Building materials

Abstract

To provide a building material having flame retardancy and capable of suppressing excessive foaming of a coating layer.SOLUTION: A building material has a base material and a coating layer formed on the surface of the base material. The coating layer comprises a coating film foamed by heating and a fiberglass part consisting of fiberglass cloth or fiberglass nonwoven fabric at least partially embedded in the coating film. The coating film contains, for example, (A) a water-soluble melamine resin, (B) a condensation-polymerized phosphate ester, and (C) one or more of phosphoric acid, boric acid, ammonium salt, and ammonia.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to building materials.

Background Art

[0002] As a method of making wood flame-retardant, there is a method of infiltrating a flame retardant into wood. The method of infiltrating a flame retardant into wood is disclosed in Patent Document 1. As a method of making plastic flame-retardant, there is a method of changing the composition of plastic. The method of changing the composition of plastic is disclosed in Patent Document 2.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] In order to infiltrate a flame retardant into wood, a special device is required. Also, in order to infiltrate a flame retardant into wood, a lot of time and energy are required. In the case of the method of changing the composition of plastic, the composition of plastic is limited.

[0005] It is conceivable to make a combustible base material flame-retardant by applying a coating composition to a combustible base material such as wood or plastic to form a coating layer. The coating layer foams when heated and becomes a heat-insulating layer. When the building material is used, for example, on a ceiling surface, if the coating layer foams excessively, the heat-insulating layer may fall off and the flame retardancy may decrease. In one aspect of the present disclosure, it is preferable to provide a building material that has flame retardancy and can suppress excessive foaming of the coating layer.

Means for Solving the Problems

[0006] One aspect of the present disclosure is a building material including a base material and a coating layer formed on the surface of the base material. The coating layer includes a coating film that foams upon heating and a glass fiber part made of a glass fiber cloth or a glass fiber non-woven fabric, at least a part of which is embedded in the coating film.

[0007] The building material, which is one aspect of the present disclosure, includes a glass fiber part, and thus has an effect (hereinafter referred to as a foaming suppression effect) of suppressing excessive foaming of the coating layer. In addition, since the coating layer includes a coating film that foams upon heating, the building material, which is one aspect of the present disclosure, has high flame retardancy.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3

Embodiments for Carrying Out the Invention

[0009] Exemplary embodiments of the present disclosure will be described with reference to the drawings. 1. Configuration of the Building Material (1) Base Material The building material includes a base material. Examples of the base material include a combustible base material. Examples of the combustible base material include wood. Examples of the wood include cedar lumber having a thickness of 12 mm, a width of 100 mm, and a length of 2000 mm.

[0010] The base material is not limited to wood and can be arbitrarily selected. Examples of the base material include plastics, wood building materials, paper, cloth, etc. Examples of plastics include polyethylene resin, polypropylene resin, acrylic resin, phenolic resin, vinyl chloride resin, expanded polystyrene resin, etc. Examples of wood building materials include sawn timber, glued laminated timber, plywood, laminated veneer lumber (LVL), cross-laminated timber (CLT), medium density fiberboard (MDF), etc. The form of the base material is not particularly limited. Examples of the form of the base material include columnar, plate-like, sheet-like, cloth-like, etc.

[0011] Examples of the base material include, for example, wooden structural members. Examples of wooden structural members include columns, beams, walls, floors, etc. As for the column, for example, there is a square column. The cross-sectional shape of the square column in the cross-section orthogonal to the longitudinal direction is, for example, square. The length of one side of the square is, for example, 90 mm or more and 1100 mm or less.

[0012] As for the beam, for example, there is a rectangular beam. The cross-sectional shape of the rectangular beam in the cross-section orthogonal to the longitudinal direction is, for example, rectangular. The length of one side of the rectangle is, for example, 90 mm or more and 800 mm or less. The length of the side adjacent to the said one side is, for example, 90 mm or more and 1200 mm or less. The length of the rectangular beam is not particularly limited, but for example, it is 3000 mm or more and 10000 mm or less.

[0013] The shape of the wall is, for example, rectangular. The length of the short side of the rectangle is, for example, 3000 mm or less. The length of the short side of the rectangle is, for example, 500 mm or more. The length of the long side of the rectangle is, for example, 12000 mm or less. The length of the long side of the rectangle is, for example, 2000 mm or more.

[0014] Examples of the base material include, for example, those with a plate-like or sheet-like member attached to the surface of wood. Examples of the plate-like or sheet-like member include gypsum board, fireproof sheet, decorative material, etc. (2) Composition of the coating layer The building material is provided with a coating layer. The coating layer is formed on the surface of the base material. The coating layer includes a coating film and a glass fiber part. The coating film foams upon heating. The glass fiber part is made of a glass fiber cloth or a glass fiber non-woven fabric. At least a part of the glass fiber part is embedded in the coating film.

[0015] For example, as shown in FIG. 1, the building material 1 includes a base material 3 and a coating layer 5. The coating layer 5 is formed on the surface of the base material 3. The coating layer 5 includes a coating film 7 and a glass fiber part 9. In the form shown in FIG. 1, the entire glass fiber part 9 is embedded in the coating film 7. The coating film 7 is impregnated inside the glass fiber part 9.

[0016] In the thickness direction, it is preferable that the glass fiber part 9 is on the side of the surface 5B of the coating layer 5 rather than the center 5A in the thickness direction of the coating layer 5. When the glass fiber part 9 is on the side of the surface 5B rather than the center 5A, the foaming suppression effect is even higher.

[0017] It is preferable that the coating layer 5 has a portion (hereinafter referred to as the non-containing part 5C) that does not include the glass fiber part 9 on the side of the base material 3. The non-containing part 5C is composed of, for example, only the coating film 7. When the coating layer 5 has the non-containing part 5C, the foaming suppression effect is even higher.

[0018] For example, as shown in FIG. 2, the building material 1 includes a base material 3 and a coating layer 5. The coating layer 5 is formed on the surface of the base material 3. The coating layer 5 includes a coating film 7 and a glass fiber part 9. In the form shown in FIG. 2, the surface 9A of the glass fiber part 9 coincides with the surface 5B of the coating layer 5. The coating film 7 is impregnated inside the glass fiber part 9. It is preferable that the coating layer 5 has the non-containing part 5C on the side of the base material 3. When the coating layer 5 has the non-containing part 5C, the foaming suppression effect is even higher.

[0019] Examples of the glass constituting the glass fiber cloth or the glass fiber nonwoven fabric include alumina borosilicate glass, soda lime glass, quartz glass, etc. Alumina borosilicate glass has a low coefficient of thermal expansion and is resistant to thermal shock, so it is preferable as the glass constituting the glass fiber cloth or the glass fiber nonwoven fabric. Among the glass constituting the glass fiber cloth or the glass fiber nonwoven fabric, it is preferable that 97% by mass or more is alumina borosilicate glass.

[0020] Examples of the sizing agent contained in the glass fiber cloth or the glass fiber nonwoven fabric include starch, acrylic resin, PVA, EVA, etc. The content of the sizing agent in the glass fiber cloth or the glass fiber nonwoven fabric is preferably 3% by mass or less.

[0021] The weaving density in the longitudinal direction of the glass fiber cloth is preferably 30 threads / 25 mm or more and 70 threads / 25 mm or less, and more preferably 53 threads / 25 mm. The weaving density in the transverse direction of the glass fiber cloth is preferably 30 threads / 25 mm or more and 70 threads / 25 mm or less, and more preferably 48 threads / 25 mm.

[0022] When the weaving density in the longitudinal or transverse direction is 70 threads / 25 mm or less, the penetration of the paint composition into the glass fiber cloth becomes better. When the weaving density in the longitudinal or transverse direction is 30 threads / 25 mm or more, the foaming suppression effect is higher.

[0023] Plain weave is preferable as the weaving method of the glass fiber cloth. The mass per unit area of the glass fiber cloth or the glass fiber nonwoven fabric is preferably 70 g / m 2 or more and 150 g / m 2 or less, and more preferably 92 g / m 2 .

[0024] The thickness of the glass fiber cloth or the glass fiber nonwoven fabric is preferably 0.05 mm or more and 0.20 mm or less, and more preferably 0.09 mm or more and 0.1 mm or less. The tensile strength in the longitudinal direction of the glass fiber cloth or glass fiber nonwoven fabric is preferably 300 N / 25 mm or more and 1000 N / 25 mm or less, more preferably 510 N / 25 mm. The tensile strength in the transverse direction of the glass fiber cloth or glass fiber nonwoven fabric is preferably 300 N / 25 mm or more and 1000 N / 25 mm or less, more preferably 451 N / 25 mm.

[0025] The mass per unit area of the coating film 7 is 250 g / m 2 or more and 550 g / m 2 or less. Among the coating film 7, the mass per unit area of the portion that has penetrated into the glass fiber portion 9 or is on the side of the surface 5B rather than the glass fiber portion 9 is 75 g / m 2 or more and 275 g / m 2 or less is preferable. In this case, the foam suppression effect is even higher.

[0026] (3) Composition of the coating composition The coating film is formed by applying the coating composition. Examples of the coating composition include a coating composition (hereinafter referred to as a specific coating composition) containing (a) a water-soluble melamine resin, (b) a polycondensed phosphate ester, and (c) one or more of phosphoric acid, boric acid, an ammonium salt, and aqueous ammonia. The specific coating composition may further contain (d) a compound having an amino group in its molecular structure, (e) kaolin, and (f) glass fiber.

[0027] Note that the coating composition used to form the coating film may be other coating compositions as long as it can form a coating film that foams upon heating. The coating film formed by applying other coating compositions preferably has transparency.

[0028] (3-1) (a) Water-soluble melamine resin The specific coating composition contains a water-soluble melamine resin. The water-soluble melamine resin can be produced, for example, by reacting aldehydes and melamine in the presence of an alkali catalyst. The production method of the water-soluble melamine resin is disclosed, for example, in Japanese Patent No. 257115, Japanese Patent Application Laid-Open No. 51-114492, Japanese Patent Application Laid-Open No. 2006-124457, etc.

[0029] Examples of the water-soluble melamine resin include methylol melamine resin, alkoxylated methylol melamine resin, etc. Examples of the methylol melamine resin include monomethylol melamine resin, dimethylol melamine resin, trimethylol melamine resin, etc. Examples of the alkoxylated methylol melamine resin include methylol melamine resin, methylated methylol melamine resin, methoxymethylolated melamine resin, butylated methylol melamine resin, etc.

[0030] The alkoxylated methylol melamine resin may be completely alkoxylated, or methylol groups may remain, or imino groups may remain. Further, the specific coating composition may contain a copolymer of a water-soluble melamine resin and a phenol resin, etc. Among the water-soluble melamine resins, methylol melamine resin is more preferable.

[0031] When the specific coating composition contains a methylol melamine resin, the flame retardancy of the base material and the transparency of the coating film become more prominent. In this specification, transparent is not limited to complete transparency, and may be, for example, translucent.

[0032] (3-2)(b) Condensed phosphoric acid ester The specific coating composition contains a condensed phosphoric acid ester. The condensed phosphoric acid ester is an ester obtained by a condensation reaction of polyphosphoric acid and alcohol. Examples of the alcohol include aliphatic alcohol, glycol, polyhydric alcohol, glycerin, etc.

[0033] Examples of the aliphatic alcohol include methanol, ethanol, butanol, propanol and the like. Examples of the glycol include ethylene glycol, propylene glycol and the like. Examples of the polyhydric alcohol include pentaerythritol, dipentaerythritol, tripentaerythritol and the like.

[0034] As the polycondensed phosphate ester, a polycondensed phosphate ester obtained using a polyhydric alcohol is preferable. When the specific coating composition contains a polycondensed phosphate ester obtained using a polyhydric alcohol, the flame retardancy of the base material and the transparency of the coating film become more prominent. As the polycondensed phosphate ester, a polycondensed phosphate ester obtained using pentaerythritol is more preferable. When the specific coating composition contains a polycondensed phosphate ester obtained using pentaerythritol, the flame retardancy of the base material and the transparency of the coating film become more prominent.

[0035] The blending ratio of the polycondensed phosphate ester with respect to 100 parts by mass of the water-soluble melamine resin is preferably 120 parts by mass or more and 350 parts by mass or less, more preferably 130 parts by mass or more and 200 parts by mass or less, and most preferably 170 parts by mass.

[0036] When the blending ratio of the polycondensed phosphate ester with respect to 100 parts by mass of the water-soluble melamine resin is 120 parts by mass or more and 350 parts by mass or less, the flame retardancy of the base material and the transparency of the coating film become more prominent. When an excessive amount of the polycondensed phosphate ester is mixed with the water-soluble melamine resin, the flame retardancy of the base material and the transparency of the coating film become more prominent.

[0037] (3-3)(c) component The specific coating composition contains the (c) component. The (c) component contains one or more of phosphoric acid, boric acid, ammonium salt, and aqueous ammonia. The (c) component contains, for example, both phosphoric acid and boric acid. Examples of the ammonium salt include ammonium phosphate salt, ammonium borate salt and the like.

[0038] Ammonia gradually volatilizes from the ammonium salt and aqueous ammonia. The volatilized ammonia delays the curing of the water-soluble melamine resin. The blending ratio of component (c) with respect to 100 parts by mass of the water-soluble melamine resin is preferably 15 parts by mass or more and 90 parts by mass or less, more preferably 20 parts by mass or more and 50 parts by mass or less, and most preferably 31 parts by mass.

[0039] When the blending ratio of component (c) with respect to 100 parts by mass of the water-soluble melamine resin is 15 parts by mass or more and 90 parts by mass or less, the flame retardancy of the base material and the transparency of the coating film become more prominent. When component (c) contains excessive phosphoric acid or boric acid with respect to the water-soluble melamine resin, the curing of the water-soluble melamine resin is promoted.

[0040] Also, when component (c) contains excessive phosphoric acid or boric acid with respect to the water-soluble melamine resin, the excess phosphoric acid or boric acid chemically bonds with the hydroxyl groups of the base material, improving the adhesion between the coating film and the base material. When the base material is wood, phosphoric acid or boric acid chemically bonds with the hydroxyl groups of cellulose. Further, the excess phosphoric acid or boric acid chemically bonds with the water-soluble melamine resin decomposed by the combustion heat during a fire, further enhancing the flame retardancy of the base material. It is presumed that the excess phosphoric acid or boric acid chemically bonds with the hydroxyl groups generated by the thermal decomposition of the water-soluble melamine resin.

[0041] (3 - 4) Compound having an amino group in the molecular structure of (d) The specific coating composition contains a compound having an amino group in the molecular structure of (d) (hereinafter also referred to as component (d)). By the specific coating composition containing component (d), the curing of the specific coating composition at room temperature is accelerated. When the curing of the specific coating composition at room temperature is accelerated, the sagging when the specific coating composition is applied to a vertical surface is reduced.

[0042] Examples of component (d) include urea, melamine, aliphatic amines, aromatic amines, and heterocyclic amines. Examples of aliphatic amines include methylamine, dimethylamine, trimethylamine, ethylamine, diethylamine, triethylamine, ethylenediamine, triethanolamine, N,N - diisopropylethylamine, tetramethylethylenediamine, hexamethylenediamine, spermidine, spermine, amantadine, etc.

[0043] Examples of aromatic amines include aniline, phenethylamine, toluidine, catecholamine, 1,8 - bis(dimethylamino)naphthalene, etc. Examples of heterocyclic amines include pyrrolidine, piperidine, piperazine, morpholine, quinuclidine, 1,4 - diazabicyclo[2.2.2]octane, pyrrole, pyrazole, imidazole, pyridine, pyridazine, pyrimidine, pyrazine, oxazole, thiazole, 4 - dimethylaminopyridine, etc.

[0044] As the component (d), those having two or more amino groups or urea are preferred. Examples of the component (d) having two or more amino groups include ethylenediamine, hexamethylenediamine, etc.

[0045] When the specific paint composition contains, as the component (d), those having two or more amino groups or urea, the curing of the specific paint composition at room temperature becomes even faster. It is presumed that the reason why the curing of the specific paint composition at room temperature becomes even faster is that the polycondensate of formaldehyde remaining in the water - soluble melamine resin and the component (d) reduces the fluidity of the specific paint composition. The polycondensate of the component (d) and formaldehyde is the component (D) described later.

[0046] The blending ratio of component (d) with respect to 100 parts by mass of the water-soluble melamine resin is preferably 0.05 part by mass or more and 5 parts by mass or less, more preferably 0.5 part by mass or more and 5 parts by mass or less, and particularly preferably 2.5 parts by mass. When the blending ratio of component (d) with respect to 100 parts by mass of the water-soluble melamine resin is 0.05 part by mass or more and 5 parts by mass or less, the curing of the specific coating composition at room temperature becomes faster.

[0047] (3-5)(e) Kaolin The specific coating composition further contains, for example, (e) kaolin. As kaolin, halloysite (Al2Si2O5(OH)4·2H2O) is preferred. Halloysite has a tubular crystal structure. Halloysite has siloxane (-Si-O-Si-) on the outside and aluminol (-Al-O-Al-) on the inside. Therefore, the surface of halloysite exhibits acidity.

[0048] When the specific coating composition contains kaolin, the curing of the specific coating composition becomes faster. When the specific coating composition contains halloysite, the curing of the specific coating composition becomes even faster. The particle size of kaolin is preferably 1 μm or more and 10 μm or less. When the particle size of kaolin is 1 μm or more and 10 μm or less, the curing of the specific coating composition becomes even earlier.

[0049] The blending ratio of kaolin with respect to 100 parts by mass of the water-soluble melamine resin is preferably 20 parts by mass or more and 250 parts by mass or less, more preferably 50 parts by mass or more and 200 parts by mass or less, and most preferably 150 parts by mass or more and 180 parts by mass or less. When the blending ratio of kaolin with respect to 100 parts by mass of the water-soluble melamine resin is 250 parts by mass or less, clouding of the coating film can be suppressed.

[0050] (3-6)(f) Glass fiber The specific coating composition further includes, for example, (f) glass fibers. The form of the glass fibers is, for example, powdery. When the specific coating composition contains glass fibers, the shape retention of the heat insulation layer after heat foaming is improved. The diameter of the glass fibers is preferably 5 μm or more and 20 μm or less, and more preferably 10 μm. The length of the glass fibers is preferably 10 μm or more and 300 μm or less, and more preferably 30 μm or more and 50 μm or less. The value obtained by dividing the length of the glass fibers by the diameter of the glass fibers is defined as the aspect ratio of the glass fibers. The aspect ratio of the glass fibers is preferably 1.5 or more and 5.5 or less.

[0051] Glass fibers may sometimes be called powder or milled. As the glass fibers, those that are not surface-treated are preferred. Examples of commercially available glass fibers include milled fibers (Central Glass Fiber Co., Ltd.), milled fibers (Asahi Fiber Glass Co., Ltd.), PF cut fibers (Nitto Boseki Co., Ltd.), and milled fibers (Nippon Electric Glass Co., Ltd.).

[0052] (3-7) Other components The specific coating composition can include additives, pigments, etc. that are used in ordinary coatings, provided that the flame retardancy, transparency of the coating film, and the speed of curing of the coating film are not significantly impaired. Examples of the additives include thickeners, pH adjusters, dispersants, wetting agents, preservatives, dyes, defoaming agents, pigments, etc.

[0053] Examples of the thickeners include polyvinyl alcohol, urethane-modified polyethers, carboxymethyl cellulose, etc. Examples of the pH adjusters include aqueous ammonia, amines, etc. Examples of the pigments include inorganic pigments, organic pigments, extender pigments, etc. Examples of the inorganic pigments include carbon black, titanium oxide, iron oxide, etc. Examples of the organic pigments include quinacridone, azo pigments, etc. Examples of the extender pigments include silica, barium sulfate, talc, mica, etc.

[0054] The specific coating composition contains, for example, an acid. The acid promotes the curing of the water-soluble melamine resin. Examples of the acid include sulfonic acid, carboxylic acid, etc. Examples of the sulfonic acid include p-toluenesulfonic acid, etc. Examples of the carboxylic acid include acetic acid, citric acid, maleic acid, acrylic acid, etc.

[0055] The specific coating composition contains, for example, components of a foaming refractory coating within a range that does not significantly impair the transparency of the coating film. Examples of the components of the foaming refractory coating include ammonium polyphosphate, melamine, polyhydric alcohol, etc. Examples of the polyhydric alcohol include pentaerythritol, etc.

[0056] (3-8) Form of the specific coating composition The form of the specific coating composition is, for example, a two-component form composed of a first agent and a second agent. The first agent contains a water-soluble melamine resin. The second agent contains a polycondensed phosphate ester and component (c). The first agent and the second agent are mixed before use. When the form of the specific coating composition is a two-component form, the storage stability of the specific coating composition is high.

[0057] Component (d) is preferably contained in the second agent and not in the first agent. When component (d) is contained in the second agent and not in the first agent, the storage stability of the specific coating composition is even higher. (4) Coating film The coating film contains, for example, (A) a water-soluble melamine resin, (B) a polycondensed phosphate ester, and one or more of (C) phosphoric acid, boric acid, ammonium salts, and ammonia. The coating film further contains, for example, one or more of (D) a polycondensate of a compound having an amino group in its molecular structure and formaldehyde, (E) kaolin, and (F) glass fiber.

[0058] (A) The water-soluble melamine resin is, for example, the same as the (a) water-soluble melamine resin contained in the specific coating composition. (B) The polycondensed phosphate ester is, for example, the same as the (b) polycondensed phosphate ester contained in the specific coating composition.

[0059] In the coating film, the blending ratio of the polycondensed phosphate ester with respect to 100 parts by mass of the water-soluble melamine resin is preferably 120 parts by mass or more and 350 parts by mass or less, more preferably 130 parts by mass or more and 200 parts by mass or less, and most preferably 170 parts by mass.

[0060] In the coating film, when the blending ratio of the polycondensed phosphate ester with respect to 100 parts by mass of the water-soluble melamine resin is 120 parts by mass or more and 350 parts by mass or less, the flame retardancy of the building material and the transparency of the coating film become more prominent. When an excessive amount of the polycondensed phosphate ester is mixed with the water-soluble melamine resin, the flame retardancy of the building material and the transparency of the coating film become more prominent.

[0061] Component (C) is basically the same as component (c) contained in the specific coating composition. However, one of the options for component (C) is ammonia instead of aqueous ammonia. In the coating film, the blending ratio of component (C) with respect to 100 parts by mass of the water-soluble melamine resin is preferably 15 parts by mass or more and 90 parts by mass or less, more preferably 20 parts by mass or more and 50 parts by mass or less, and most preferably 31 parts by mass.

[0062] In the coating film, when the blending ratio of component (C) with respect to 100 parts by mass of the water-soluble melamine resin is 15 parts by mass or more and 90 parts by mass or less, the flame retardancy of the building material and the transparency of the coating film become more prominent. When component (C) contains an excessive amount of phosphoric acid or boric acid with respect to the water-soluble melamine resin, the curing of the water-soluble melamine resin is promoted.

[0063] Also, when component (C) contains an excessive amount of phosphoric acid or boric acid with respect to the water-soluble melamine resin, the excess phosphoric acid or boric acid chemically bonds with the hydroxyl groups of the substrate, improving the adhesion between the coating film and the substrate. When the substrate is wood, phosphoric acid or boric acid chemically bonds with the hydroxyl groups of cellulose. Further, the excess phosphoric acid or boric acid chemically bonds with the water-soluble melamine resin decomposed by the combustion heat during a fire, further enhancing the flame retardancy of the building material. It is presumed that the excess phosphoric acid or boric acid chemically bonds with the hydroxyl groups generated by the thermal decomposition of the water-soluble melamine resin.

[0064] (D) component, a compound having an amino group in its molecular structure, is, for example, the same as the (d) component contained in a specific coating composition. In the coating film, the blending ratio of the (D) component with respect to 100 parts by mass of the water-soluble melamine resin is preferably 0.05 part by mass or more and 5 parts by mass or less, more preferably 0.5 part by mass or more and 5 parts by mass or less. When the blending ratio of the (D) component with respect to 100 parts by mass of the water-soluble melamine resin is 0.05 part by mass or more and 5 parts by mass or less, the curing of the coating film at room temperature becomes even faster when manufacturing building materials.

[0065] The coating film contains, for example, (E) kaolin. (E) kaolin is, for example, the same as the (e) component contained in a specific coating composition. In the coating film, the blending ratio of kaolin with respect to 100 parts by mass of the water-soluble melamine resin is preferably 20 parts by mass or more and 250 parts by mass or less, more preferably 50 parts by mass or more and 200 parts by mass or less, and most preferably 150 parts by mass or more and 180 parts by mass or less. When the blending ratio of kaolin with respect to 100 parts by mass of the water-soluble melamine resin is 250 parts by mass or less, clouding of the coating film can be suppressed.

[0066] The coating film contains, for example, (F) glass fiber. (F) glass fiber is, for example, the same as the (f) component contained in a specific coating composition. The coating film may contain, for example, "other components" in a specific coating composition.

[0067] In addition, as long as the coating film has the effect of foaming by heating, it may be a coating film formed by applying a coating composition other than the specific coating composition. The coating film preferably has transparency. 2. Method for manufacturing building materials The building material can be manufactured, for example, by the method shown in FIG. 3. As shown in S1 of FIG. 3, a coating composition is applied to the surface of the base material 3 to form a first coating film 11. The coating composition is, for example, a specific coating composition. Next, the first coating film 11 is left to cure until it loses its fluidity. The standing time is, for example, several hours to several weeks. Next, as shown in S2, a glass fiber part 9 is placed on the first coating film 11.

[0068] Next, as shown in S3, a coating composition is applied onto the glass fiber part 9 to form a second coating film 13. The coating composition applied in S3 is, for example, the same type of coating composition as the coating composition applied in S1. At least a part of the coating composition applied in S3 penetrates into the glass fiber part 9.

[0069] Next, the second coating film 13 is cured. Through the above steps, the building material 1 is completed. The first coating film 11 and the second coating film 13 become the coating film 7 that constitutes the covering layer 5. The first coating film 11 becomes the non-containing part 5C. When there is a sufficient amount of the coating composition applied in S3, as shown in FIG. 1, the entire glass fiber part 9 is embedded in the coating film 7. When the amount of the coating composition applied in S3 is small, as shown in FIG. 2, the surface 9A of the glass fiber part 9 and the surface 5B of the covering layer 5 coincide. The second coating film 13 is a part of the coating film 7 that has penetrated into the glass fiber part 9 or is on the side of the surface 5B rather than the glass fiber part 9.

[0070] 3. Effects Exhibited by the Building Material (3-1) When a fire breaks out around the building material 1 and the covering layer 5 is heated, the coating film 7 contained in the covering layer 5 foams. As a result, the covering layer 5 forms a heat-insulating layer. The formed heat-insulating layer suppresses the combustion of the base material 3. Since the covering layer 5 includes the glass fiber part 9, it exhibits a foaming suppression effect.

[0071] (3-2) The coating film 7 is, for example, a coating film formed by applying a specific coating composition. In that case, the building material 1 can further suppress the combustion of the base material 3. (3-3) The mass per unit area of the coating film 7 is, for example, 250 g / m 2 or more and 550 g / m 2 or less, and the mass per unit area of the part of the coating film 7 that has penetrated into the glass fiber part 9 or is on the side of the surface 5B rather than the glass fiber part 9 is, for example, 75 g / m 2 or more and 275 g / m 2 or less. In that case, the foaming suppression effect of the building material 1 is even higher.

[0072] (3-4) The coating layer 5 includes, for example, a non-containing portion 5C. In that case, the foaming suppression effect of the building material 1 is even higher. 4. Examples (4-1) Production of a specific coating composition The first agent and the second agent of the specific coating composition were produced by mixing the following components. <First agent> Water-soluble melamine resin: 20 parts by mass Glass fiber: 50 parts by mass Kaolin: 1.5 parts by mass Wetting agent: 0.5 parts by mass <Second agent> Condensation polymerization phosphate ester: 30 parts by mass Phosphoric acid: 5 parts by mass Urea: 0.5 parts by mass The first agent and the second agent each contained water as a solvent. In each of the first agent and the second agent, the mass ratio of the non-volatile component to the total mass was 76% by mass. The diameter of the glass fiber contained in the first agent was 10 μm, and the fiber length was 30 to 50 μm.

[0073] (4-2) Production of the building material 1 (i) Example 1 As the base material 3, a rectangular plate-shaped laminated wood was prepared. The dimensions of the base material 3 were 99 mm in length, 99 mm in width, and 30 mm in thickness. As shown in S1 of FIG. 3, the specific coating composition produced in (4-1) was applied to the surface of the base material 3 to form a first coating film 11. The specific coating composition was a mixture of 100 parts by mass of the first agent and 100 parts by mass of the second agent.

[0074] Next, the first coating film 11 was left to stand for 16 hours until it hardened and lost its fluidity. The mass per unit area of the first coating film 11 was 183 g / m 2 It was. The mass per unit area of the first coating film 11 is the mass per unit area of the non-volatile component.

[0075] Next, as shown in S2 of FIG. 3, a glass fiber part 9 made of a glass fiber cloth was placed on the first coating film 11. Among the glasses constituting the glass fiber cloth, 97% by mass or more was alumina borosilicate glass. The sizing agent contained in the glass fiber cloth was an acrylic resin. The content of the sizing agent in the glass fiber cloth was 13% by mass. The content of the glass in the glass fiber cloth was 87% by mass.

[0076] The weft density in the longitudinal direction of the glass fiber cloth was 53 threads / 25 mm. The warp density in the transverse direction of the glass fiber cloth was 48 threads / 25 mm. The weaving method of the glass fiber cloth was plain weave. The mass per unit area of the glass fiber cloth was 150 g / m 2 2. The thickness of the glass fiber cloth was 0.1 mm.

[0077] Next, as shown in S3 of FIG. 3, a specific paint composition was applied from above the glass fiber part 9 to form a second coating film 13. Next, the second coating film 13 was cured. The mass per unit area of the second coating film 13 was 197 g / m 2 2. The mass per unit area of the second coating film 13 is the mass per unit area of the non-volatile component.

[0078] Through the above steps, the building material 1 of Example 1 was completed. The first coating film 11 and the second coating film 13 became the coating film 7 constituting the coating layer 5. The first coating film 11 became the non-containing part 5C. As shown in FIG. 1, all of the glass fiber part 9 was embedded in the coating film 7. The second coating film 13 was the part of the coating film 7 that penetrated into the glass fiber part 9 or was on the side of the surface 5B rather than the glass fiber part 9.

[0079] (ii) Examples 2 to 7 Basically in the same manner as in Example 1, the building materials 1 of Examples 2 to 7 were manufactured. However, the mass per unit area of the first coating film 11 and the mass per unit area of the second coating film 13 were as shown in Table 1.

[0080]

Table 1

[0081] In Example 4, instead of the glass fiber part 9 made of a glass fiber cloth, a glass fiber part 9 made of a glass fiber nonwoven fabric was used. Among the glass constituting the glass fiber nonwoven fabric, 97% by mass or more was alumina borosilicate glass. The sizing agent contained in the glass fiber nonwoven fabric was an acrylic resin. The content of the sizing agent in the glass fiber nonwoven fabric was 13% by mass. The content of the glass in the glass fiber nonwoven fabric was 87% by mass. The mass per unit area of the glass fiber nonwoven fabric was 150 g / m 2 It was. The thickness of the glass fiber nonwoven fabric was 0.1 mm.

[0082] In Examples 5 and 6, since the specific coating composition applied in S3 was small, as shown in FIG. 2, the surface 9A of the glass fiber part 9 and the surface 5B of the coating layer 5 coincided with each other. (iii) Comparative Examples 1 and 2 Basically, the building materials 1 of Comparative Examples 1 and 2 were manufactured in the same manner as in the case of Example 1. However, in Comparative Example 1, after forming and curing the first coating film 11, the second coating film 13 was formed without placing the glass fiber part 9 thereon. Therefore, in Comparative Example 1, the coating layer 5 does not include the glass fiber part 9.

[0083] In Comparative Example 2, after forming the first coating film 11 and the second coating film 13 in the same manner as in Comparative Example 1, the glass fiber part 9 made of a glass fiber cloth was placed on the second coating film 13. Therefore, in Comparative Example 2, the glass fiber part 9 was not embedded in the coating film 7.

[0084] Also, the mass per unit area of the first coating film 11 and the mass per unit area of the second coating film 13 in Comparative Examples 1 and 2 were as shown in Table 1. (4-3) Evaluation of the building material 1 Tests were conducted on the building materials 1 of each example and each comparative example. By the cone calorimeter method specified in ISO5660-1, 50 kW / m was applied to the test piece 2The total heat generation and the maximum heat generation rate were measured when heating was performed for 10 minutes at the radiation intensity of . The measured values were applied to the following evaluation criteria to evaluate the flame retardancy. The evaluation results are shown in Table 1.

[0085] (Evaluation criteria for flame retardancy based on the total heat generation) 〇: 7.2 MJ / m 2 Below △: 8 MJ / m 2 Below ×: 8 MJ / m 2 Exceeding (Evaluation criteria for flame retardancy based on the maximum heat generation rate) 〇: 180 kW / m 2 Below △: 200 kW / m 2 Below ×: 200 kW / m 2 Exceeding Also, when performing the cone calorimeter method, an igniter is installed above the test piece. When the coating layer 5 foamed, it was observed whether the coating layer 5 contacted the igniter. Based on the observation results, the foam suppression effect was evaluated according to the following criteria. The evaluation results are shown in Table 1. Note that when the coating layer 5 foams excessively, the coating layer 5 is likely to contact the igniter.

[0086] (Evaluation criteria for the foam suppression effect) 〇: The coating layer 5 does not contact the igniter. △: The coating layer 5 contacts the igniter, but the contact time is within 10 seconds.

[0087] ×: The coating layer 5 contacts the igniter, and the contact time exceeds 10 seconds. Also, the building material 1 was visually observed, and the transparency of the coating layer 5 was evaluated according to the following criteria. The evaluation results are shown in Table 1.

[0088] (Evaluation criteria for transparency) 〇: The grain of the base material 3 can be visually recognized through the coating layer 5. △: The grain of the base material 3 can be seen vaguely through the coating layer 5.

[0089] ×: The grain of the base material 3 cannot be seen. 5. Other embodiments Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to the above-described embodiments and can be implemented with various modifications.

[0090] For example, another coating film may be further formed on the second coating film 13.

Explanation of reference numerals

[0091] 1... building material, 3... base material, 5... coating layer, 5A... center, 5B... surface, 5C... non-containing part, 7... coating film, 9... glass fiber part, 9A... surface, 11... first coating film, 13... second coating film

Claims

1. a base material, a coating layer formed on the surface of the base material, and comprising, the coating layer, a coating film that foams upon heating, a glass fiber part made of a glass fiber cloth or a glass fiber non-woven fabric, at least a part of which is embedded in the coating film, and comprising, the mass per unit area of the coating film is 250 g / m² or more and 550 g / m² or less, among the coating film, the mass per unit area of the part that infiltrates the glass fiber part or is on the surface side of the glass fiber part is 75 g / m² or more and 197 g / m² or less, a building material.

2. a base material, a coating layer formed on the surface of the base material, and comprising, the coating layer, a coating film that foams upon heating, a glass fiber part made of a glass fiber cloth or a glass fiber non-woven fabric, at least a part of which is embedded in the coating film, and comprising, the coating film contains (A) a water-soluble melamine resin, (B) a polycondensed phosphate ester, (C) one or more of phosphoric acid, boric acid, ammonium salts, and ammonia, and (D) urea, a building material.

3. The building material according to Claim 2, The mass per unit area of the coating film is 250 g / m ２ or more and 550 g / m ２ or less, and Among the coating films, the mass per unit area of the portion that has penetrated into the glass fiber portion or is on the surface side of the glass fiber portion is 75 g / m ２ or more and 197 g / m ２ or less. a building material.

4. The building material according to any one of Claims 1 to 3, the coating layer includes a portion that does not contain the glass fiber part on the side of the base material, a building material.

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