Covering structure and method for forming the same

Abstract

This invention provides a covering structure with improved workability, heat resistance, and other properties. [Solution] The present invention provides a covering structure in which a base material is surrounded by a plurality of laminates, wherein at least a heat reflective layer, a heat absorbing layer, and a heat foaming layer are laminated in order, and the laminates are installed on the base material such that the heat absorbing layer side of the laminates faces the base material and the heat foaming layer side faces outward, and the laminates are installed on the base material using fasteners. Furthermore, the base material is a rectangular base material with a square cross-section, and in a cross-sectional view of the rectangular base material, a plurality of the laminates are installed along the outside of each side of the rectangular base material, and at the corners of the rectangular base material, the back surface of one laminate and the side surface of the other laminate are in contact.

Description

Technical Field

[0001] The present invention relates to a novel coating structure and a method for forming the same.

Background Art

[0002] Conventionally, in building structures, for the purpose of protecting buildings from fire, it has been required to make main structures such as columns and beams into heat-resistant structures. As one method of applying a heat-resistant structure, there is a method of coating a base material such as a main structure with a material that foams by heat (a heat-expandable coating material). The heat-expandable coating material is thin and lightweight under normal conditions, and when the temperature rises due to a fire or the like, it foams and carbonizes to form a heat-insulating layer, thereby exhibiting heat-resistant protection.

[0003] Regarding coating structures using such heat-expandable coating materials, various proposals have been made. As an example, Patent Document 1 describes obtaining a coating structure by coating the periphery of a long wooden base material having a rectangular cross-section with a heat-expandable coating material, further applying an adhesive to each outer surface thereof, and then joining incombustible sheet pieces.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, in the above patent document, the process of obtaining a coating structure is complicated, and there is still room for improvement in terms of heat-resistant protection.

Means for Solving the Problems

[0006] The present invention has been made in view of the above problems, and an object thereof is to provide a coating structure excellent in workability, heat-resistant protection, and the like.

[0007] As a result of diligent research to solve the above problems, the inventors conceived of a coating structure using multiple specific laminates and a method for forming the same, leading to the completion of the present invention.

[0008] In other words, the present invention has the following features. 1. A covering structure in which the periphery of the base material is surrounded by multiple laminates, The above laminate is formed by sequentially laminating at least a heat-reflective layer, a heat-absorbing layer, and a heat-foaming layer. (However, this excludes the air layer.) dea the law of nature, A laminate formed by bonding the above heat reflective layer and the above heat absorbing layer, and bonding the above heat absorbing layer and the above heat foaming layer, That is A covering structure characterized by the following: 2. The coating structure according to 1., characterized in that the laminate is installed on the substrate such that the heat-absorbing layer side of the laminate faces the substrate and the thermal foaming layer side faces outward. 3. The covering structure according to 2., characterized in that the laminate is installed on a substrate using fasteners. 4. The above-mentioned substrate is a rectangular substrate with a square cross-section. In a cross-sectional view of the above-mentioned rectangular substrate, a plurality of the above-mentioned laminates are installed along the outer edges of each side of the rectangular substrate. At the corners of the above-mentioned rectangular substrate, the back surface of one laminate and the side surface of the other laminate are in contact. The covering structure according to 1., characterized by the above. 5. The coating structure according to 4, characterized in that a heat reflective layer and / or a heat foaming layer are provided on the side surface exposed to the outside of the laminate. 6. A method for forming a covering structure in which the periphery of a substrate is surrounded by multiple laminates, The above laminate is formed by sequentially laminating at least a heat-reflective layer, a heat-absorbing layer, and a heat-foaming layer. (However, this excludes the air layer.) And, The above heat-reflective layer and the above heat-absorbing layer are bonded together, and the above heat-absorbing layer and the above heat-foaming layer are bonded together to form a laminate. A method for forming a covering structure, characterized by installing a plurality of the above-mentioned laminates around the above-mentioned base material. 7. A method for forming a coating structure according to 6., characterized in that the laminate is installed on a substrate such that the heat-absorbing layer side of the laminate faces the substrate and the heat-foaming layer side faces outwards. 8. The method for forming the covering structure according to 7, characterized in that the laminate is installed on a substrate using a fastener. 9. The above-mentioned substrate is a rectangular substrate with a square cross-section. In a cross-sectional view of the above-mentioned rectangular substrate, a plurality of the above-mentioned laminates are installed along the outer edges of each side of the rectangular substrate, At the corners of the rectangular base material, it is installed such that the back surface of one laminate contacts the side surface of the other laminate. characterized by 6. the method for forming the coating structure described above. 10. A method for forming a coating structure according to 9, characterized in that a heat reflective layer and / or a heat foamed layer are provided on the side surface exposed to the outside of the laminate.

Effect of the Invention

[0009] According to the present invention, a coating structure excellent in workability, heat protection property, etc. can be obtained.

Brief Description of the Drawings

[0010] [Figure 1] It is a cross-sectional view showing an example of the laminate of the present invention. [Figure 2] It is a cross-sectional view showing an example of the laminate of the present invention. [Figure 3] It is a cross-sectional view showing an example of the coating structure of the present invention. [Figure 4] It is a cross-sectional view showing an example of the coating structure of the present invention. [Figure 5] It is a cross-sectional view showing an example of the coating structure of the present invention.

Explanation of Reference Numerals

[0011] 1, 11 to 18: laminate 2: heat absorption layer 3, 4: thermal foam layer 5, 6: adhesive layer 7: heat reflection layer 8: base material

Mode for Carrying Out the Invention

[0012] Hereinafter, the mode for carrying out the present invention will be described.

[0013] The coating structure of the present invention is characterized in that the periphery of a base material is surrounded by multiple laminates, and the laminates are made up of at least a heat-absorbing layer and a thermal foaming layer. In the present invention, by surrounding the base material with such specific laminates, a coating structure can be efficiently obtained, resulting in excellent workability. Furthermore, the combined action of the heat-absorbing layer and the thermal foaming layer constituting the laminate provides excellent heat-resistant protection.

[0014] [Base material] Examples of base materials include columns, beams, and other elements that constitute structures such as buildings and civil engineering structures. Such base materials may be made of materials such as cement-based materials, plastics, wood materials, and metals. The shape of these base materials is preferably elongated, and their cross-sectional shapes may be circular, polygonal (square, etc.). The present invention is particularly useful when the base material is a rectangular base material with a square cross-section, and can be preferably applied to, for example, a rectangular wood base material.

[0015] [Laminated structure] The laminate of the present invention comprises at least a heat-absorbing layer and a thermal foaming layer. The laminate of the present invention can be configured to have one of each of these layers, or to have multiple layers of any one of them, and so on.

[0016] In the present invention, the heat-absorbing layer can be one that exhibits an endothermic effect when the temperature rises. Preferably, the heat-absorbing layer is a layer having bound water and / or free water, and such a heat-absorbing layer can absorb heat by dehydrating (evaporating, etc.) bound water and / or free water when the temperature rises. Here, bound water is water that is bound to the components constituting the heat-absorbing layer, and examples include hydration water, crystal water, and adsorbed water. On the other hand, free water is water other than bound water that is contained in the heat-absorbing layer without being bound to the components constituting the heat-absorbing layer.

[0017] Examples of materials that constitute the heat-absorbing layer include hardened products made from cement, gypsum, etc. (e.g., mortar, concrete, gypsum board, etc.), hardened products made from calcium silicate, etc. (e.g., calcium silicate board, etc.), or boards, sheets, hardened products containing superabsorbent polymers, hydrogels, etc. These can be used individually or in combination of two or more types.

[0018] In this invention, one example of a suitable material for constituting the heat-absorbing layer is gypsum board. Gypsum board typically contains calcium sulfate dihydrate as its main component, and therefore contains a large amount of bound water, exhibiting an endothermic effect in the temperature range of 100 to 200°C. As such, it can exhibit a stable endothermic effect when the temperature rises due to flames or heat. In addition to general gypsum board, non-combustible laminated gypsum board (gypsum board using non-combustible base paper as the cover), reinforced gypsum board (gypsum board with gypsum mixed with inorganic fibers such as glass fibers as the core material), and glass fiber nonwoven gypsum board (gypsum board with gypsum mixed with glass fibers as the core material, with glass fiber nonwoven fabric inserted on the front and back surfaces) can be used.

[0019] The thickness of the heat-absorbing layer is preferably 1 to 30 mm, more preferably 3 to 28 mm, and even more preferably 5 to 25 mm, from the viewpoint of thermal insulation, heat protection, strength, and light weight. In this invention, "a to b" is synonymous with "a or more and b or less".

[0020] As a thermal foaming layer, one can be used in which, 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, it foams due to the action of the various raw materials constituting the thermal foaming layer, forming a carbonized insulation layer.

[0021] The foaming temperature of the thermal foaming layer is preferably 150°C or higher, more preferably 180°C or higher, and even more preferably 200-400°C, from the standpoint of temperature rise due to flames or heat.

[0022] The thermal foam layer can be formed, for example, by a thermal foam coating material or a thermal foam sheet, and these can also be used in combination.

[0023] The thermal foam layer is preferably composed of a mixture of components including a resin component, a flame retardant, a blowing agent, a carbonizing agent, and a filler. Examples of the resin component include thermoplastic resins such as acrylic resin, acrylic styrene resin, vinyl acetate resin, and ethylene vinyl acetate resin. Examples of flame retardants include ammonium polyphosphate, and examples of blowing agents include melamine, dicyandiamide, and azodicarbonamide. Examples of carbonizing agents include pentaerythritol and dipentaerythritol, and examples of fillers include titanium dioxide, calcium carbonate, and inorganic fibers. These components can be used individually or in combination of two or more.

[0024] From the viewpoint of heat protection and other factors, the mixing ratio (weight ratio) of each component constituting the heat-foamed layer is preferably, in terms of solid content, 200 to 600 parts by weight of flame retardant, 40 to 150 parts by weight of foaming agent, 40 to 150 parts by weight of carbonizing agent, and 50 to 160 parts by weight of filler, per 100 parts by weight of resin component.

[0025] The mixture forming the thermal foam layer may include various additives in addition to the above components, as needed. The additives should not significantly impair the effects of the present invention, and examples include pigments, fibers, wetting agents, plasticizers, lubricants, preservatives, antifungal agents, antialgal agents, antibacterial agents, thickeners, dispersants, defoaming agents, crosslinking agents, ultraviolet absorbers, light stabilizers, antioxidants, diluent solvents, and the like.

[0026] The heat-expandable coating material used to form the heat-expandable layer can be used as a liquid mixture containing the above-mentioned components and additives. Furthermore, the heat-expandable sheet used to form the heat-expandable layer can be a sheet formed from the mixture containing the above-mentioned components and additives.

[0027] The thickness of the heat-foamed layer can be set appropriately depending on the application, but from the viewpoint of heat protection and light weight, it is preferably 0.1 to 10 mm, more preferably 0.3 to 8 mm, and even more preferably 0.5 to 6 mm.

[0028] The thermal foam layer may consist solely of a mixture containing the above-mentioned components and additives, or it may have a fibrous sheet or the like laminated on its surface or back surface. As such a fibrous sheet, for example, a known sheet containing organic fibers and / or inorganic fibers can be used.

[0029] Figure 1 shows an example (cross-sectional view) of the laminate of the present invention. In the laminates shown in Figures 1(a) and (b), the heat-absorbing layer 2 and the thermal foaming layer 3 are laminated in that order.

[0030] In Figure 1(a), the heat-absorbing layer 2 and the thermal foaming layer 3 are bonded together via an adhesive layer 5. In this case, a thermal foaming sheet or the like can be used as the thermal foaming layer 3.

[0031] In Figure 1(b), a thermal foam layer 3 is formed on the surface of the heat-absorbing layer 2 by applying a thermal foam coating material.

[0032] In the present invention, for example, as shown in Figure 1(a), each layer can be bonded together using an adhesive. As the adhesive, known adhesives such as water-dispersible, water-soluble, and solvent-based adhesives mainly composed of acrylic resin, silicone resin, epoxy resin, vinyl resin, phenolic resin, polyester resin, urethane resin, paraffin, etc. may be used. The adhesive may be compounded with additives such as flame retardants, foaming agents, carbonizing agents, and fillers, as necessary, similar to those compounded in the aforementioned heat-expandable layer. In this invention, the term "adhesive" also includes adhesives.

[0033] In the laminates shown in Figures 1(a) and 1(b), when the thermal foaming layer expands to form a carbonized insulation layer, it is possible to maintain the shape of the carbonized insulation layer and prevent it from falling off, thereby stably obtaining effects such as heat resistance protection.

[0034] Figure 2 shows another example (cross-sectional view) of the laminate of the present invention. In the laminates of Figures 2(c) and (d), the heat reflective layer 7, the heat-absorbing layer 2, and the heat-foamed layer 3 are laminated in that order. In the present invention, by laminating the heat reflective layer, the heat-resistant protection can be further enhanced by its heat shielding effect, etc.

[0035] As the heat reflective layer, for example, a metal plate, sheet, or tape with high heat reflectivity can be used. Examples of metals that make up the heat reflective layer include aluminum, copper, and silver, with aluminum being preferred among these. Specifically, examples of heat reflective layers 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. For example, when using aluminum tape, a tape with an adhesive layer formed on one side of the aluminum layer can be used. These can be used individually or in combination of two or more types.

[0036] The thickness of the heat reflective layer is preferably 0.01 to 1 mm, more preferably 0.02 to 0.5 mm, and even more preferably 0.03 to 0.1 mm, from the viewpoint of heat reflectivity, heat protection, and lightweight properties.

[0037] In Figure 2(c), the heat reflective layer 7 and the heat-absorbing layer 2 are bonded together via an adhesive layer 6, and the heat-absorbing layer 2 and the thermal foaming layer 3 are bonded together via an adhesive layer 5. In this case, a thermal foaming sheet or the like can be used as the thermal foaming layer 3.

[0038] In Figure 2(d), the heat reflective layer 7 and the heat-absorbing layer 2 are bonded together via an adhesive layer 6, and a heat-foamed layer 3 is formed on the surface of the heat-absorbing layer 2 by coating it with a heat-foaming coating material.

[0039] In the laminates shown in Figures 2(c) and (d), when the thermal foaming layer expands to form a carbonized insulation layer, it is possible to maintain the shape of the carbonized insulation layer and prevent it from falling off, thereby stably obtaining effects such as heat resistance protection.

[0040] [Covered structure] The coating structure of the present invention is formed by using multiple of the above-mentioned laminates to coat the periphery of a substrate.

[0041] In this invention, the laminate is installed on the substrate so that the heat-absorbing layer side of the laminate faces the substrate and the heat-foamed layer side faces outward. Each laminate can be installed on the substrate using fasteners such as nails, screws, rivets, pins, bolts, or staples. This makes it possible to efficiently obtain a covering structure in which at least a heat-absorbing layer and a heat-foamed layer are laminated in order on the substrate, which is advantageous in terms of workability. Furthermore, by laminating each layer in the above order, the effect of suppressing temperature rise due to heat such as fire is enhanced, excellent effects in heat resistance and protection are exhibited, and the reduction in strength of the substrate can be suppressed. In addition, it is possible to exhibit performance in preventing the detachment of the carbonized insulation layer, and effects such as heat resistance and protection can be obtained stably.

[0042] Figures 3 and 4 show an example (cross-sectional view) of the coating structure of the present invention. In Figures 3 and 4, multiple laminates are installed around the perimeter of a rectangular substrate with a rectangular cross-section, along the outside of each side of the rectangular substrate in a cross-sectional view. At the corners of the rectangular substrate where the laminates meet, the laminates are installed so that the back surface of one laminate is in contact with the side surface of the other laminate. Although Figures 3 and 4 show an example of a coating structure with the laminates shown in Figure 2(c), the same method can be used to obtain coating structures with the laminates shown in Figures 1(a), 1(b), 2(d), etc.

[0043] Specifically, in the covering structure shown in Figure 3, four laminates are placed along the outside of the four sides of the base material 8 (square base material) in a cross-sectional view. Of these, laminates 11 and 13 have a size equal to the length of one side (left side, right side) of the square base material, while laminates 12 and 14 have a size equal to the sum of the length of one side (top side, bottom side) of the square base material and the thickness of two laminates (laminated laminates 11 and 13).

[0044] At the upper left corner where laminates 11 and 12 meet, the back surface of laminate 12 is in contact with the side surface of laminate 11. At the upper right corner where laminates 12 and 13 meet, the back surface of laminate 12 is in contact with the side surface of laminate 13. At the lower right corner where laminates 13 and 14 meet, the back surface of laminate 14 is in contact with the side surface of laminate 13. At the lower left corner where laminates 14 and 11 meet, the back surface of laminate 14 is in contact with the side surface of laminate 11. As a result, the entire perimeter of the rectangular substrate is covered by the laminate.

[0045] When the covering structure shown in Figure 3 is exposed to high temperatures due to fire or other reasons, the thermal foaming layer 3 foams up to form a carbonized insulating layer, the heat-absorbing layer 2 exhibits insulating properties, and the heat-reflective layer 7 exhibits heat-shielding properties, thereby suppressing the temperature rise of the base material 8 and maintaining its strength.

[0046] In the covering structure shown in Figure 4, four laminates 15-18 are placed along the outside of the four sides of the base material 8 (square base material) in a cross-sectional view. Each laminate has a size equal to the sum of the length of one side of the square base material and the thickness of one laminate.

[0047] Furthermore, at each corner of the rectangular substrate where the laminates meet, the back surface of one laminate and the side surface of the other laminate are in contact. As a result, the entire perimeter of the rectangular substrate is covered by the laminate. In Figure 4, if the cross-section of the substrate 8 is square, the four laminates (laminated 15-18) can be set to the same size, which is even more advantageous in terms of ease of installation.

[0048] Such a covering structure can be obtained, for example, by the following method. (1) A 50 μm thick aluminum sheet (heat reflective layer) is attached to the back side of an 8 mm thick gypsum board (heat absorbing layer) using an adhesive, and a 3 mm thick heat-expandable sheet (heat-expanded layer) is attached to the front side of the gypsum board using an acrylic adhesive to create the laminate shown in Figure 2(c). (2) As shown in Figure 4, the four laminates are fixed to a square-shaped wooden base material with a square cross-section using staples.

[0049] When the covering structure shown in Figure 4 is exposed to high temperatures due to fire or other reasons, the thermal foaming layer 3 foams up to form a carbonized insulating layer, the heat-absorbing layer 2 exhibits an insulating effect, and the heat-reflective layer 7 exhibits a heat-shielding effect, thereby suppressing the temperature rise of the base material 8 and maintaining its strength.

[0050] In Figure 3, the sides (heat-absorbing layers) of laminates 12 and 14 are exposed to the outside. In Figure 4, one side (heat-absorbing layer) of each of laminates 15 to 18 is exposed to the outside. In the present invention, a heat-reflective layer, a heat-foamed layer, etc., can also be provided on the exposed sides in this manner. For example, the above-mentioned sides can be provided with a heat-foamed layer, a heat-reflective layer, or both.

[0051] In Figure 5, a thermal foam layer 4 (a narrow thermal foam layer) is provided on one side of each of the laminates 15 to 18. The thermal foam layer 4 can be a thermal foam coating material, thermal foam sheet, or thermal foam tape, similar to the thermal foam layer 3. The thermal foam layer 4 may be provided in advance during the manufacturing of the laminate, or it can be provided after the covering structure shown in Figure 4 has been formed. The thermal foam layer 3 and the thermal foam layer 4 can also be in a continuous form.

[0052] The joints between laminates (where laminates meet) can be treated as appropriate. Examples of such joint treatment methods include covering (straddling) the joint with a heat-expandable coating material or heat-expandable sheet, filling the joint with a heat-expandable putty, or installing a fibrous reinforcing material that straddles the joint. Two or more of these treatment methods can also be combined. Furthermore, when a heat-expandable layer (a narrow heat-expandable layer) is provided on the side of the laminate, a heat-expandable layer wider than the thickness of the laminate can be used to straddle the joints between the laminates. The heat-expandable layer or fibrous reinforcing material that straddles the joint can also be flattened by heating, pressing, or other treatments.

[0053] In the longitudinal direction of the substrate, the laminates can be installed butted together so that they are adjacent to each other. The joints between the laminates can be treated as needed. The methods described above can be used for treating the joints.

[0054] In the coating structure of the present invention, a decorative layer may be provided on the outside of the heat-foamed layer as needed. The decorative layer only needs to be one that does not hinder the foaming of the heat-foamed layer. Various types of decorative layers can be used, exhibiting appearances such as transparent or opaque, colorless or colored, matte or glossy, single-color or multi-colored, flat or uneven, etc. In the present invention, by providing a decorative layer, the aesthetics, water resistance, weather resistance, etc. of the coating structure can be improved.

[0055] The decorative layer can be pre-formed during the manufacturing of the laminate, for example, or it can be formed after the covering structure shown in Figures 3-5 has been formed. The decorative layer can be formed by known methods, such as painting various coating materials or attaching films, sheets, etc. Multiple materials can also be laminated as the decorative layer.

[0056] The coating structure of the present invention can be applied to applications requiring heat protection in various fields such as architecture and civil engineering. When used as a building material, it can be applied to columns, beams, etc. The coating structure of the present invention can exhibit heat protection (fire resistance) that meets the specified conditions in tests specified in JIS A1304:2017, for example. Such performance can be appropriately adjusted by selecting the type and thickness of the heat-absorbing layer, thermal foaming layer, heat-reflective layer, etc.

Claims

1. A covering structure in which the periphery of the base material is surrounded by multiple laminates, The above laminate consists of at least a heat-reflective layer, a heat-absorbing layer, and a heat-foaming layer laminated in that order (excluding an air layer). A laminate formed by bonding the above heat reflective layer and the above heat absorbing layer, and bonding the above heat absorbing layer and the above heat foaming layer, A covering structure characterized by being such.

2. The coating structure according to Claim 1, characterized in that the laminate is installed on the substrate such that the heat-absorbing layer side of the laminate faces the substrate and the heat-foaming layer side faces outward.

3. The coating structure according to claim 2, characterized in that the laminate is installed on a substrate using a fastener.

4. The above-mentioned substrate is a rectangular substrate with a square cross-section. In a cross-sectional view of the above-mentioned rectangular substrate, a plurality of the above-mentioned laminates are installed along the outer edges of each side of the rectangular substrate. At the corners of the above-mentioned rectangular substrate, the back surface of one laminate and the side surface of the other laminate are in contact. The coating structure according to claim 1, characterized in that it is a coating structure according to claim 1.

5. The coating structure according to claim 4, characterized in that a heat reflective layer and / or a heat foaming layer are provided on the side surface exposed to the outside of the laminate.

6. A method for forming a covering structure in which the periphery of a substrate is surrounded by multiple laminates, The above laminate consists of at least a heat-reflective layer, a heat-absorbing layer, and a heat-foaming layer laminated in that order (excluding an air layer). The above heat-reflective layer and the above heat-absorbing layer are bonded together, and the above heat-absorbing layer and the above heat-foaming layer are bonded together to form a laminate. A method for forming a covering structure, characterized by installing a plurality of the above-mentioned laminates around the above-mentioned base material.

7. The method for forming a coating structure according to claim 6, characterized in that the laminate is installed on a substrate such that the heat-absorbing layer side of the laminate faces the substrate and the heat-foaming layer side faces outwards.

8. The method for forming a coating structure according to claim 7, characterized in that the laminate is installed on a substrate using a fastener.

9. The above-mentioned substrate is a rectangular substrate with a square cross-section. In a cross-sectional view of the above-mentioned rectangular substrate, a plurality of the above-mentioned laminates are installed along the outer edges of each side of the rectangular substrate, At the corners of the above-mentioned rectangular substrate, the back surface of one laminate and the side surface of the other laminate are placed in contact. A method for forming a coating structure according to claim 6, characterized in that it is a method for forming a coating structure according to claim 6.

10. The method for forming a coating structure according to claim 9, characterized in that a heat reflective layer and / or a heat foamed layer are provided on the side surface of the laminate that is exposed to the outside.

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