobiscarbonamide, and 2-phenylazo-2,4-dimethyl-4-methoxyvaleronitrile, and these can be used alone or in combination of two or more.

[0096] In particular, when the organic binder is an unsaturated polyester resin, the amount of the initiator mixed is preferably 0.05 to 10 parts by mass, more preferably 0.1 to 80 parts by mass, relative to 100 parts by mass of the unsaturated monomer.

[0097] The heat-absorbing layer may contain other metal hydrates in addition to the sodium tetraborate. Examples of such metal hydrates include sulfates such as ammonium aluminum sulfate dodecahydrate, sodium aluminum sulfate dodecahydrate, aluminum sulfate 27hydrate, aluminum sulfate 18hydrate, aluminum sulfate 16hydrate, aluminum sulfate decahydrate, aluminum sulfate 6hydrate, potassium aluminum sulfate dodecahydrate, iron sulfate heptahydrate, iron sulfate nonahydrate, potassium iron sulfate dodecahydrate, magnesium sulfate heptahydrate, sodium sulfate decahydrate, nickel sulfate hexahydrate, zinc sulfate heptahydrate, beryllium sulfate tetrahydrate, and zirconium sulfate tetrahydrate; sulfites such as zinc sulfite dihydrate and sodium sulfite heptahydrate; aluminum phosphate dihydrate, cobalt phosphate octahydrate, and magnesium phosphate. phosphates such as cerium octahydrate, magnesium ammonium phosphate hexahydrate, magnesium hydrogen phosphate trihydrate, magnesium hydrogen phosphate heptahydrate, zinc phosphate tetrahydrate, and zinc dihydrogen phosphate dihydrate; nitrates such as aluminum nitrate nonahydrate, zinc nitrate hexahydrate, calcium nitrate tetrahydrate, cobalt nitrate hexahydrate, bismuth nitrate pentahydrate, zirconium nitrate pentahydrate, cerium nitrate hexahydrate, iron nitrate hexahydrate, iron nitrate nonahydrate, nickel nitrate hexahydrate, and magnesium nitrate hexahydrate; acetates such as zinc acetate dihydrate and cobalt acetate tetrahydrate; chloride salts such as cobalt chloride hexahydrate and iron chloride tetrahydrate; and metal hydrates such as borates such as disodium octaborate tetrahydrate and zinc borate 3.5hydrate.

[0098] The heat-absorbing layer can be prepared by mixing the polyol, the isocyanate, and the sodium tetraborate, adding other additives as needed, and curing the mixture to obtain a heat-absorbing layer containing a urethane resin and sodium tetraborate. In particular, a first liquid (first component) containing the polyol, the sodium tetraborate, and, if necessary, other additives is prepared, and a second liquid (second component) containing an isocyanate is prepared, and the first and second liquids are mixed and reacted to obtain a heat-absorbing layer. The sodium tetraborate and other additives may be mixed only with the first component, or may also be mixed with the second component if necessary. In such a case, it is particularly preferable to mix and react at a temperature of 10°C or higher and 70°C or lower (more preferably 15°C or higher and 50°C or lower).

[0099] The heat-absorbing layer can be obtained by mixing the unsaturated polyester, the unsaturated monomer, and the sodium tetraborate, adding and mixing other additives as necessary, and curing the mixture to obtain a heat-absorbing layer containing the unsaturated polyester resin and sodium tetraborate. In particular, a first liquid (first component) containing the unsaturated polyester, the unsaturated monomer, and the sodium tetraborate, and optionally other additives, and a second liquid (second component) containing an initiator are prepared, and the first and second liquids are mixed and reacted to obtain a heat-absorbing layer. The sodium tetraborate and other additives may be mixed only with the first component, or may also be mixed with the second component as needed. In such a case, it is particularly preferable to mix and react at a temperature of 10°C or higher and 70°C or lower (more preferably 15°C or higher and 50°C or lower).

[0100] The density of the heat absorption layer is 0.05 g / cm 3 More than 1.5g / cm 3 Less than (more preferably 0.08 g / cm 3 More than 1.2g / cm 3 or less, more preferably 0.1 g / cm 3 More than 1.0g / cm 3 (see below) is preferred.

[0101] The thickness of the heat-absorbing layer (one layer) is preferably 3 mm or more and 60 mm or less (more preferably 4 mm or more and 50 mm or less, even more preferably 5 mm or more and 30 mm or less, and most preferably 6 mm or more and 25 mm or less).

[0102] (Other layers) The corner material of the present invention includes the heat-absorbing layer, but may also include a layer other than the heat-absorbing layer as an integral part of the corner material, as needed, as long as the effect of the present invention is not significantly impaired. Examples of such layers include a thermal foaming layer, an adhesive layer, a decorative layer, and other layers (e.g., a reinforcing material layer, a non-flammable material layer, a heat-reflecting layer, a heat-shielding layer, a waterproof layer, a water-repellent layer, a water-shielding layer, a heat-insulating material layer, etc.). In the present invention, particularly preferred embodiments include a corner material consisting of only a heat absorption layer, or a corner material including a heat absorption layer and a reinforcing layer. Corner materials consisting of only a heat absorption layer are particularly preferred because they can be easily manufactured. Corner materials including a heat absorption layer and a reinforcing layer are also preferred because they can improve the strength of the corner material and further improve fire resistance and formability. Such corner materials including a heat absorption layer and a reinforcing layer can be obtained by laminating a reinforcing layer on the surface (inside, outside, or both) of a corner material consisting of a heat absorption layer, or by embedding a reinforcing layer during the manufacturing of a corner material using a heat absorption layer to integrate the heat absorption layer and the reinforcing layer.

[0103] The corner material of the present invention includes the heat absorption layer, and may also include a thermal foaming layer, if necessary. The thermal foaming layer can be one that foams from the respective materials that make up the thermal foaming layer and forms a carbonized heat insulating layer when the ambient temperature rises due to a fire or the like and the temperature of the thermal foaming layer reaches a predetermined foaming temperature.

[0104] The foaming temperature of the thermal foamable layer is preferably 150°C or higher, more preferably 180°C or higher, and even more preferably 200 to 400°C, in view of temperature rise due to flames, heat, and the like.

[0105] The thermally foamable layer can be formed, for example, from a thermally foamable coating material or a thermally foamable sheet, and these can be used alone or in a laminate of two or more kinds.

[0106] The thermally foamable layer is preferably made of a mixture of components including a resin component, a flame retardant, a foaming agent, a carbonizing agent, and a filler. Each of these components can be used alone or in combination of two or more.

[0107] Examples of the resin component include thermoplastic resins such as polyester resin, polybutadiene resin, acrylic resin, styrene resin, acrylic-styrene resin, vinyl acetate resin, vinyl acetate / versatic acid vinyl ester copolymer resin, vinyl acetate / ethylene copolymer resin, vinyl acetate / versatic acid vinyl ester / acrylic copolymer resin, vinyl acetate / acrylic copolymer resin, polyethylene resin, vinyl chloride resin, polypropylene resin, and polystyrene resin; and thermosetting resins such as epoxy resin, urethane resin, alkyd resin, phenolic resin, and melamine resin.

[0108] Examples of the flame retardant include organic phosphorus compounds such as tricresyl phosphate and diphenyl cresyl phosphate; chlorine compounds such as chlorinated polyphenyl, chlorinated polyethylene, diphenyl chloride, triphenyl chloride, chlorinated paraffin, pentachlorinated fatty acid ester, perchloropentacyclodecane, chlorinated naphthalene and tetrachlorophthalic anhydride; antimony compounds such as antimony trioxide and antimony pentachloride; phosphorus compounds such as phosphorus trichloride, phosphorus pentachloride, ammonium phosphate, ammonium polyphosphate, melamine phosphate, melamine polyphosphate, melam polyphosphate, melem polyphosphate, boron phosphate, boron polyphosphate, aluminum phosphate and aluminum polyphosphate; and inorganic compounds such as zinc borate.

[0109] Examples of the foaming agent include melamine and its derivatives, dicyandiamide and its derivatives, azobistetrazole and its derivatives, azodicarbonamide, urea, and thiourea.

[0110] Examples of the carbonizing agent include pentaerythritol, dipentaerythritol, trimethylolpropane, starch, and casein.

[0111] Examples of the filler include talc, calcium carbonate, sodium carbonate, aluminum oxide (alumina), titanium oxide, zinc oxide, silica, clay, shirasu, mica, silica sand, silica powder, quartz powder, barium sulfate, and inorganic fibers.

[0112] The mixing ratio (mass ratio) of each of the components is preferably 200 to 600 parts by mass of the flame retardant, 40 to 150 parts by mass of the foaming agent, 40 to 150 parts by mass of the carbonizing agent, and 50 to 160 parts by mass of the filler, calculated as solid content, relative to 100 parts by mass of the resin component. When used in the above mixing ratio, flame retardancy, fire resistance, etc. can be satisfied, which is a preferred embodiment.

[0113] The mixture that forms the thermally foamable layer may contain, in addition to the above-mentioned components, various additives as needed. The additives may be any additives that do not significantly impair the effects of the present invention, and examples thereof include pigments, fibers, wetting agents, plasticizers, lubricants, preservatives, antifungal agents, anti-algae agents, antibacterial agents, thickeners, dispersants, antifoaming agents, crosslinking agents, UV absorbers, light stabilizers, antioxidants, dilution solvents, etc.

[0114] The thermally foamable coating material used to form the thermally foamable layer can be a liquid mixture containing the components and additives, and the thermally foamable sheet used to form the thermally foamable layer can be a sheet-shaped mixture containing the components and additives.

[0115] The thickness of the thermally foamable layer may be appropriately set depending on the application, etc., but from the viewpoints of fire resistance, light weight, etc., it is preferably 0.1 to 10 mm, more preferably 0.3 to 8 mm, and even more preferably 0.5 to 6 mm.

[0116] The thermally foamable layer may be composed only of a mixture containing the components and additives, or may have a fibrous sheet or the like laminated on the front or back surface of the thermally foamable layer from the viewpoints of productivity, workability, flexibility, etc. As such a fibrous sheet, for example, a known sheet containing organic fibers and / or inorganic fibers can be used.

[0117] The adhesive layer is formed by an adhesive or the like used when bonding the various layers together. The adhesive used in the adhesive layer can be any known adhesive, such as a water-dispersible, water-soluble, or solvent-based adhesive whose main ingredient is, for example, acrylic resin, silicone resin, epoxy resin, vinyl resin, phenolic resin, polyester resin, urethane resin, or paraffin. The adhesive can contain additives such as flame retardants, foaming agents, carbonizing agents, and fillers, as are contained in the thermally foamable layer described above, as needed. In the present invention, the adhesive also encompasses pressure-sensitive adhesives.

[0118] The decorative layer can be provided on the surface of the thermally foamed layer. Examples of the decorative layer that can be used include woodblocks, various coating materials, sheet materials, and film materials. These can have various appearances, such as transparent or opaque, colorless or colored, non-glossy or glossy, monochromatic or multicolored, and flat or uneven. The provision of the decorative layer is useful because it can improve the aesthetics, water resistance, weather resistance, and the like of the corner material of the present invention.

[0119] The heat-reflecting layer can be provided between the thermal foam layer and the heat-absorbing layer, or between the heat-absorbing layer and the organic substrate. A highly heat-reflective metal sheet or tape can be used as the heat-reflecting layer. Specific examples of the heat-reflecting layer include aluminum foil, aluminum tape, aluminum cloth, aluminum foil / glass nonwoven fabric laminated sheet, aluminum foil / mesh laminated sheet, and aluminum foil / synthetic resin laminated sheet.

[0120] By providing the heat reflecting layer between the heat foaming layer and the heat absorbing layer, the heat foaming layer can be smoothly foamed, and an excellent carbonized heat insulating layer can be formed.

[0121] The thickness of the heat reflective layer may be appropriately set depending on the application, etc., but from the viewpoints of fire resistance, light weight, etc., it is preferably 0.01 to 1 mm, more preferably 0.02 to 0.8 mm, and even more preferably 0.03 to 0.6 mm.

[0122] Examples of the reinforcing material layer include nonwoven fabrics, woven fabrics, and woven fabrics, and these may be used alone or in combination of two or more.

[0123] The nonwoven fabric is a fabric (sheet) made of individual independent fibers (formed without weaving), and examples thereof include fabrics in which the fibers are arranged crosswise, fabrics in which the fibers are arranged randomly, etc. Furthermore, methods for bonding the fibers include, for example, chemical bonding using a resin component (chemical bonding), fusion bonding by heating (thermal bonding), mechanical intertwining (needle punching), stitch bonding, etc.

[0124] Examples of the woven fabric include those in which fibers aligned in one direction and fibers aligned in a different direction are woven vertically, horizontally, or diagonally and laminated together. The woven fabric may have a mesh structure, and examples of the woven fabric include multi-axial woven fabrics such as biaxial woven fabrics, triaxial woven fabrics, and tetraaxial woven fabrics, depending on the number of axes of the fiber groups.

[0125] The woven fabric is formed from a group of fibers, similar to a woven fabric, and is woven by interlacing warp fibers and weft fibers. Examples of the woven structure include plain weave, twill weave, satin weave, double warp weave, double weft weave, double warp and weft weave, pile weave, leno weave, and figured weave.

[0126] Examples of fibers used in the reinforcing material layer include inorganic fibers such as rock wool, glass fiber, silica fiber, silica-alumina fiber, carbon fiber, and silicon carbide fiber; thin metal wires such as iron and copper; and organic fibers such as pulp fiber, polyester fiber, polypropylene fiber, aramid fiber, vinylon fiber, polyethylene fiber, polyarylate fiber, PBO fiber, nylon fiber, acrylic fiber, vinyl chloride fiber, and cellulose fiber. One or more of these fibers may be used.

[0127] In the present invention, it is particularly preferred to use a nonwoven fabric in which fibers are randomly arranged as the reinforcing material layer, and it is particularly preferred to use an inorganic fiber nonwoven fabric in which inorganic fibers are randomly arranged and bonded together with a resin component.Furthermore, it is preferred to use glass fibers as the inorganic fibers. Such a reinforcing material layer can reinforce the strength of the corner material, as well as the fire resistance and formability.

[0128] Examples of the non-combustible material layer include concrete, glass, metal, wood wool cement, gypsum, and calcium silicate.

[0129] (Characteristics of corner materials) The corner material of the present invention can be made thinner than those of conventional technologies, and the thickness (total thickness) of the corner material is preferably 3 to 40 mm, more preferably 4 to 30 mm, and even more preferably 5 to 25 mm. Having a thickness of the corner material equal to or less than the upper limit of the above range reduces the burden on workers and the risk of injury during transportation and installation, thereby improving work efficiency. When installed on indoor pillars, beams, etc., it also makes it possible to expand the indoor space. Having a thickness of the corner material equal to or greater than the lower limit of the above range is preferable in terms of insulation, fire resistance, strength, etc. The thickness of the corner material may be set appropriately depending on the application, but it is preferable to make the thickness the same as that of the other layers that are covered together with the corner material, as described below, to form a coated surface without any steps.

[0130] The length of the corner material is preferably 600 to 3000 mm. By keeping the length of the corner material at or below the upper limit of the range, work efficiency can be improved in transportation, construction work, etc. Furthermore, the corner material can be cut or joined together depending on the application. When corner materials are joined together, the corner materials expand slightly at the joints due to the action of hydrated water liberated from the sodium tetraborate in the heat absorption layer, which has the effect of sealing the joints and preventing a decrease in fire resistance. In addition, for example, by joining corner materials that have been cut at an angle rather than perpendicular to the longitudinal direction, or by joining corner materials that have been given a step in the longitudinal direction, the decrease in fire resistance can be further suppressed.

[0131] The length of one side of the cross section of the corner material is preferably 10 mm or more, more preferably 20 to 200 mm, and even more preferably 30 to 150 mm. By ensuring that the length of one side of the cross section of the corner material is at least the lower limit of the above range, it is possible to suppress temperature rise in the corner portion. Furthermore, the length of one side of the cross section of the corner material may be different in both directions or may be the same length.

[0132] The corner angle of the corner material may be set to match the angle of the corner of the organic substrate, which will be described later, but is usually preferably 90°. For example, when using an organic substrate with a square cross section, the corner angle should be 90° and the length of one side of the cross section of the corner material should be the same in both directions. When using an organic substrate with a rectangular cross section, the corner angle should be 90° and the length of one side of the cross section of the corner material should be different, taking into account the coating of other layers described below.

[0133] The corner material can be produced by any known method, such as injection molding, extrusion molding, pultrusion molding, compression molding, rotational molding, thermoforming, hot melt molding, blow molding, transfer molding, bulk molding, hand layup, spray-up, matched die molding, filament winding, sheet molding, cold pressing, SMC, BMC, and preform matched die molding.

[0134] The shape of the corner material is, for example, as shown in Figures 1 and 2, and the cross section of the corner material itself has no seams. By covering the corner portion of a core material made of an organic base material with such a corner material, a seamless corner structure is formed, and it is possible to suppress the penetration of heat from the corner portion into the interior.

[0135] [Covering structure] The present invention relates to a covered structure in which corner portions of a core material formed from an organic base material are covered with the corner materials. The covered structure is preferable because the corner portions of the core material formed from the organic base material are covered with the corner materials including the heat absorption layer, which suppresses heat penetration from the corner portions to the interior, thereby suppressing temperature rise and providing excellent fire resistance.

[0136] (Organic base material) Examples of the organic substrate include a wood substrate, a plastic substrate, a fiber-reinforced plastic substrate, a paper substrate, a fibrous substrate, or a substrate made by combining these. From the viewpoints of strength and lightness, a wood substrate, a plastic substrate, a fiber-reinforced plastic substrate, or a substrate made by combining these is preferred.

[0137] Examples of the wood substrate include Japanese cypress, cedar, hiba, Japanese pine (Japanese larch, larch, Yezo spruce, Abies sachalinensis, and spruce), Douglas fir, Norway spruce, and Norway sylvestris, as well as lumber, plywood, laminated lumber, LVL (Laminated Veneer Lumber), CLT (Cross Laminated Timber), particle board, and fiberboard. The use of such wood substrates also contributes to the promotion of carbon neutrality.

[0138] Among the wood substrates, the CLT is called cross-laminated timber, a wood material made by arranging sawn boards (laminae) and then laminating and gluing them so that the fiber directions are perpendicular to each other. Specifically, CLT is defined in the Japanese Agricultural Standard JAS3079:2019 "Cross-laminated timber" as "wood made of sawn boards or timbers (including those prepared by joining and gluing them lengthwise with the fiber directions approximately parallel to each other) arranged or glued widthwise with the fiber directions approximately parallel to each other, mainly laminated and glued with the fiber directions approximately perpendicular to each other to form a three- or more-layer structure." Using CLT as a wood substrate enables the corner material of the present invention to be applied to structural members (structural frameworks).

[0139] The thickness of the wood substrate can be appropriately set depending on the application.

[0140] As the plastic substrate, a substrate containing a thermoplastic resin and / or a thermosetting resin as a main component can be used.

[0141] Examples of the thermoplastic resin include polyamide, polyacetal, polysulfone, polyester, polybutylene terephthalate, polycarbonate, polyethylene terephthalate, polyethylene, polypropylene, polyphenylene sulfide, polyether ether ketone, polyetherimide, polyether ketone ketone, polyvinyl chloride, acrylic resin, ABS resin, fluororesin, and silicone resin.

[0142] The thermosetting resin can be one that forms a three-dimensional crosslinked structure by a crosslinking reaction, and examples thereof include unsaturated polyester resin, vinyl ester resin, epoxy resin, benzoxazine resin, phenol resin, urethane resin, urea resin, melamine resin, polyimide resin, etc. These can be used alone or in combination of two or more.

[0143] In the present invention, a fiber-reinforced plastic substrate can be used as the plastic substrate. A fiber-reinforced plastic substrate is a composite of the above-mentioned resin and fiber, and is a substrate having properties such as high specific rigidity and high specific strength. By using a fiber-reinforced plastic substrate as the plastic substrate, it becomes possible to apply the corner material of the present invention to structural members (structural bodies) and the like.

[0144] Examples of fibers used in the fiber-reinforced plastic substrate include glass fibers, aramid fibers, Kevlar fibers, carbon fibers, graphite fibers, boron fibers, Tyranno fibers, silicon carbide fibers, silicon nitride fibers, alumina fibers, and mineral fibers. Among these, glass fibers and carbon fibers are preferred from the viewpoint of improving mechanical strength, and glass fibers are also preferred from the viewpoint of cost. These fibers can be used alone or in combination of two or more.

[0145] The thickness of the plastic substrate can be appropriately set depending on the application.

[0146] The covered structure of the present invention is a covered structure in which the corner portions of the organic substrate are covered with the corner material, and in addition to the seamless corner material, other layers may be included as necessary as long as the effects of the present invention are not significantly impaired. Examples of such layers include a non-flammable material layer, a heat-absorbing layer, a thermal foaming layer, an adhesive layer, a decorative layer, and other layers (e.g., a reinforcing material layer, a heat-reflecting layer, a heat-shielding layer, a waterproof layer, a water-repellent layer, a water-shielding layer, a heat-insulating material layer, etc.) used in addition to the corner material. The raw materials used in the other layers may be the same as the raw materials used in the heat-absorbing layer, etc. used in the corner material.

[0147] Examples of the non-combustible material layer used other than the corner material include a concrete plate, a glass plate, a metal plate, a wood wool cement plate, a gypsum board, and a calcium silicate plate.

[0148] The heat-absorbing layer used other than the corner material may be a board-shaped heat-absorbing layer formed from the binder, sodium tetraborate, and, if necessary, other additives that can be used in the heat-absorbing layer.

[0149] Furthermore, the corner material of the present invention expands slightly due to the action of hydrated water liberated from the sodium tetraborate in the heat absorption layer, which has the effect of sealing the joints and preventing a decrease in fire resistance. However, when corner materials are used by overlapping each other on an organic substrate, or when other layers mentioned above (preferably a non-combustible material layer, heat absorption layer, heat foam layer, reinforcing material layer, heat reflection layer, heat shielding layer, heat insulation material layer, etc.) are coated, it is preferable to obtain a coated structure by shifting the joints so that they do not overlap.

[0150] Hereinafter, a covered structure in which the corner portions of a core material formed from the organic base material are covered with the corner material will be described with reference to the drawings.

[0151] 3 to 12 show an example of the covering structure of the present invention.

[0152] In the coated structure of Figure 3, the corner portions of the organic substrate 1 are coated with corner materials 2, and the organic substrate 1 is coated with a heat absorption layer 3 (board-shaped) other than the corner portions, and the surface of that is further coated with a decorative layer 4. Although there are no particular limitations on such a coated structure, it can be obtained by first coating the corner portions of the organic substrate 1 with a corner material 2, then coating the portions other than the corner portions with a heat absorption layer 3, and then coating the surface thereof with a decorative layer 4. In such a structure, corner material 2 (corner angle: 90°) is coated along the corner portion (corner angle: 90°) of organic substrate 1, and by using corner material 2 with the same thickness as heat absorption layer 3, the surface formed by corner material 2 and heat absorption layer 3 can be made flat and step-free, allowing for easy coating of board-shaped decorative layer 4. In this case, there can be no voids inside decorative layer 4 around the entire periphery, including the corner portion, and strength can also be increased. Corner materials such as corner material 2 with a 90° corner angle are preferred because they are easy to manufacture. Alternatively, after the corner portions of the organic substrate 1 are covered with the corner material 2, a laminate of the heat-absorbing layer 3 and the decorative layer 4 that has been produced in advance can be covered. Each material can be coated using a known adhesive or fasteners such as nails, screws, tacks, pins, bolts, staples, etc.

[0153] In the coated structure of Figure 4, an organic substrate 1 is coated with a non-combustible material layer 5, the corners of which are coated with corner materials 2, and the areas other than the corners are coated with a heat-absorbing layer 3, and the surface of these is further coated with a thermal foam layer 6 and a decorative layer 4 in that order.

[0154] In the coated structure of Figure 5, the corner portions of the organic substrate 1 are coated with corner materials 2, and the organic substrate 1 is coated with a heat absorption layer 3 other than the corner portions, and the surface thereof is further coated with a thermal foam layer 6 and a decorative layer 4 in that order.

[0155] In the coated structure of Figure 6, an organic substrate 1 is coated with a non-combustible material layer 5, the corners of which are coated with corner materials 2, and the rest of the surface is coated with a heat-absorbing layer 3. The corners of the surface are coated with corner materials 2, and the rest of the surface is coated with a heat-absorbing layer 3 again, and the surface is then coated with a thermal foam layer 6 and a decorative layer 4 in that order.

[0156] In the coated structure shown in FIG. 7 , an organic substrate 1 is coated with a non-combustible material layer 5, and curved corner members 2 are coated on the corners of the non-combustible material layer 5. The area other than the corners is coated with two heat-absorbing layers 3, which are then coated with a thermally foamed layer 6 and a decorative layer 4, in that order. In this structure, the thermally foamed layer 6 can be easily coated along the curve of the corner members 2, and the corner seams of the thermally foamed layer 6 can be easily avoided. This structure further suppresses heat penetration through the corner seams, resulting in superior fire resistance. This is particularly preferable because the thermally foamed layer 6 can be easily coated along the curve of the corner members 2, even when the thermally foamed layer 6 is thick or has low flexibility. Furthermore, the thickness of the thermally foamed layer 6 at the corners is consistent, which makes it easier to form a carbonized insulating layer of consistent thickness even at the corners in the event of a fire, resulting in superior fire resistance.

[0157] In the coated structure of Figure 8, the corner portions of the organic substrate 1 are coated with corner materials 2, and the organic substrate 1 is coated with a non-combustible material layer 5 other than the corner portions, and the surface thereof is further coated with a thermal foam layer 6 and a decorative layer 4 in that order.

[0158] In the coated structure of Figure 9, an organic substrate 1 is coated with a non-combustible material layer 5, the corner portions of which are coated with corner materials 2, and the non-combustible material layer 5 is coated on the portions other than the corner portions, and further coated on the surface thereof with a thermal foam layer 6 and a decorative layer 4 in that order.

[0159] In the coated structure of Figure 10, an organic substrate 1 is coated with a non-combustible material layer 5, the corner portions of which are coated with corner materials 2, and the area other than the corner portions is coated with a non-combustible material layer 5, and the corner portions of the surface of the corner material 2 are further coated with corner materials 2, and the area other than the corner portions is again coated with a non-combustible material layer 5, and the surface of this structure is further coated with a thermal foam layer 6 and a decorative layer 4 in that order.

[0160] In the coated structure of Figure 11, the corner portions of the organic substrate 1 are coated with corner materials 2, and the portions other than the corner portions are coated in order with a non-combustible material layer 5 and a heat absorption layer 3, and further coated on the surface thereof in order with a thermal foam layer 6 and a decorative layer 4.

[0161] In the coated structure of Figure 12, the corner portions of the organic substrate 1 are coated with corner materials 2, and the rest of the structure is coated with a non-combustible material layer 5, and further coated on the surface thereof with a thermal foam layer 6 and a decorative layer 4 in that order.

[0162] The corner material of the present invention can be used in applications requiring fire resistance, for example, in various fields such as construction and civil engineering. When used as a building material, it can be applied to corners of pillars, beams, etc., and is particularly preferably applied to structural frameworks such as pillars and beams.

[0163] Furthermore, the covered structure of the present invention has excellent fire resistance, etc., since the corner portions of the core material formed from an organic base material are covered with the corner material. In particular, since the corner material has a seamless structure, it is possible to suppress the temperature rise in the corner portions, which are prone to heat penetration (transmission), when the temperature rises during a fire, etc. [Example]

[0164] The following examples and comparative examples will be presented to clarify the features of the present invention, but the present invention should not be construed as being limited to these examples.

[0165] The following materials were used to construct the corner members used as test specimens.

[0166] Example 1 [Corner material manufacturing] (Heat absorption layer first component): 50 parts by mass of unsaturated polyester resin (unsaturated polyester / styrene (mass ratio 60 / 40)), 50 parts by mass of sodium tetraborate decahydrate (Heat absorption layer second constituent component): 1 part by mass of methyl ethyl peroxide The mixture of the first component of the heat absorption layer and the second component of the heat absorption layer was poured into a formwork and hardened to produce an L-shaped corner material having a longitudinal length (Figure 1(1): L) of 1000 mm, a cross-sectional side length (Figure 1(2): H) of 35 mm, and a thickness (Figure 1(2): T) of 12.5 mm. The corner material was then cut to a longitudinal length of 100 mm to obtain an L-shaped corner material.

[0167] [Manufacturing of test specimens] The manufactured corner material (thickness: 12.5 mm, length in the longitudinal direction: 100 mm, length of one side of the cross section: 35 mm) was coated on two sides of one corner of a wooden base material (height: 100 mm, length of one side of the cross section: 70 mm, square pillar) using vinyl acetate resin adhesive, and reinforced gypsum board (thickness: 12.5 mm, height: 100 mm, width: 35 mm) was fixed to the part of the wooden base material other than the corner using screws to create a test specimen. A thermocouple was installed between the corner portion of the wood base material and the corner material. A fire resistance test was carried out using this test specimen, and it took 40 minutes for the temperature of the corner portion to reach 200°C.

[0168] (Comparative Example 1) Two reinforced gypsum boards (thickness: 12.5 mm, height: 100 mm, width: 82.5 mm) were fixed to two sides of one corner of a wooden substrate (height: 100 mm, length of one side of cross section: 70 mm, square pillar) using screws to create a test specimen. Thermocouples were installed between the corners of the wood substrate and the reinforced gypsum board. A fire resistance test was carried out using this test specimen, and it took 24 minutes for the temperature of the corner portion to reach 200°C.

[0169] (Fire resistance test) Using a cone calorimeter specified in ISO 5660, the test specimens were placed as shown in Figure 13, and a heating test was performed, measuring the temperature at the corners of each specimen with a thermocouple. The distance from the bottom of the cone heater to the corners was set to 25 mm.

[0170] From the above fire resistance test, in Comparative Example 1, the time from the start of the fire resistance test to reach 200°C was 24 minutes, whereas in Example 1, the time from the start of the fire resistance test to reach 200°C was 40 minutes, demonstrating the usefulness of fire resistance.

[0171] In addition, in order to further improve the fire resistance of the corner material of the present invention, methods such as increasing the sodium tetraborate content in the corner material, increasing the thickness of the corner material, and laminating other layers (e.g., a non-combustible material layer, a heat-absorbing layer, a thermal foam layer, a reinforcing material layer, a heat-reflecting layer, a heat-shielding layer, a heat-insulating material layer, etc.) that are used in places other than the corner portion and are not used in the corner material can be mentioned.

Claims

1. A corner material having fire resistance, a binder and a heat-absorbing layer formed by sodium tetraborate; Corner material with a seamless structure.

2. the binder is an organic binder, 2. The corner material according to claim 1, wherein the sodium tetraborate comprises sodium tetraborate decahydrate.

3. A covered structure in which corner portions of a core material formed from an organic base material are covered with the corner material according to claim 1 or 2.

4. 4. The covered structure according to claim 3, wherein the organic substrate is a wood substrate and / or a plastic substrate.

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