Coating equipment

Abstract

To provide a coating apparatus capable of applying coating materials with high precision. [Solution] A coating apparatus for applying a coating material to an object to be coated, comprising a nozzle 10A for discharging the coating material onto the object to be coated, and a coating material supply passage 20 for supplying the coating material to the nozzle 10A, wherein the nozzle 10A has thickness adjustment sections 12A1 and 12A2 for adjusting the coating thickness of the coating material, and the thickness adjustment sections 12A1 and 12A2 constitute at least a part of the discharge port 11 for discharging the coating material.

Description

Technical Field

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[0003]

[0001] The present invention relates to a coating apparatus for coating a coating material onto an object to be coated.

Background Art

[0002] In the construction field, for fire prevention, refractory materials are arranged on building materials such as fittings, columns, and wall materials. Conventionally, various types of refractory materials have been developed, and a thermally expandable refractory material that expands upon heating may be used. The thermally expandable refractory material forms an expansion residue obtained by expansion upon heating to form a refractory heat insulation layer and exhibits refractory heat insulation performance, so it can prevent the occurrence of a fire and the spread of fire when a fire occurs. As the thermally expandable refractory material, for example, as described in Patent Document 1, those containing a resin and a thermally expandable compound such as thermally expandable graphite are widely used (for example, see Patent Document 1). <00 supp> The thermally expandable refractory material is mainly a sheet-shaped molded product laminated on an adhesive layer, and construction is performed by arranging it on building materials or the like through the adhesive layer. As another construction method for arranging the thermally expandable refractory material on building materials, there is a case where the thermally expandable refractory material is directly coated on building materials or the like as a coating material and hardened by heat curing, moisture curing, or the like before being arranged.

[0004] However, in the construction of directly coating the thermally expandable refractory material on building materials or the like, it is difficult to accurately coat the thickness and width of the thermally expandable refractory material as the coating material, and at present, it has not been possible to impart stable fire resistance to building materials or the like. Therefore, in an apparatus for directly coating a coating material, it has been proposed to attach a shaping plate at a position separated rearward from the discharge port of the coating material and sequentially shape the coating material discharged by the shaping plate into a flat shape before curing (for example, see Patent Document 2).

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

[0006] However, when the extruded coating material is shaped into a flat surface using a shaping plate, the coating material scraped off during the shaping process accumulates on the surface of the shaping plate. Any coating material exceeding the capacity of the shaping plate may leak onto building materials, making it difficult to apply the fire-resistant material with precise thickness and width.

[0007] Therefore, the object of the present invention is to provide a coating apparatus capable of applying coating materials with high precision. [Means for solving the problem]

[0008] This invention was made to solve the above problems, and the gist of this invention is as follows. [1] A coating apparatus for coating an object to be coated, comprising a nozzle for discharging the coating material onto the object to be coated, and a coating material supply passage for supplying the coating material to the nozzle, wherein the nozzle has a thickness adjustment section for adjusting the coating thickness of the coating material, and the thickness adjustment section constitutes at least a part of the discharge port for discharging the coating material. [2] The coating apparatus according to [1], wherein the nozzle further has a width adjustment section for adjusting the coating width of the coating material, and the width adjustment section constitutes at least a part of the discharge port. [3] The coating apparatus according to [2], wherein the width adjustment section has a first width adjustment section and a second width adjustment section, and the first width adjustment section and the second width adjustment section are arranged opposite each other so as to correspond to the coating width of the coating material. [4] The coating apparatus according to any one of [1] to [3], wherein the thickness adjustment section is provided at least on the rear side in the coating direction of the coating material at the discharge port. [5] The coating apparatus according to [4], wherein the thickness adjustment portion protrudes from the discharge port on the rear side in the coating direction of the coating material. [6] The coating apparatus according to any one of [1] to [5], wherein the nozzle, when viewed from the discharge port side, has a U-shape in plan view. [7] The coating apparatus according to any one of [1] to [5], wherein the nozzle, when viewed from the discharge port side, has a square shape in plan view. [8] The coating apparatus according to any one of [1] to [7], wherein the coating material is a fire-resistant material. [9] The coating apparatus according to any one of [1] to [7], wherein the coating material contains thermally expandable graphite.

[10] The coating apparatus according to any one of [1] to [7], wherein the coating material comprises a hot melt resin.

[11] The coating apparatus according to any one of [1] to [7], wherein the coating material comprises a modified silicone resin. [Effects of the Invention]

[0009] According to the present invention, it is possible to provide a coating apparatus that can apply coating materials with high precision. [Brief explanation of the drawing]

[0010] [Figure 1] Figure 1(a) is a perspective view of the nozzle of a coating apparatus according to the first embodiment of the present invention, Figure 1(b) is a side view of the nozzle of a coating apparatus according to the first embodiment of the present invention, and Figure 1(c) is a top view of the nozzle of a coating apparatus according to the first embodiment of the present invention. [Figure 2] This is a perspective view showing the thickness adjustment section (top surface) of the nozzle of a coating apparatus according to the first embodiment of the present invention, with the section open. [Figure 3] This is a perspective view showing the coating process of a coating apparatus according to a first embodiment of the present invention. [Figure 4] Figure 4(a) is a perspective view of the nozzle of a coating apparatus according to a second embodiment of the present invention, Figure 4(b) is a side view of the nozzle of a coating apparatus according to a second embodiment of the present invention, and Figure 4(c) is a top view of the nozzle of a coating apparatus according to a second embodiment of the present invention. [Figure 5] Perspective view of the thickness adjustment part (upper surface) of the nozzle of the coating device according to the second embodiment of the present invention, with it open. [Figure 6] Perspective view showing the coating of the coating device according to the second embodiment of the present invention. [Figure 7] Fig. 4(a) is a perspective view of the nozzle of the coating device according to the third embodiment of the present invention, Fig. 4(b) is a side view of the nozzle of the coating device according to the third embodiment of the present invention, and Fig. 4(c) is a top view of the nozzle of the coating device according to the third embodiment of the present invention. [Figure 8] Perspective view of the thickness adjustment part (upper surface) of the nozzle of the coating device according to the third embodiment of the present invention, with it open. [Figure 9] Perspective view showing the coating of the coating device according to the third embodiment of the present invention. [Figure 10] Fig. 10(a) is a perspective view of the nozzle of the coating device according to the fourth embodiment of the present invention, Fig. 10(b) is a side view of the nozzle of the coating device according to the fourth embodiment of the present invention, and Fig. 10(c) is a top view of the nozzle of the coating device according to the fourth embodiment of the present invention. [Figure 11] Perspective view of the thickness adjustment part (upper surface) of the nozzle of the coating device according to the fourth embodiment of the present invention, with it open. [Figure 12] Perspective view showing the coating of the coating device according to the fourth embodiment of the present invention.

Embodiments for Carrying Out the Invention

[0011] Hereinafter, the present invention will be described in more detail using embodiments.

[0012] [First Embodiment] As shown in Figs. 1(a) to (c), the coating device according to the first embodiment of the present invention includes a nozzle 10A that discharges a coating material onto a workpiece, and a coating material supply path 20 that supplies the coating material to the nozzle 10A. A connection section 21 is located at the boundary between the nozzle 10A and the coating material supply path 20. The nozzle 10A and the coating material supply path 20 are connected by the connection section 21, and the coating material is supplied from the coating material supply path 20 to the nozzle 10A through the connection section 21. As shown in Figure 2, the nozzle 10A is provided with a hollow section 14 connecting the connection section 21 and the discharge port 11. The hollow section 14 is filled with coating material flowing in from the connection section 21, and the filled coating material is discharged from the discharge port 11 in a fixed amount.

[0013] The nozzle 10A has thickness adjustment sections 12A1 and 12A2 for adjusting the coating thickness of the coating material, and the thickness adjustment sections 12A1 and 12A2 are arranged opposite each other to correspond to the coating thickness of the coating material. The thickness adjustment sections 12A1 and 12A2 constitute at least a part of the discharge port 11 for discharging the coating material. The thickness adjustment sections 12A1 and 12A2 constitute two opposing sides of the discharge port 11. The thickness adjustment sections 12A1 and 12A2 are arranged on the front and rear sides in the coating direction D of the coating material 40, which will be described later, and can shape two sides of the coating material discharged from the discharge port 11.

[0014] As shown in Figure 3, the coating apparatus of this embodiment applies the coating material 40 to the workpiece 30 with the discharge port 11 positioned above the coating surface of the workpiece 30 at a distance and facing the coating surface. The discharge port 11 discharges the coating material, which has been shaped by the thickness adjustment sections 12A1 and 12A2, so that one side of the discharged coating material contacts the workpiece, and the thickness of the discharged coating material becomes approximately the same as the distance between the two sides of the coating material shaped by the thickness adjustment sections 12A1 and 12A2. In other words, the coating thickness of the coating material is adjusted to a width approximately the same as the distance between the thickness adjustment sections 12A1 and 12A2. The coating thickness of the coating material is not particularly limited, but is preferably 0.1 to 3 mm, more preferably 0.2 to 2.5 mm, and more preferably 0.3 to 2 mm. Since the coating thickness of the coating material is approximately the same as the spacing between the thickness adjustment sections 12A1 and 12A2, the preferred range for the spacing between the thickness adjustment sections 12A1 and 12A2 is also within this range.

[0015] The nozzle 10A further has a width adjustment section that adjusts the coating width of the coating material and also constitutes at least a part of the discharge port 11. In this embodiment, the nozzle 10A has first and second width adjustment sections 13A1 and 13A2 for adjusting the coating width of the coating material, and the first and second width adjustment sections 13A1 and 13A2 are arranged opposite each other so as to correspond to the coating width of the coating material. The width adjustment sections 13A1 and 13A2 constitute two opposing sides of the discharge port 11. The width adjustment sections 13A1 and 13A2 are positioned to sandwich the coating material 40 to be coated from both sides, and can shape two sides of the coating material discharged from the discharge port 11. The discharge port 11 discharges the coating material shaped by the width adjustment sections 13A1 and 13A2 onto the object to be coated, so that the width of the discharged coating material is approximately the same as the distance between the two surfaces of the coating material shaped by the width adjustment sections 13A1 and 13A2. In other words, the coating width of the coating material is adjusted to be approximately the same as the distance between the width adjustment sections 13A1 and 13A2. The coating width of the coating material is not particularly limited, but is 1 to 40 mm, preferably 2 to 30 mm, and more preferably 3 to 25 mm. Since the coating width of the coating material is approximately the same as the spacing between the width adjustment sections 13A1 and 13A2, the preferred range for the spacing between the width adjustment sections 13A1 and 13A2 is also within this range.

[0016] In the coating apparatus of this embodiment, the plan view of the nozzle 10A as seen from the discharge port 11 side is square-shaped. In this embodiment, the thickness adjustment sections 12A1, 12A2 and the width adjustment sections 13A1, 13A2 form a flat surface on the inner surface of the nozzle 10A, and as a result, the plan view of the nozzle 10A as seen from the discharge port 11 side is square-shaped with each side being a straight line. In the nozzle 10A of this embodiment, the cross-sectional shape of the coating material 40 discharged from the discharge port 11 is substantially the same as that of the discharge port 11. Therefore, the coating material 40 discharged from the discharge port 11 in the coating apparatus of this embodiment has a rectangular cross-section, corresponding to the shape of a square.

[0017] Furthermore, when the coating material 40 is discharged from the discharge port 11, the inner surface of the nozzle 10A, which is composed of thickness adjustment sections 12A1, 12A2 and width adjustment sections 13A1, 13A2, should be perpendicular to the object to be coated 30, and the coating material 40 should also be discharged perpendicular to the object to be coated 30 from the discharge port 11. This makes it possible to discharge coating material 40 with higher precision in thickness and width. Furthermore, the thickness of the coating material 40 can be changed by adjusting the spacing between the thickness adjustment sections 12A1 and 12A2, and the width can also be changed by adjusting the spacing between the width adjustment sections 13A1 and 13A2. Therefore, a coating material 40 that is adjusted with high precision and has the desired thickness and width can be easily obtained.

[0018] <Coating Method> In the coating method using the coating apparatus of this embodiment, first, as described above, the nozzle 10A is positioned above the coating surface of the object to be coated 30 with a gap in between. Then, the coating material 40 is supplied from the coating material supply passage 20 through the connection part 21 to the nozzle 10A, and the coating material 40 is discharged from the discharge port 11 of the nozzle 10A to coat the surface of the object to be coated 30. The coating material supply passage 20 is part of the coating apparatus, and the coating material 40 is sent from a tank provided in the coating apparatus, and the liquid coating material 40 is discharged from the nozzle 10A. The nozzle 10A of the coating apparatus of the present invention can be moved in the coating direction D relative to the workpiece 30, thereby positioning the coating material 40 extending in the coating direction D on the coated surface of the workpiece 30. Methods for moving the nozzle 10A in the coating direction D relative to the workpiece 30 include, for example, fixing the workpiece 30 and moving the nozzle 10A in the coating direction D, or fixing the nozzle 10A and moving the workpiece 30 in the opposite direction to the coating direction D. Furthermore, a method can be provided in which the nozzle 10A is moved in the coating direction D and the workpiece 30 is moved in the opposite direction to the coating direction D.

[0019] In the coating method using the coating apparatus of the present invention, the coating material 40 may be heated before discharge. When heating the coating material 40, it is preferable to heat the coating material 40 in a tank. Alternatively, the coating material supply passage 20 may be heated, and the heated coating material 40 may be supplied to the nozzle 10A, and the heated coating material 40 may be discharged from the discharge port 11. When heating the coating material supply passage 20, it is preferable to appropriately install heaters on the outer circumference or inside the coating material supply passage 20. For example, if the coating material 40 is a hot-melt type fire-resistant resin composition, the fire-resistant resin composition can be melted by heating, and the melted fire-resistant resin composition coating material 40 can then be applied to the object to be coated 30. The refractory resin composition is preferably heated to a temperature below the expansion initiation temperature of the thermally expandable graphite when melted, and the heating temperature is, for example, 100°C or more and less than 160°C, preferably 120°C or more and less than 150°C. The expansion initiation temperature of the thermally expandable graphite referred to here is the expansion initiation temperature of the thermally expandable graphite with the lowest expansion initiation temperature when the refractory resin composition contains two or more types of thermally expandable graphite. Furthermore, it is preferable that the temperature is maintained within the above temperature range when discharged from the discharge port 11.

[0020] The coating material 40 applied to the object to be coated 30 may be solidified or cured. The method for solidifying or curing the coating material 40 is not particularly limited and may be appropriately selected depending on the type of resin contained in the refractory resin composition constituting the coating material 40. For example, it may be solidified or cured by leaving it at room temperature (for example, around 0 to 40°C) in the atmosphere, or the curing may be accelerated by heating the refractory resin composition.

[0021] Examples of materials that make up the nozzle 10A include metal and resin materials. Examples of metal materials include one or more alloys of steel, aluminum, copper, stainless steel, tin, lead, etc. Examples of resin materials include resin materials containing at least one of polycarbonate resin, acrylic resin, acrylonitrile-butadiene-styrene resin (ABS resin), polypropylene resin, vinyl chloride resin, and epoxy resin. When dispensing a hot-melt type fire-resistant resin composition, it is preferable that the material making up the nozzle 10A be a metal material from the viewpoint that it is possible to dispensing the fire-resistant resin composition while heating it.

[0022] From the viewpoint of obtaining ease of application and maintaining the cross-sectional shape when discharged from the discharge port 11, the viscosity of the coating material 40 is preferably 10,000 mPa·s or more and 2,000,000 mPa·s or less, more preferably 50,000 mPa·s or more and 1,500,000 mPa·s or less, and even more preferably 100,000 mPa·s or more and 1,000,000 mPa·s or less. The viscosity of the coating material is the viscosity measured with a B-type viscometer at 5 rpm under the same temperature conditions as the liquid temperature of the coating material during application.

[0023] Examples of objects to be coated include various buildings such as detached houses, apartment buildings, high-rise buildings, commercial facilities, and public facilities; building materials such as windows, doors, shoji screens, and other fixtures and components that make up fixtures; various vehicles such as automobiles and trains; ships, aircraft, and electronic equipment. Examples of objects to be coated 30 include materials such as metal, inorganic, resin, and wood. Examples of metallic materials include steel, aluminum, copper, stainless steel, tin, lead, and alloys of one or more of these materials. Examples of inorganic materials include ceramics and porcelain. Examples of resin materials include polyethylene resin, such as high-density polyethylene (HDPE); polypropylene resin, such as homopolypropylene and random polypropylene; polyolefin resin, such as cyclic polyolefin resin; ethylene-vinyl acetate copolymer resin; ABS resin (acrylonitrile-butadiene-styrene copolymer resin); AS resin (acrylonitrile-styrene copolymer resin); polystyrene resin; polyester resin, such as PET resin; polycarbonate resin; polyamide resin; rigid polyurethane resin; acrylic resin, such as polymethyl methacrylate; polyacetal resin; polyphenylene sulfide resin; polyethersulfone resin; polyphenylene oxide resin; polyacrylonitrile resin; polylactic acid; polyamide-imide resin; polyimide resin; polyvinyl chloride resin; and fluororesin. Examples of wooden materials include solid wood and laminated wood from oak, zelkova, beech, horse chestnut, katsura, cherry, magnolia, sen, chestnut, paulownia, teak, and maple.

[0024] From the viewpoint of imparting fire resistance to the object to be coated 30, the coating material 40 is preferably a fire-resistant material. The fire-resistant coating material 40 is preferably made of a fire-resistant resin composition and contains thermally expandable graphite, as described later. By including thermally expandable graphite in the fire-resistant resin composition, it becomes possible to expand at a high expansion ratio in the event of a fire, making it easier to improve fire resistance.

[0025] <Fire-resistant resin composition> The fire-resistant resin composition comprises thermally expandable graphite and resin.

[0026] (Thermally expandable graphite) Thermally expandable graphite is a conventionally known substance that expands when heated. It is produced by treating powders of natural scaly graphite, pyrolysis graphite, quiche graphite, etc., with an inorganic acid and a strong oxidizing agent to generate graphite intercalation compounds, and is a type of crystalline compound that maintains the layered structure of carbon. Examples of inorganic acids include concentrated sulfuric acid, nitric acid, and selenic acid. Examples of strong oxidizing agents include concentrated nitric acid, persulfates, perchloric acid, perchlorates, permanganates, dichromates, and hydrogen peroxide. The thermally expandable graphite obtained by acid treatment as described above may be further neutralized with ammonia, aliphatic lower amines, alkali metal compounds, alkaline earth metal compounds, etc.

[0027] The particle size of the thermally expandable graphite is preferably 20 to 200 mesh. When the particle size of the thermally expandable graphite is within this range, it expands easily, creating large voids, which improves fire resistance. It also improves dispersibility in resin. Thermally expandable graphite has an expansion initiation temperature of, for example, 100 to 200°C, preferably 110 to 160°C. The expansion initiation temperature of thermally expandable graphite can be measured by raising the temperature of the thermally expandable graphite at a constant temperature using a device with a temperature control function and a device that measures the force in the normal direction, and measuring the temperature at which the force in the normal direction rises. The measuring device is not limited as long as it is capable of controlling the measurement temperature and measuring the stress in the normal direction, but for example, a rheometer can be used.

[0028] The amount of thermally expandable graphite in the fire-resistant resin composition may be, for example, 10 to 200 parts by mass per 100 parts by mass of resin, preferably 20 to 150 parts by mass, and more preferably 25 to 100 parts by mass. If the amount of thermally expandable graphite is above the lower limit, it becomes easier to increase the expansion pressure of the fire-resistant material, for example, making it easier to exhibit excellent fire-resistant performance in the event of a fire. On the other hand, if the amount of thermally expandable graphite is below the upper limit, the shape retention and processability will be improved.

[0029] (resin) The heat-expandable fire-resistant material composition contains a resin. By forming the coating material 40 with a heat-expandable resin composition containing a resin, it becomes easy to adjust the coating thickness and width of the coating material 40. The resin may be a curable resin such as a thermosetting resin or a moisture-curing resin, or a thermoplastic resin. The curable resin may be a one-component curable resin or a two-component curable resin. Furthermore, the resin may be an emulsion dispersed in an organic solvent or water, or a solvent-based resin dissolved in a solvent. Among these, it is preferable to use a thermoplastic resin, and if a thermoplastic resin is used, it is more preferable that the resin be a hot-melt type resin.

[0030] (Hot melt type resin) Hot-melt resins are non-fluid at room temperature but become fluid when heated. Furthermore, heated hot-melt resins solidify again when cooled. The heat-expandable refractory material composition of the present invention, by containing a hot-melt resin, becomes a hot-melt composition. When a hot-melt resin is used as the resin in a heat-expandable fire-resistant material composition, it becomes easier to maintain good adhesion to the coated object not only before combustion but also after combustion. As a result, the expanded residue after combustion can continue to adhere to the coated object, resulting in better fire resistance. Furthermore, by using a hot-melt resin, the heat-expandable fire-resistant composition can cool and solidify immediately when left at room temperature after coating, resulting in improved workability. In addition, immediate solidification after coating makes it easier to improve the thickness and width accuracy of the coated material.

[0031] As the hot-melt resin, resins conventionally used as the main component of hot-melt adhesives (hereinafter also referred to as "main component resin") can be used. Specifically, resins such as ethylene-vinyl acetate copolymer resin (EVA), ethylene-(meth)acrylic acid ester copolymer resin, polyolefin resin, and rubber can be used. Examples of polyolefin resins include at least one olefin copolymer obtained by copolymerizing ethylene with an α-olefin having 3 to 20 carbon atoms. Examples of rubbers used in hot-melt resins include dienes such as butadiene, styrene-butadiene, chloroprene, and butadiene-acrylonitrile; non-dienes such as isobutylene-isoprene and ethylene-propylene; and thermoplastics (also called thermoplastic elastomers) such as styrene, olefin, ester, and urethane. Among these, ethylene-vinyl acetate copolymer resin (EVA) and ethylene-(meth)acrylic acid ester copolymer resin are preferred, with EVA being more preferred. In hot-melt type resins, the main resin may be used alone or in combination of two or more types.

[0032] The hot-melt type resin preferably contains a tackifying resin in addition to the main resin mentioned above. Examples of tackifying resins include rosin-based, terpene-based, petroleum resin-based, and coumarone resin-based resins. When the resin contains a main resin and a tackifying resin as a hot-melt type resin, the content of the tackifying resin is preferably 10 to 300 parts by mass, more preferably 25 to 200 parts by mass, and even more preferably 40 to 120 parts by mass, per 100 parts by mass of the main resin.

[0033] (1-component curing resin) In this invention, by using a one-component curing resin, the heat-expandable fire-resistant material composition can be made into a one-component curing type. The one-component curing resin is preferably a moisture-curing resin that hardens with moisture in the air. By using a moisture-curing resin, the coated material can be hardened by leaving it in the atmosphere at or near room temperature for a certain period of time after coating. Suitable one-component curing resins include crosslinkable silyl group-containing polymers, isocyanate group-containing polymers, and cyanoisocyanate resins. These may be used individually or in combination of two or more. Among the above, a polymer containing a crosslinkable silyl group is preferred as the one-component curing resin. Of the crosslinkable silyl groups, an alkoxysilyl group is more preferred. Furthermore, as the crosslinkable silyl group-containing polymer, at least one selected from crosslinkable silyl group-containing polyoxyalkylene polymers, crosslinkable silyl group-containing acrylic polymers, and crosslinkable silyl group-containing acrylic-modified polyoxyalkylene polymers (these are sometimes collectively referred to as "modified silicones") is preferred.

[0034] (2-component curing resin) A two-component curing resin is a resin that hardens when two components are mixed. In this invention, by using a two-component curing resin, a heat-expandable refractory material composition can be made into a two-component curing type. Using a two-component curing resin allows for relatively high adhesive strength. Furthermore, it makes it easier to improve adhesion to the coated object not only before combustion but also after combustion. In addition, the curing time can be easily controlled by appropriately changing the resin used. Two-component curing resins consist of a main component and a curing agent, and it is preferable to store them separately until immediately before use. Therefore, when using a two-component curing resin, it is preferable to incorporate components other than the two-component curing resin into either the main component or the curing agent. Then, it is preferable to mix the one-component component containing the main component and the two-component component containing the curing agent immediately before use to obtain a heat-expandable refractory material composition. For example, the one-component and two-component components may be stored separately in a tank, and the coating material obtained by mixing them may be supplied to the nozzle 10A via the coating material supply passage 20. When using a two-component curing type, it is preferable to cure the coating material by leaving it at or near room temperature for a certain period of time after coating, but depending on the type of resin, it may be heated as appropriate after coating.

[0035] As a two-component curing resin, any resin commonly used for two-component curing resins is acceptable, including polyurethane resins, epoxy resins, and acrylic resins, with epoxy resins being preferred among these. In the case of epoxy resins, an epoxy compound having epoxy groups should be used as the main component, and a curing agent that cures epoxy groups should be used as the curing agent. Known curing agents can be used, including polyamine-based, imidazole-based, polymercaptan-based, and acid anhydride-based curing agents.

[0036] (Emulsion type) In the case of an emulsion type, the resin is dispersed in a dispersion medium, preferably water, in the heat-expandable refractory material composition. In this invention, by using an emulsion-type resin as the resin, the heat-expandable refractory material composition is made into an emulsion dispersion liquid, thus becoming an emulsion type. The emulsion-type heat-expandable refractory material composition can be solidified by volatilizing the dispersion medium. As emulsion-type resins, vinyl acetate resins, ethylene-vinyl acetate resins, acrylic resins, and aqueous polymer-isocyanate resins can be used. Among these, ethylene-vinyl acetate resins are preferred. For ethylene-vinyl acetate resins, an ethylene-vinyl acetate copolymer resin may be used as the resin.

[0037] (Solvent-based) In the case of solvent-type materials, the resin is preferably dissolved in an organic solvent in the heat-expandable refractory material composition. In the present invention, by using a solvent-based resin as the resin, the heat-expandable refractory material composition contains an organic solvent and the solvent-based resin is dissolved in the organic solvent, resulting in a solvent-based composition. The solvent-based heat-expandable refractory material composition can be solidified by volatilizing the organic solvent. Examples of solvent-based resins include vinyl acetate resins, chloroprene rubbers, and acrylic resins, among which chloroprene rubbers and acrylic resins are preferred. In the case of emulsion or solvent-type refractory resin compositions, the refractory resin composition may be allowed to solidify by leaving it at or near room temperature after coating, or the solidification of the thermally expandable refractory material composition may be accelerated by heating to volatilize organic solvents or water.

[0038] The resin content in the heat-expandable fire-resistant material composition of the present invention is preferably 10 to 80% by mass, more preferably 15 to 70% by mass or more, and even more preferably 20 to 60% by mass, based on solid content.

[0039] (Inorganic filler) The refractory resin composition may also contain inorganic fillers other than the thermally expandable graphite described above. When heated to form a refractory layer, the inorganic fillers increase the heat capacity and suppress heat transfer, while acting as aggregates to improve the strength of the expanded residue. The inorganic fillers that can be used in the present invention are not particularly limited, and include, for example, alumina, zinc oxide, titanium oxide, calcium oxide, magnesium oxide, iron oxide, tin oxide, antimony oxide, metal oxides such as ferrite, metal carbonates such as calcium carbonate, zinc carbonate, strontium carbonate, barium carbonate, metal hydroxides such as calcium hydroxide, magnesium hydroxide, aluminum hydroxide, hydrotalcite, gypsum fiber, calcium salts such as calcium silicate, silica, diatomaceous earth, dawsonite, talc, clay, mica, montmorillonite, bentonite, activated clay, sepiolite, imogolite, sericite, glass fiber, glass beads, silica balloons, aluminum nitride, boron nitride, silicon nitride, etc. Examples include carbon black, graphite, carbon fiber, carbon balloons, various metal powders, potassium titanate, lead zirconate titanate, aluminum borate, molybdenum sulfide, silicon carbide, stainless steel fibers, zinc borate, various magnetic powders, slag fibers, fly ash, sodium phosphate, potassium phosphate, magnesium phosphate, metal phosphates such as aluminum phosphate, metal phosphates such as sodium phosphite, potassium phosphite, magnesium phosphite, aluminum phosphite, polyphosphates such as ammonium polyphosphate, piperazine polyphosphate, melamine polyphosphate, ammonium polyphosphate amide, aluminum polyphosphate, metal orthophosphates, metal metaphosphates, and metal tripolyphosphates. Inorganic fillers may be used individually or in combination of two or more types. When the fire-resistant resin composition contains an inorganic filler, the amount of the inorganic filler is preferably 10 to 100 parts by mass, more preferably 20 to 90 parts by mass, and even more preferably 30 to 70 parts by mass, per 100 parts by mass of resin.

[0040] (Other additives) The fire-resistant resin composition may contain various additive components as long as the objective of the present invention is not impaired. The type of additive component is not particularly limited, and various additives can be used. Examples of such additives include flame retardants, plasticizers, tackifiers, shrinkage inhibitors, nucleating agents, colorants (pigments, dyes, etc.), ultraviolet absorbers, antioxidants, anti-aging agents, dispersants, gelling accelerators, fillers, reinforcing agents, flame retardant aids, antistatic agents, surfactants, and surface treatment agents. The amount of additives added can be appropriately selected as long as it does not impair moldability, etc. Additives may be used individually or in combination of two or more types.

[0041] [Second Embodiment] Next, a second embodiment of the present invention will be described in detail. As shown in Figures 4(a) to 4(c), the coating apparatus according to the second embodiment differs from the coating apparatus according to the first embodiment in the shape of the nozzle 10B. The differences between the second embodiment and the first embodiment will be described below. Parts that are omitted from the description are the same as in the first embodiment. In the following description, the same reference numerals are used for components having the same configuration as in the first embodiment.

[0042] As shown in Figures 4 and 5, the nozzle 10B has a thickness adjustment section 12B1 for adjusting the coating thickness of the coating material, and the thickness adjustment section 12B1 constitutes at least a part of the discharge port 11 from which the coating material is discharged. The thickness adjustment section 12B1 constitutes one side of the discharge port 11 and can shape one side of the coating material discharged from the discharge port 11. In nozzle 10B, the bottom portion 15, which forms the surface facing the thickness adjustment portion 12B1, is shorter than the thickness adjustment portion 12B1, as shown in Figures 4 and 5. In other words, the discharge port 11 in nozzle 10B forms an opening from the tip of the thickness adjustment portion 12B1 to the tip of the bottom portion 15. Therefore, the discharge port 11 in nozzle 10B includes not only the opening on the tip side of the thickness adjustment portion 12B1, but also the opening formed from the tip of the thickness adjustment portion 12B1 to the tip of the bottom portion 15. That is, in this embodiment, there is also an opening at the position facing the thickness adjustment portion 12B1. Furthermore, the bottom portion 15, like the width adjustment portions 13B1, 13B2, and the thickness adjustment portion 12B1, has a flat surface in the portion that constitutes the inner surface of the nozzle 10B.

[0043] As shown in Figure 6, the coating apparatus of this embodiment applies the coating material 40 to the workpiece 30 by bringing the nozzle 10B into contact with the coating surface of the workpiece 30. Specifically, the bottom 15 and width adjustment parts 13B1 and 13B2 of the nozzle 10B are positioned to be in contact with the workpiece 30, and the coating process is performed while maintaining this state. As a result, the thickness of the coating material 40 applied to the workpiece 30 using the nozzle 10B becomes the distance from the coating surface of the workpiece 30 to the surface of the coating material 40 shaped by the thickness adjustment part 12B1. Furthermore, similar to the first embodiment, the coating width of the coating material 40 is adjusted by the width adjustment sections 13B1 and 13B2.

[0044] <Coating Method> In this embodiment, as described above, the nozzle 10B is positioned to come into contact with the object to be coated 30. Then, the coating material 40 is supplied from the coating material supply path 20 through the connection part 21 to the nozzle 10B, and the coating material 40 is discharged from the discharge port 11 of the nozzle 10B to coat the surface of the object to be coated 30. Similar to the first embodiment, the nozzle 10B of the coating apparatus moves relative to the workpiece 30 in the coating direction D, thereby allowing the coating material 40 extending in the coating direction D to be placed on the coating surface of the workpiece 30.

[0045] In the coating apparatus of this embodiment, the plan view of the nozzle 10B, as seen from the discharge port 11 side in the coating direction D, is U-shaped. In the nozzle 10B of this embodiment, the cross-sectional shape of the coating material 40 discharged from the discharge port 11 is the same as that of the discharge port 11. Therefore, the coating material 40 discharged from the discharge port 11 in the coating apparatus of this embodiment has a rectangular cross-section, corresponding to the U-shape.

[0046] [Third Embodiment] Next, a third embodiment of the present invention will be described in detail. As shown in Figures 7(a) to 7(c), the coating apparatus according to the third embodiment differs from the coating apparatus according to the first embodiment in the shape of the nozzle 10C. The differences between the third embodiment and the first embodiment will be described below. Parts that are omitted from the description are the same as in the first embodiment. In the following description, the same reference numerals are used for components having the same configuration as in the first embodiment.

[0047] As shown in Figures 7 and 8, the nozzle 10C has a thickness adjustment section 12C1 for adjusting the coating thickness of the coating material, and the thickness adjustment section 12C1 constitutes at least a part of the discharge port 11 from which the coating material is discharged. The thickness adjustment section 12C1 constitutes one side of the discharge port 11. The thickness adjustment section 12C1 is positioned on the rear side in the coating direction D of the coating material 40 and can shape one side of the coating material 40 discharged from the discharge port 11.

[0048] In the nozzle 10C, the bottom portion 15 that forms the surface facing the thickness adjustment portion 12C1 is shorter than the thickness adjustment portion 12C1, as shown in Figures 7 and 8. Furthermore, the width adjustment sections 13C1 and 13C2 are shorter than the thickness adjustment section 12C1. As a result, the discharge port 11 is composed of the width adjustment sections 13C1 and 13C2, the tip of the bottom section 15, and the portion inside the tip of the thickness adjustment section 12C1. The thickness adjustment section 12C1 then protrudes from the discharge port 11 on the rear side in the coating direction D. In this embodiment as well, the bottom portion 15, like the width adjustment portions 13C1, 13C2, and thickness adjustment portion 12C1, has a flat surface in the portion that constitutes the inner surface of the nozzle 10C. Furthermore, when viewed from the discharge port 11 side, the nozzle 10C has a square shape with each side being a straight line, and the tip of the thickness adjustment portion 12C1 is also a straight line.

[0049] In this embodiment, as shown in Figure 9, the nozzle 10C is positioned such that the tip of the thickness adjustment portion 12C1 of the nozzle 10C is above the coated surface of the object to be coated 30, at a distance equal to the desired coating thickness of the coating material 40, and the coating process is performed while maintaining this state. The coating material 40 is discharged from the discharge port 11 with its width adjusted by the width adjustment sections 13C1 and 13C2, and its thickness further restricted to a constant level by the thickness adjustment section 12C1 and the bottom section 15. Furthermore, the coating thickness is further adjusted by the tip of the thickness adjustment section 12C1, which protrudes from the rear side of the coating material 40 in the coating direction D. Therefore, in this embodiment, the thickness of the coating material 40 placed on the workpiece 30 using the nozzle 10C is the distance from the surface of the workpiece 30 to the surface of the coating material 40 shaped by the thickness adjustment unit 12C1. Thus, the coating thickness of the coating material 40 is approximately the same as the distance from the end of the thickness adjustment unit 12C1 of the nozzle 10C, which is positioned above the coating surface of the workpiece 30, to the coating surface of the workpiece 30. As a result, the coating thickness of the coating material 40 can be appropriately set by adjusting the distance from the coating surface of the workpiece 30 to the tip of the thickness adjustment unit 12C1 of the nozzle 10C, so that coating material 40 of various thicknesses can be applied to the coating surface using a single nozzle 10C. Furthermore, since it is discharged from the discharge port 11 at a constant thickness, the amount of excess coating material generated by shaping by the thickness adjustment unit 12C1 can be minimized.

[0050] <Coating Method> As described above, the coating method using the coating apparatus of the present invention involves positioning the nozzle 10C such that the thickness adjustment section 12C1 of the nozzle 10C is above the coating surface of the object to be coated 30, at a distance equal to the desired coating thickness of the coating material 40. The thickness adjustment section 12C1 of the nozzle 10C is positioned at the discharge port 11 so as to be on the rear side in the coating direction D of the coating material 40. The coating material 40 is then supplied from the coating material supply path 20 through the connection section 21 to the nozzle 10C, and the coating material 40 is discharged from the discharge port 11 of the nozzle 10C to coat the surface of the object to be coated 30. Similar to the first embodiment, the nozzle 10C of the coating apparatus of the present invention moves relative to the workpiece 30 in the coating direction D, thereby allowing the coating material 40 extending in the coating direction D to be placed on the coating surface of the workpiece 30.

[0051] In the coating apparatus of this embodiment, the thickness adjustment section 12C1 of the nozzle 10C protrudes from the discharge port 11 on the rear side in the coating direction D of the coating material 40. Because the thickness adjustment section 12C1 protrudes from the discharge port 11 on the rear side in the coating direction D of the coating material 40, it becomes possible to shape the coating material 40 discharged from the discharge port 11 with the thickness adjustment section 12C1, and the coating thickness of the coating material 40 can be adjusted.

[0052] [Fourth Embodiment] Next, a fourth embodiment of the present invention will be described in detail. As shown in Figures 10(a) to (c), the coating apparatus according to the fourth embodiment differs from the coating apparatus according to the first embodiment in the shape of the nozzle 10D. The differences between the fourth embodiment and the first embodiment will be described below. Parts that are omitted from the description are the same as in the first embodiment. In the following description, the same reference numerals are used for components having the same configuration as in the first embodiment.

[0053] As shown in Figures 10 and 11, the nozzle 10D has a thickness adjustment section 12D1 for adjusting the coating thickness of the coating material, and the thickness adjustment section 12D1 constitutes at least a part of the discharge port 11 from which the coating material is discharged. The thickness adjustment section 12D1 constitutes one side of the discharge port 11. The thickness adjustment section 12D1 is positioned on the rear side in the coating direction D of the coating material 40 and can shape one side of the coating material discharged from the discharge port 11.

[0054] In the nozzle 10D, the bottom portion 15 that forms the surface facing the thickness adjustment portion 12D1 is shorter than the thickness adjustment portion 12D1, as shown in Figures 10 and 11. The nozzle 10D has width adjustment sections 13D1 and 13D2 for adjusting the coating width of the coating material, and the width adjustment sections 13D1 and 13D2 constitute at least a part of the discharge port 11. The ends of the width adjustment sections 13D1 and 13D2 are inclined to connect the end of the thickness adjustment section 12D1 and the bottom section 15. As a result, the discharge port 11 is composed of the width adjustment sections 13D1 and 13D2, the tip of the bottom section 15, and the thickness adjustment section 12D1, with the tip of the thickness adjustment section 12D1 protruding from the discharge port 11 on the rear side in the coating direction D.

[0055] In this embodiment, as shown in Figure 12, the nozzle 10D is positioned such that the tip of the thickness adjustment portion 12D1 of the nozzle 10D is above the coated surface of the object to be coated 30, at a distance equal to the desired coating thickness of the coating material 40, and the coating process is performed while maintaining this state. In the coating process, the coating material 40 is discharged from the discharge port 11, similar to the third embodiment, and the coating thickness is adjusted by the tip of the thickness adjustment section 12C1. Therefore, in this embodiment as well, the thickness of the coating material 40 placed on the workpiece 30 using the nozzle 10D is the distance from the surface of the workpiece 30 to the surface of the coating material 40 shaped by the thickness adjustment unit 12D1. Thus, the coating thickness of the coating material 40 is approximately the same as the distance from the end of the thickness adjustment unit 12D1 of the nozzle 10D, which is positioned above the coating surface of the workpiece 30, to the coating surface of the workpiece 30. As a result, the coating thickness of the coating material 40 can be appropriately set by adjusting the distance from the coating surface of the workpiece 30 to the tip of the thickness adjustment unit 12D1 of the nozzle 10D, so that coating material 40 of various thicknesses can be applied to the coating surface using a single nozzle 10C. Furthermore, since it is discharged from the discharge port 11 at a constant thickness, the amount of excess coating material generated by shaping by the thickness adjustment unit 12C1 can be minimized.

[0056] <Coating Method> As described above, the coating method using the coating apparatus of the present invention involves positioning the nozzle 10D such that the thickness adjustment section 12D1 of the nozzle 10D is above the coating surface of the object to be coated 30, at a distance equal to the desired coating thickness of the coating material 40. The thickness adjustment section 12D1 of the nozzle 10D is positioned at the discharge port 11 so as to be on the rear side in the coating direction D of the coating material 40. The coating material 40 is then supplied from the coating material supply path 20 through the connection section 21 to the nozzle 10D, and the coating material 40 is discharged from the discharge port 11 of the nozzle 10D to coat the surface of the object to be coated 30. Similar to the first embodiment, the nozzle 10D of the coating apparatus of the present invention moves relative to the workpiece 30 in the coating direction D, thereby allowing the coating material 40 extending in the coating direction D to be placed on the coating surface of the workpiece 30.

[0057] [Other embodiments] The present invention is not limited to the configurations of the first to fourth embodiments described above, and any improvements or modifications may be made as long as they do not deviate from the technical concept of the present invention. For example, in the second embodiment, a bottom portion 15 was provided, but the bottom portion 15 may be omitted. Also, in the fourth embodiment, the width adjustment portion was provided with a linear incline to connect the thickness adjustment portion and the bottom portion, but it is not limited to this, and may be provided with a curved shape. [Explanation of Symbols]

[0058] 10A~D Nozzle 11 Discharge port 12A1~D1, 12A2 Thickness Adjustment Section 13A1~D1, 13A2~D2 width adjustment section 14 Hollow part 15 Bottom plate 20 Coating material supply routes 21 Connection part 30 Object to be coated 40 Coating materials

Claims

1. A coating apparatus for applying a coating material to an object to be coated, A nozzle for dispensing the coating material onto the object to be coated, The nozzle is provided with a coating material supply path for supplying the coating material, A coating apparatus wherein the nozzle has a thickness adjustment section for adjusting the coating thickness of the coating material, and the thickness adjustment section constitutes at least a part of the discharge port for discharging the coating material.

2. The coating apparatus according to claim 1, wherein the nozzle further has a width adjustment section for adjusting the coating width of the coating material, and the width adjustment section constitutes at least a part of the discharge port.

3. The width adjustment section has a first width adjustment section and a second width adjustment section. The coating apparatus according to claim 2, wherein the first width adjustment section and the second width adjustment section are provided opposite each other so as to correspond to the coating width of the coating material.

4. The coating apparatus according to claim 1, wherein the thickness adjustment section is provided at least on the rear side in the coating direction of the coating material at the discharge port.

5. The coating apparatus according to claim 4, wherein the thickness adjustment portion protrudes from the discharge port on the rear side in the coating direction of the coating material.

6. The coating apparatus according to claim 1, wherein the nozzle, viewed from the discharge port side, has a U-shape in plan view.

7. The coating apparatus according to claim 1, wherein the nozzle, when viewed from the discharge port side, has a square shape in plan view.

8. The coating apparatus according to any one of claims 1 to 7, wherein the coating material is a fire-resistant material.

9. The coating apparatus according to any one of claims 1 to 7, wherein the coating material contains thermally expandable graphite.

10. The coating apparatus according to any one of claims 1 to 7, wherein the coating material includes a hot melt resin.

11. The coating apparatus according to any one of claims 1 to 7, wherein the coating material includes a modified silicone resin.

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