Fire-resistant panels and fire-resistant panel joint structures

Abstract

To provide a fireproof panel with improved fire resistance performance.SOLUTION: A fireproof panel comprises: a first noncombustible board having a first face and a second face opposite the first face; a second noncombustible board having a first face and a second face opposite the first face; a third noncombustible board covering the first face of the first noncombustible board; a fourth noncombustible board covering the first face of the second noncombustible board; a honeycomb material provided between the third and the fourth noncombustible boards; and a first channel steel provided between the third and the fourth noncombustible boards and extending along a first side face of the honeycomb material; and a second channel steel provided between the third noncombustible board and the fourth noncombustible board and extending along the second side face opposite the first side face. An opening of the first channel steel is provided at the opposite position of an opening of the second channel steel across the honeycomb material.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] An embodiment of the present invention relates to a fire-resistant panel, a method for manufacturing a fire-resistant panel, a joining structure for fire-resistant panels, and a joining method for fire-resistant panels.

[0002] Sandwich panel (SWP) technology, which has its roots in Europe, is a highly functional material that excels in design, heat insulation, and light weight. The use of sandwich panels is expected to reduce the burden on the building's structural frame, and to reduce the labor and construction time required for construction.

[0003] Patent Document 1 discloses a fire-resistant panel manufactured by bonding non-combustible boards containing calcium silicate and unexpanded vermiculite with adhesive to both sides of a non-combustible honeycomb structural material made by stacking non-combustible sheets whose main component is sepiolite in a honeycomb shape using a heat-resistant adhesive between the layers. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2005-254478 Summary of the Invention [Problem to be solved by the invention]

[0005] The fire-resistant panel described in Patent Document 1 must use sepiolite, which has a heat-resistant temperature of 400°C to 500°C or higher, as the non-combustible honeycomb structural material, and materials that can be used as the non-combustible honeycomb structural material are limited.

[0006] In view of the above problems, one object of one embodiment of the present invention is to provide a fire-resistant panel having improved fire resistance performance, regardless of the honeycomb material. [Means for solving the problem]

[0007] A fire-resistant panel according to one embodiment of the present invention further comprises a first non-combustible board having a first surface and a second surface opposite the first surface, a second non-combustible board having a first surface and a second surface opposite the first surface, a third non-combustible board covering the first surface of the first non-combustible board, a fourth non-combustible board covering the first surface of the second non-combustible board, a honeycomb material arranged between the third and fourth non-combustible boards, a first channel steel arranged between the third and fourth non-combustible boards and extending along a first side surface of the honeycomb material, and a second channel steel arranged between the third and fourth non-combustible boards and extending along a second side surface opposite the first side surface, and the opening of the first channel steel is arranged in a position opposite the opening of the second channel steel, with the honeycomb material in between.

[0008] In the above configuration, there is provided a concave fitting member that is arranged between the third non-combustible board and the fourth non-combustible board and has a web that extends along the third side of the honeycomb material and a first flange and a second flange that sandwich the web, and a fifth non-combustible board that is arranged in a position opposite the concave fitting member with the honeycomb material in between, and the fifth non-combustible board is arranged in contact with the third non-combustible board and the fourth non-combustible board.

[0009] In the above configuration, the concave fitting member contacts the third side surface of the honeycomb material.

[0010] In the above configuration, the concave fitting member is a channel steel or a setting block.

[0011] The above-mentioned configuration further includes a first decorative material covering the second surface of the first noncombustible board, and a second decorative material covering the second surface of the second noncombustible board.

[0012] In the above-described configuration, the honeycomb material has an inorganic foam material filled in each of the plurality of cell spaces that constitute the honeycomb material.

[0013] The above-mentioned configuration further includes an inorganic foam material sandwiched between the honeycomb material and the third noncombustible board.

[0014] In the above configuration, the first noncombustible board and the second noncombustible board are calcium silicate boards, and the third noncombustible board and the fourth noncombustible board are fiber-mixed gypsum boards.

[0015] A joint structure for fire-resistant panels in which a plurality of fire-resistant panels according to the above configuration are lined up and joined together, in which a connecting material is provided between the third non-combustible board and the fourth non-combustible board of one of the adjacent fire-resistant panels, and between the third non-combustible board and the fourth non-combustible board of the other fire-resistant panel.

[0016] In the above configuration, the connecting material is a calcium silicate board, a gypsum board, or a gypsum board. [Effects of the Invention]

[0017] According to one embodiment of the present invention, it is possible to provide a fire-resistant panel with improved fire resistance, regardless of the honeycomb material. [Brief explanation of the drawings]

[0018] [Figure 1] 1 is a front view of a fireproof structure according to an embodiment of the present invention. [Figure 2] 1 is a horizontal cross-sectional view of a fire-resistant panel according to an embodiment of the present invention. [Figure 3] 1 is a cross-sectional elevation view of a fire-resistant panel according to an embodiment of the present invention. [Figure 4A] 1 is a perspective view of a honeycomb material of a fire-resistant panel according to an embodiment of the present invention. FIG. [Figure 4B] 1 is a perspective view of a honeycomb material of a fire-resistant panel according to an embodiment of the present invention. FIG. [Figure 4C] 1 is a perspective view of a honeycomb material of a fire-resistant panel according to an embodiment of the present invention. FIG. [Figure 5] 1 is a cross-sectional view of a joint structure of a fire-resistant panel according to one embodiment of the present invention. [Figure 6] FIG. 2 is an end view illustrating a method for joining fire-resistant panels in one embodiment of the present invention. [Figure 7] 1 is a cross-sectional elevation view of a fire-resistant panel according to an embodiment of the present invention. [Figure 8] 1 is a cross-sectional elevation view of a fire-resistant panel according to an embodiment of the present invention. [Figure 9] 1 is a cross-sectional elevation view of a fire-resistant panel according to an embodiment of the present invention. [Figure 10A] 1 is a cross-sectional view of a connecting material used in a joint structure of fire-resistant panels according to one embodiment of the present invention. [Figure 10B] 1 is a cross-sectional view of a connecting material used in a joint structure of fire-resistant panels according to one embodiment of the present invention. [Figure 10C] 1 is a cross-sectional view of a connecting material used in a joint structure of fire-resistant panels according to one embodiment of the present invention. [Figure 10D] 1 is a cross-sectional view of a connecting material used in a joint structure of fire-resistant panels according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0019] Each embodiment of the present invention will be described below with reference to the drawings. The disclosure is merely an example, and any modifications that a person skilled in the art can easily make while maintaining the spirit of the invention are naturally included within the scope of the present invention. Furthermore, the drawings may be schematic in terms of the width, thickness, shape, etc. of each part compared to the actual embodiment for clarity of explanation, but these are merely examples and are not intended to limit the interpretation of the present invention. Furthermore, in this specification and each drawing, elements similar to those previously described with reference to the previous drawings are designated by the same reference numerals (or reference numerals with A, B, etc. suffixed thereto), and detailed descriptions may be omitted as appropriate. Furthermore, the letters "first" and "second" attached to each element are convenient labels used to distinguish each element and have no further meaning unless otherwise specified.

[0020] (First embodiment) A fire-resistant structure 1000 and a fire-resistant panel 100 according to one embodiment of the present invention will be described with reference to FIGS.

[0021] <1. Overview> FIG. 1 is a front view showing a fireproof structure 1000 according to one embodiment of the present invention. The fireproof structure 1000 is applicable to compartment members inside or outside buildings such as logistics cold storage warehouses, clean rooms, hospitals, homes, production factories, livestock factories, commercial facilities, and office buildings. The fireproof structure 1000 includes a plurality of fireproof panels 100-1 to 100-3. In the following description, the fireproof panels 100-1 to 100-3 have the same structure except for their placement locations. The same applies to each of the components of the fireproof panel 100.

[0022] The fireproof structure 1000 and the fireproof panel 100 are defined as having a first direction D1, a second direction D2 perpendicular to the first direction D1, and a third direction D3 perpendicular to the first direction D1 and the second direction D2. The fireproof panel 100 has a height H, a width W, and a thickness T (not shown in FIG. 1 ). The height H is greater than the width W and the thickness T, and the width W is greater than the thickness T. In this embodiment, an example will be described in which the fireproof panel 100 is installed by vertical installation so that the height H of the fireproof panel 100 is in the second direction D2 and the width W is in the first direction D1. However, one embodiment of the present invention is not limited thereto, and the fireproof panel 100 may also be installed by horizontal installation so that the height H of the fireproof panel 100 is in the first direction D1 and the width W is in the second direction D2.

[0023] The fire-resistant panel 100 has a first surface 100a and a second surface 100b opposite the first surface 100a. Fig. 1 illustrates the first surface 100-1a of the fire-resistant panel 100-1. A plurality of connectors are provided at predetermined intervals in the fire-resistant panel 100 along the second direction D2. Connectors 166, 168, 182, 188, 192, and 194 shown in Fig. 1 will be described in detail later.

[0024] In the fireproof structure 1000, for example, the fireproof panels 100-1 to 100-3 are arranged side by side in the first direction D1. Adjacent fireproof panels 100-1 and 100-2 are joined by a connector 110-1. Adjacent fireproof panels 100-2 and 100-3 are joined by a connector 110-2.

[0025] <2. Fireproof Panel Structure> Fig. 2 is a horizontal cross-sectional view of the fire-resistant panel 100 according to one embodiment of the present invention. Fig. 2 corresponds to a cross-section of the fire-resistant panel shown in Fig. 1 taken along line A1-A2 passing through the connectors 166 and 168.

[0026] The fire-resistant panel 100 includes a honeycomb material 102, non-combustible boards 104, 106, non-combustible boards 108, 112, and channel steel 142, 144. The honeycomb material 102 has a first surface 102a and a second surface 102b opposite the first surface 102a. The non-combustible board 104 has a first surface 104a and a second surface 104b opposite the first surface 104a. The non-combustible board 106 has a first surface 106a and a second surface 106b opposite the first surface 106a.

[0027] The non-combustible board 108 covers the first surface 104a of the non-combustible board 104. The non-combustible board 112 covers the first surface 106a of the non-combustible board 106. The honeycomb material 102 is provided between the non-combustible board 108 and the non-combustible board 112. The channel steel 142 is provided between the non-combustible board 108 and the non-combustible board 112, and extends along the side surface 102c that is continuous with the first surface 102a of the honeycomb material 102. The channel steel 144 is provided between the non-combustible board 108 and the non-combustible board 112, and extends along the side surface 102d that is continuous with the first surface 102a of the honeycomb material 102. The opening of the channel steel 142 is provided in a position facing the opening of the channel steel 144, with the honeycomb material 102 in between.

[0028] In other words, the honeycomb material 102 is sandwiched between the two non-combustible boards 108 and 112. Furthermore, the two non-combustible boards 108 and 112 are sandwiched between the two non-combustible boards 104 and 106. In this manner, by sandwiching the non-combustible board 108 between the honeycomb material 102 and the non-combustible board 104, and sandwiching the non-combustible board 112 between the honeycomb material 102 and the non-combustible board 106, the fire resistance of the fire-resistant panel 100 can be improved.

[0029] As shown in FIG. 2 , the opening of the channel steel 142 faces the side surface 102c of the honeycomb material 102. Therefore, a space 154 is formed between the channel steel 142 and the side surface 102c of the honeycomb material 102. Similarly, the opening of the channel steel 144 faces the side surface 102d of the honeycomb material 102. Therefore, a space 156 is formed between the channel steel 144 and the side surface 102d of the honeycomb material 102. By providing the channel steel 142 and the channel steel 144, the strength of the fire-resistant panel 100 can be improved. Furthermore, in the event of a fire, the channel steels 142 and 144 expand due to heating. By providing the spaces 154 and 156, the expansion allowance of the channel steels 142 and 144 can be absorbed. Therefore, even if the channel steel expands during a fire, the fire-resistant panel on the side where the fire occurred can be prevented from being significantly deformed. Furthermore, by providing a U-shaped support hole member, when fastening the decorative panel, non-combustible board, and non-combustible board with a fastener, the fastener can be firmly fixed by the flange of the channel steel.

[0030] The channel steel 142 has a web 142a extending along the first direction D1 and flanges 142b and 142c that sandwich the web 142a. The flanges 142b and 142c also extend along the first direction D1. The channel steel 144 has a channel steel 144a extending along the first direction D1 and flanges 144b and 144c that sandwich the web 144a. The flanges 144b and 144c also extend along the first direction D1.

[0031] A decorative material 114 is provided on the second surface 104b of the non-combustible board 104. A decorative material 116 is provided on the second surface 106b of the non-combustible board 106. The decorative material 114, the non-combustible board 104, the non-combustible board 108, and the flange 142b of the channel steel 142 are fixed together by a connector 162. The decorative material 114, the non-combustible board 104, the non-combustible board 108, and the flange 144b of the channel steel 144 are fixed together by a connector 164. The decorative material 116, the non-combustible board 106, the non-combustible board 112, and the flange 142c of the channel steel 142 are fixed together by a connector 166. The decorative material 116, the non-combustible board 106, the non-combustible board 112, and the flange 144c of the channel steel 144 are fixed together by a connector 168.

[0032] A recess 172 is formed by the non-combustible board 108, the web 142a of the channel steel 142, and the non-combustible board 112. A recess 174 is formed by the non-combustible board 108, the web 144a of the channel steel 144, and the non-combustible board 112. The recesses 172, 174 function as joints for connecting adjacent fire-resistant panels 100 in the first direction D1. Adjacent fire-resistant panels 100 can be joined by fitting connecting members 110 into the recesses 172, 174. The joining structure of the fire-resistant panels 100 will be described later.

[0033] Fig. 3 is an elevational cross-sectional view of a fire-resistant panel according to one embodiment of the present invention. Fig. 3 corresponds to a cross section of the fire-resistant panel shown in Fig. 1 taken along line B1-B2. In Fig. 3, the fire-resistant panel 100 is cut along connectors 182 and 184. In Fig. 1, the fire-resistant panel 100 is provided with a plurality of connectors, but Fig. 3 only shows some of the connectors 182 and 184.

[0034] The elevational cross-sectional view of the fire-resistant panel 100 shown in Fig. 3 is cut at the position where the channel steel 142 is provided. As described above, a space 152 is provided between the flange 144b and the flange 144c of the channel steel 142. Therefore, in Fig. 2, the side surface 102c of the honeycomb material 102 is shown in the second direction D2 (the depth direction of the paper).

[0035] A concave fitting member 146 is provided between the noncombustible board 108 and the noncombustible board 112. The web 146a of the concave fitting member 146 has a web 146a extending along the second direction D2 and flanges 146b and 146c that sandwich the web 146a. In other words, the web 146a extends along the side surface 102e of the honeycomb material 102. The flanges 146b and 146c also extend along the second direction D2. The web 146a of the concave fitting member 146 is in contact with the side surface 102e of the honeycomb material 102.

[0036] The opening of the concave fitting member 146 is fitted with the runner 202. The runner 202 extends along the second direction D2. The runner 202 is fixed to the floor material 302 by a connector 204. This allows the fire-resistant panel 100 to be installed in a desired location. Although not shown, the runner 202 and the floor material 302 are fixed together by a plurality of connectors 204 positioned at predetermined intervals.

[0037] A non-combustible board 122 is provided between the non-combustible board 108 and the non-combustible board 112. The non-combustible board 122 extends along the second direction D2. In other words, the non-combustible board 122 extends along the side surface 102f of the honeycomb material 102. The non-combustible board 122 is provided at a distance from the side surface 102f of the honeycomb material 102. In other words, a space 156 is provided that is surrounded by the side surface 102f of the honeycomb material 102, the non-combustible boards 108 and 112, and the non-combustible board 122.

[0038] A fastening angle 206 is provided to secure the fire-resistant panel 100 to the ceiling 304. The fastening angle 206, decorative material 116, non-combustible board 106, non-combustible board 112, and flange 142c of channel steel 142 are secured together by connectors 188. A backup material 208 is provided in the gap between the ceiling 304 and the fire-resistant panel 100.

[0039] <3. Fireproof Panel Materials> Next, various materials used in the fire-resistant panel 100 according to one embodiment of the present invention will be described.

[0040] FIG. 4A is a perspective view illustrating an example of a honeycomb material 102. The honeycomb material 102 is used as a heat insulating material. The honeycomb material 102 does not need to have fire resistance, and any honeycomb material 102 can be used. Here, fire resistance refers to the ability to suppress the spread of a normal fire that occurs around a building. The honeycomb material 102 is made of various materials, such as non-combustible paper honeycomb material, cardboard, aluminum honeycomb material, or ceramic honeycomb material. When, for example, ceramic honeycomb material, aluminum honeycomb material, or non-combustible paper is used as the honeycomb material 102, fire resistance can be improved. The thickness of the honeycomb material is 15 mm to 50 mm, 20 mm to 50 mm, or 20 mm to 40 mm, and in this embodiment, it is 30 mm.

[0041] The shape of the cells in the cross section of the honeycomb material 102 perpendicular to the cell extension direction (third direction D3) is not particularly limited, and may be, for example, a rectangle, a hexagon, an octagon, or a combination of these shapes. The cell size d in the cross section of the honeycomb material 102 is 5 mm to 50 mm, 10 mm to 40 mm, or 25 mm to 35 mm, and is 30 mm in this embodiment. The porosity of the honeycomb material 102 is, for example, 91% to 95%. In FIG. 4A, the cell shape is shown as a hexagon.

[0042] The honeycomb material 102 has a honeycomb structure, and more than 90% of its volume is air, which makes it possible to reduce the weight of the fire-resistant panel 100. The honeycomb structure also prevents air convection, improving the heat insulation of the fire-resistant panel 100. The honeycomb structure also provides high bending strength, and can increase strength against planar pressure.

[0043] 4B shows a configuration in which the cells of the honeycomb material 102 are filled with an inorganic foam material 124. By filling each of the multiple cells of the honeycomb material 102 with the inorganic foam material 124, the sound insulation and heat insulation properties of the fire-resistant panel 100 can be further improved.

[0044] FIG. 4C shows a configuration in which a sheet-like inorganic foam material 126 is provided on the first surface 102a of the honeycomb material 102. In this case, the inorganic foam material 126 is provided between the first surface 102a of the honeycomb material 102 and the non-combustible board 108. Alternatively, the inorganic foam material 126 may be provided between the second surface 102b of the honeycomb material 102 and the non-combustible board 112. By providing the inorganic foam material 126 on at least one of the first surface 102a and the second surface 102b of the honeycomb material 102, the sound insulation performance of the surface on which the inorganic foam material 126 is provided can be improved. Therefore, when the inorganic foam material 126 is provided on either the first surface 102a or the second surface 102b of the honeycomb material 102, the sound insulation performance of the fire-resistant panel 100 can be made directional.

[0045] The non-combustible boards 104, 106, 108, and 122 are made of a material that has fire-resistant properties, low heat storage, and high cooling properties. The non-combustible boards 104, 106, 108, and 122 are made of various materials, such as wood-based boards (e.g., insulation boards, cellulose fiberboards, and wood-wool cement boards) and inorganic boards (e.g., concrete, cement mortar, gypsum boards, gypsum boards, fiber-mixed gypsum boards, and calcium silicate boards). The non-combustible boards 104, 106, 108, and 122 are preferably made of a fire-resistant covering material with excellent strength and heat resistance. Examples of fire-resistant covering materials include inorganic boards (e.g., concrete, cement mortar, gypsum boards, gypsum boards, fiber-mixed gypsum boards, and calcium silicate boards). In this embodiment, calcium silicate boards are used for the non-combustible boards 104 and 106, and fiber-mixed gypsum boards are used for the non-combustible boards 108 and 122. The thickness of the non-combustible boards 104, 106, 108, 122 is 7 mm to 50 mm, 7 mm to 40 mm, or 9.5 mm to 30 mm.

[0046] Lightweight channel steel and C-shaped steel (lip channel steel) having a C-shape are used as the channel steels 142, 144. Channel steel and lightweight channel steel have a shape that has a web and two flanges that sandwich the web. Also, C-shaped steel has a shape that has a web, two flanges that sandwich the web, and a lip at the tip of the flange. In this embodiment, the channel steels 142, 144 are illustrated as channel steels that do not have a lip. The channel steels 142, 144 are made of various materials, for example, alloys such as aluminum, stainless steel, etc.

[0047] The concave fitting member 146 is a channel steel or a setting block. When a channel steel is used as the concave fitting member 146, the same material as the channel steels 142 and 144 is used.

[0048] The decorative materials 114, 116 are made of various materials, such as wood-based materials, ceramic-based decorative materials (ceramics), color steel sheets, galvalume steel sheets, aluminum sheets, wallpaper, etc. The thickness of the decorative materials 114, 116 is thinner than the thickness of the non-combustible boards 104, 106, and is 4 mm to 15 mm, 5 mm to 12 mm, or 8 mm to 12 mm, and is 9.5 mm in this embodiment.

[0049] In the fire-resistant panel 100, a pair of non-combustible boards 104, 106 are provided symmetrically with respect to the honeycomb material 102. The pair of non-combustible boards 104, 106 are preferably provided to be made of the same material, have the same shape, and have the same thickness.

[0050] In a fire-resistant panel 100 according to one embodiment of the present invention, a honeycomb material 102 is sandwiched between non-combustible boards 108 and 112, which are then sandwiched between non-combustible boards 104 and 106. This laminated structure of the non-combustible boards 108 and 112 and the non-combustible boards 104 and 106 improves fire resistance. It also improves the bending strength of the fire-resistant panel 100. This allows for the use of various decorative materials, such as wood-based materials and paper materials, instead of the steel decorative materials typically used in conventional sandwich panels, improving the appearance of the fire-resistant panel 100 and enhancing its design. Furthermore, this allows for a change in the design concept of sandwich panels, making them applicable to buildings requiring diverse designs.

[0051] In this embodiment, calcium silicate boards are used as the non-combustible boards 104 and 106, and fiber-mixed gypsum boards are used as the non-combustible boards 108 and 112. Calcium silicate boards have the effect of quickly reducing the temperature after being heated in the event of a fire. Furthermore, fiber-mixed gypsum boards have the effect of suppressing the temperature rise of the fire-resistant panel 100 by releasing moisture (crystal water) when heated in the event of a fire. This configuration ensures sufficient fire resistance to meet the fire resistance requirements of the fire-resistant panel 100.

[0052] According to the fire-resistant panel 100 of one embodiment of the present invention, a honeycomb material 102 is used as the heat insulating material. The honeycomb material 102 is lighter than rock wool, which has traditionally been used as a heat insulating material. Therefore, the weight of the entire fire-resistant panel 100 can be reduced. Furthermore, while having the same thermal conductivity as rock wool, CO2 emissions during its manufacture can be reduced. According to the fire-resistant panel 100 of one embodiment of the present invention, various materials can be used as the honeycomb material 102 regardless of the heat resistance temperature.

[0053] Furthermore, when gypsum boards are used as the non-combustible boards 104 and 106, moisture (crystal water) contained in the gypsum boards is released in the event of a fire, thereby suppressing the temperature rise of the fire-resistant panel 100. Furthermore, the non-combustible boards 104 and 106 may be impregnated with a flame retardant such as a phosphoric acid-based agent, thereby further improving the fire resistance performance.

[0054] <4. Joint structure of fire-resistant panels> FIG. 5 is a cross-sectional view of a joint structure when a plurality of fire-resistant panels 100 according to one embodiment of the present invention are arranged and joined together.

[0055] The fire-resistant panels 100-1 and 100-2 are arranged in the third direction D3, with a thickness T1 in the first direction D1, a width W in the second direction D2, and a height H1 in the third direction D3. The fire-resistant panels 100-1 and 100-2 are arranged so that the recess 174 of the fire-resistant panel 100-1 faces the recess 172 of the fire-resistant panel 100-2. A connecting member 110 is provided between the fire-resistant panels 100-1 and 100-2. Specifically, the connecting member 110 is fitted into the recess 174 of the fire-resistant panel 100-1 and the recess 172 of the fire-resistant panel 100-2. Depending on the length of the connecting member 110 in the second direction D2, a gap (also referred to as a joint) is provided between the fire-resistant panels 100-1 and 100-2. This gap may be filled with sealing materials 120a and 120b. By filling the gap between the fire-resistant panel 100-1 and the fire-resistant panel 100-2 with the sealants 120a and 120b, it is possible to prevent water from entering the gap between the fire-resistant panel 100-1 and the fire-resistant panel 100-2.

[0056] Furthermore, the length of the connecting material 110 in the second direction D2 is preferably, for example, 65 mm or more. If the length of the connecting material 110 in the second direction D2 is less than 65 mm, the heat during a fire may cause the fitting portion to open, which may lead to the spread of the fire. Furthermore, the length (thickness) of the connecting material 110 in the third direction D3 corresponds to the distance between the non-combustible board 108 and the non-combustible board 112.

[0057] The connecting material 110 may be, for example, a calcium silicate board, a gypsum board, a gypsum board, a fiber-mixed gypsum board, or a reinforcing steel plate. For example, when a single material is used for the connecting material 110, a calcium silicate board, a gypsum board, or a gypsum board is used. By using such a material for the connecting material 110, even if a fire breaks out in the fire-resistant panel 100-1, the connecting material 110 can prevent the fire from spreading. Therefore, the fire can be prevented from spreading in the second direction D2 of the fire-resistant panel 100. In other words, the fire can be prevented from spreading to the adjacent fire-resistant panel 100-2. The connecting material 110 may have various configurations, which will be described in detail below.

[0058] <5. Fireproof Panel Manufacturing Method> Next, an example of a method for manufacturing the fire-resistant panel 100 will be described.

[0059] An admixture is applied to the first surface 102a and the second surface 102b of the honeycomb material 102. A non-combustible board 108 is attached to the first surface 102a of the honeycomb material 102, and a non-combustible board 112 is attached to the second surface 102b. Next, the first surface 104a of the non-combustible board 104 is attached to the non-combustible board 108, and the first surface 106a of the non-combustible board 106 is attached to the non-combustible board 112. Next, a decorative material 114 is attached to the second surface 104b of the non-combustible board, and a decorative material 116 is attached to the second surface 106b of the non-combustible board 106.

[0060] A channel steel 142 is fitted between the non-combustible board 108 and the non-combustible board 112 so as to face the side surface 102c of the honeycomb material 102. Similarly, a channel steel 144 is fitted between the non-combustible board 108 and the non-combustible board 112 so as to face the side surface 102d of the honeycomb material 102. Furthermore, a concave fitting member 146 is fitted between the non-combustible board 108 and the non-combustible board 112 on the side surface 102e of the honeycomb material 102. A web 146a of the concave fitting member 146 is provided in contact with the side surface 102e of the honeycomb material 102. A non-combustible board 122 is provided between the non-combustible board 108 and the non-combustible board 112. The non-combustible board 122 is adhered to the non-combustible board 108 and the non-combustible board 112 with a gap between the non-combustible board 122 and the side surface 102f of the honeycomb material 102.

[0061] The decorative material 114, the non-combustible board 104, the non-combustible board 108, the channel steel 142, and the honeycomb material 102 are fixed together by a plurality of fasteners. The plurality of fasteners are arranged at predetermined intervals along the first direction D1. The decorative material 116, the non-combustible board 106, the non-combustible board 112, the channel steel 144, and the honeycomb material 102 are fixed together by a plurality of fasteners. The plurality of fasteners are arranged at predetermined intervals along the first direction D1.

[0062] Through the above steps, the fire-resistant panel 100 can be manufactured.

[0063] <6. Fireproof Panel Installation Method> Next, an example of a method for installing the fire-resistant panel 100-1 according to one embodiment of the present invention will be described.

[0064] 3, the runner 202 is fixed to the floor material 302 by the connector 204. The concave fitting member 146 of the fire-resistant panel 100-1 is fitted into the runner 202, thereby fixing the fire-resistant panel 100-1 in place.

[0065] Next, the fastening angle 206 is fixed so as to contact the fire-resistant panel 100-1 and the ceiling 304. The fastening angle 206, decorative material 116, non-combustible board 106, non-combustible board 112, and flange 142c of the channel steel 142 are fixed together with connectors 188. The fire-resistant panel 100-1 can be installed by fitting the backup material 208 into the gap formed between the ceiling 405 and the top of the fire-resistant panel 100-1.

[0066] Next, the connecting material 110 is fitted into the recess 174 of the fire-resistant panel 100. FIG. 6 shows the fitting of the connecting material 110 into the recess 174 of the fire-resistant panel 100-1. The fire-resistant panel 100-1 shown in FIG. 6 shows the second surface 102b of the honeycomb material 102, the flange 142c of the channel steel 142, the flange 144c of the channel steel 144, the non-combustible board 122, and the recessed fitting member 146. For ease of explanation, the non-combustible board 112, the non-combustible board 106, and the decorative material 116 are not shown in FIG. 6. The connecting material 110 extends along a first direction D1. The length of the connecting material 110 in the first direction D1 corresponds to the length from the recessed fitting member 146 to the non-combustible board 122. The connector 110 is moved in the direction of the arrow to fit into the recess 174 of the fire-resistant panel 100. The connector 110 may be provided in contact with the recessed fitting member 146 and the non-combustible board 122.

[0067] Although not shown, the fire-resistant panel 100-2 is fixed to the fire-resistant panel 100-1 by fitting the concave fitting member 146 of the fire-resistant panel 100-2 adjacent to the fire-resistant panel 100-1 into the runner 202. The fire-resistant panel 100-1 and the fire-resistant panel 100-2 can be joined by fitting the connecting material 110 into the recess 172 of the fire-resistant panel 100-2.

[0068] Through the above steps, the fire-resistant panel 100 according to one embodiment of the present invention can be installed.

[0069] (Second embodiment) In this embodiment, a modified example of the fire-resistant panel 100 in one embodiment of the present invention will be described with reference to Figures 7 to 9. In this embodiment, the method of fixing the fire-resistant panel 100 to the floor material 302 and the ceiling 304 is different from that of the first embodiment. In this embodiment, only the differences from the first embodiment will be described, and for similar points, the description of the first embodiment shall be referred to.

[0070] <1. Structure of Fire-Resistant Panel 100A> Fig. 7 is a cross-sectional elevation view of a fire-resistant panel 100A according to one embodiment of the present invention. In the fire-resistant panel 100A, holes 181 and 183 are formed in the decorative material 114, and a hole 185 is formed in the decorative material 116. Hole 181 is a recess for inserting connector 182, and hole 183 is a recess for inserting connector 184. Hole 185 is a recess for inserting connector 186. In Fig. 7, holes 181 and 183 are shown as recesses in the decorative material 114, and hole 185 is shown as a recess in the decorative material 116, but they may also be through-holes.

[0071] By pre-forming holes in the decorative materials 114, 116, the positions at which the connectors are fixed during construction can be determined, facilitating construction of the fire-resistant panel 100. Furthermore, the accuracy of the positions at which the connectors are driven into the fire-resistant panel 100 can be ensured. Furthermore, the design of the fire-resistant panel 100 can be improved. Furthermore, shorter connectors can be used compared to when no holes are provided in the fire-resistant panel 100. When long connectors are used, there is a risk that the connectors may become thermal bridges. In contrast, when short connectors are used, the connectors can be prevented from becoming thermal bridges, improving safety. Furthermore, the heads of the connectors can be sealed by filling the holes with a sealant or cap (lid). This is preferable because it prevents rust from forming on the connectors.

[0072] Furthermore, the fire-resistant panel 100A is fixed by a fixing member 212 and a fixing member 216. The fixing member 212 is fixed to the floor material 302 by a fastener 214, and the fixing member 216 is fixed to the floor material 302 by a fastener 218. This allows the fire-resistant panel 100A to be firmly fixed. Therefore, in FIG. 7, the fire-resistant panel 100A does not need to be fitted with a runner. This allows the step of fixing the floor material 302 and the runner to be eliminated.

[0073] <2. Structure of Fire-Resistant Panel 100B> Fig. 8 is a cross-sectional elevation view of a fire-resistant panel 100B according to one embodiment of the present invention. In the fire-resistant panel 100B, holes 181 and 183 are formed in the decorative material 114, and holes 185 and 187 are formed in the decorative material 116. Hole 181 is a recess for inserting connector 182, and hole 183 is a recess for inserting connector 184. Hole 185 is a recess for inserting connector 186, and hole 187 is a recess for inserting connector 188. In Fig. 8, holes 181, 183, 185, and 187 may be through-holes.

[0074] In FIG. 8, a C-shaped steel 148 is provided instead of the concave fitting member 146. The C-shaped steel 148 has a web 148a and flanges 148b and 148c that are provided so as to sandwich the web 148a, and lips 148d and 148e are provided at the tips of the flanges 148b and 148c. By using the C-shaped steel 148, the lower end of the fire-resistant panel 100 can be protected and reinforced when fitting with the runner 202. Furthermore, automated installation of the fire-resistant panel 100 can be made easier.

[0075] Furthermore, the fire-resistant panel 100B is fixed by a fixing member 212 and a fastener 214. The fixing member 212 is fixed to the floor material 302 by a fastener 214, and the fastener 214 is fixed to the floor material 302 by a fastener 218. Therefore, in Fig. 8, the fire-resistant panel 100A does not need to be fitted with a runner. This makes it possible to eliminate the step of fixing the floor material 302 and the runner.

[0076] Furthermore, the fire-resistant panel 100B is fixed by a fixing member 222 and a fixing tool 224. The fixing member 222 is fixed to the ceiling 304 by the fixing tool 224, and the fixing member 226 is fixed to the ceiling 304 by the fixing tool 228. This allows the fire-resistant panel 100B to be firmly fixed.

[0077] <3. Structure of Fire-Resistant Panel 100C> 9 is a cross-sectional elevation view of a fire-resistant panel 100C according to one embodiment of the present invention. In the fire-resistant panel 100C, holes 181 and 183 are formed in the decorative material 114, and a hole 185 is formed in the decorative material 116. Hole 181 is a recess for inserting a connector 182, and hole 183 is a recess for inserting a connector 184. Hole 185 is a recess for inserting a connector 186.

[0078] In FIG. 9, the shape of the runner 232 that secures the fire-resistant panel 100C is different from the shape of the runner 202. The runner 232 has a web 232a that extends along the second direction D2. The web 232a is sandwiched between flanges 232b and 232c. The web 232a is fixed to the floor material 302 by a fastener 234. The fire-resistant panel 100C is provided between the flanges 232b and 232c. This allows the fire-resistant panel 100C to be firmly fixed.

[0079] As described above, the fire-resistant panels 100A to 100C according to one embodiment of the present invention can be fixed to the floor material 302 and the ceiling 304 by various methods.

[0080] (Third embodiment) In this embodiment, the configuration of a connecting material 110 that joins adjacent fire-resistant panels 100-1 and 100-2 will be described with reference to Figures 10A to 10D. In this embodiment, differences from the first embodiment will be described, and for similar points, the description of the first embodiment shall be referred to.

[0081] 10A is an end view of the connecting material 110A. The connecting material 110A is composed of a non-combustible board 1101 and a non-combustible board 1102. The non-combustible board 1101 and the non-combustible board 1102 can be made of the same material as the non-combustible boards 104, 106, 108, and 122. For example, a calcium silicate board or a gypsum board can be used as the non-combustible board 1101, and a fiber-mixed gypsum board can be used as the non-combustible board 1102. The thickness of the non-combustible board 1101 is preferably greater than the thickness of the non-combustible board 1102. With this configuration, moisture (crystallization water) contained in the connecting material 110A is released by heating in the event of a fire, thereby preventing flames and heat from penetrating through the joints and fittings of the fire-resistant panel 100 to the back surface.

[0082] FIG. 10B is an end view of the connecting material 110B. The connecting material is composed of a non-combustible board 1101 and non-combustible boards 1102 and 1103. The non-combustible boards 1101 and 1102 and 1103 can be made of the same materials as the non-combustible boards 104, 106, 108, and 122. For example, the non-combustible board 1101 can be made of a calcium silicate board or a gypsum board, and the non-combustible boards 1102 and 1103 can be made of a fiber-mixed gypsum board. The thickness of the non-combustible board 1101 is preferably greater than the thickness of the non-combustible boards 1102 and 1103. This configuration allows moisture (crystallization water) contained in the connecting material 110A to be released by heating during a fire, thereby preventing flames and heat from penetrating through the joints and fittings of the fire-resistant panel 100 to the back surface.

[0083] 10C is an end view of the connecting material 110C. The connecting material 110C is composed of non-combustible boards 1104 and 1105 and a reinforcing steel plate 1106. The non-combustible boards 1104 and 1105 can be made of the same material as the non-combustible boards 104, 106, 108, and 122. For example, the non-combustible boards 1104 and 1105 can be made of calcium silicate boards or gypsum boards, and the reinforcing steel plate 1106 can be made of iron. The thickness of the non-combustible boards 1104 and 1105 is preferably greater than the thickness of the reinforcing steel plate 1106. By sandwiching the reinforcing steel plate 1106 between the non-combustible boards 1104 and 1105, the strength of the connecting material 110C can be improved.

[0084] 10D is an end view of the connecting material 110D. The connecting material 110D is composed of a non-combustible board 1107 and reinforcing steel plates 1108 and 1109. The non-combustible board 1107 can be made of the same material as the non-combustible boards 104, 106, 108, and 122. For example, the non-combustible board 1107 can be made of a calcium silicate board or a gypsum board, and the reinforcing steel plates 1108 and 1109 can be made of iron plates. The thickness of the non-combustible board 1107 is preferably greater than the thickness of the reinforcing steel plates 1108 and 1109. By sandwiching the non-combustible board 1107 between the reinforcing steel plates 1108 and 1109, the strength of the connecting material 110D can be improved.

[0085] Although one embodiment of the present invention has been described above with reference to the drawings, the present invention is not limited to the above embodiment and can be modified as appropriate within the scope of the present invention. For example, even if a person skilled in the art appropriately adds or deletes components or modifies the design based on the fire-resistant panel of this embodiment, it will still fall within the scope of the present invention as long as it includes the gist of the present invention. Furthermore, the above-described embodiments can be combined as appropriate as long as there is no mutual contradiction, and technical matters common to the embodiments are included in the embodiments even if not explicitly stated.

[0086] Even if there are other effects and advantages different from those brought about by the aspects of each of the above-mentioned embodiments, those that are clear from the description in this specification or that can be easily predicted by a person skilled in the art are naturally understood to be brought about by the present invention. [Explanation of symbols]

[0087] 100, 100-1 to 100-3, 100A, 100B, 100C: fireproof panel, 100a, 100a-1: first surface, 100b: second surface, 102: honeycomb material, 102a: first surface, 102b: second surface, 102c to 102f: side, 104: non-combustible board, 104a: first surface, 104b: second surface, 106: non-combustible board, 106a: first surface, 106b: second surface, 108: non-combustible board, 110, 110-1, 110-2, 110A to 110 D: connecting material, 112: non-combustible board, 114: decorative material, 116: decorative material, 120a, 120b: sealing material, 122: non-combustible board, 124, 126: inorganic foam material, 142: channel steel, 142a: web, 142b, 142c: flange, 144: channel steel, 144a: web, 144b, 144c: flange, 146: concave fitting member, 146a: web, 146b, 146c: flange, 148: C-shaped steel, 148b, 148c: flange, 148d, 148e: lip, 162, 164, 166, 168: connector, 172, 174: recess, 181: hole, 182: connector, 183: hole, 184: connector, 185: hole, 186: connector, 187: hole, 188: connector, 192: connector, 194: connector, 202: runner, 204: connector, 206: fastening angle, 208: backup material, 212: fixing member, 214: fixing member, 216: fixing member, 218: fixing member, 2 22: fixing member, 224: fixing tool, 226: fixing member, 228: fixing tool, 232: runner, 232a: web, 232b, 232c: flange, 234: fixing tool, 302: flooring material, 304: ceiling, 1000: fire-resistant structure, 1101: non-combustible board, 1102: non-combustible board, 1103: non-combustible board, 1104: non-combustible board, 1105: non-combustible board, 1106: reinforcing steel plate, 1107: non-combustible board, 1108: reinforcing steel plate, 1109: reinforcing steel plate

Claims

1. a first non-combustible board having a first surface and a second surface opposite to the first surface; a second non-combustible board having a first surface and a second surface opposite to the first surface; a third non-combustible board covering the first surface of the first non-combustible board; a fourth noncombustible board covering the first surface of the second noncombustible board; a honeycomb material provided between the third noncombustible board and the fourth noncombustible board; a first channel steel provided between the third noncombustible board and the fourth noncombustible board and extending along a first side surface of the honeycomb material; a second channel steel provided between the third noncombustible board and the fourth noncombustible board and extending along a second side surface opposite to the first side surface; a concave fitting member provided between the third noncombustible board and the fourth noncombustible board, the concave fitting member having a web extending along a third side surface adjacent to the first side surface and the second side surface of the honeycomb material, and a first flange and a second flange sandwiching the web; a fifth noncombustible board provided between the third noncombustible board and the fourth noncombustible board, and provided at a position facing a fourth side surface of the honeycomb material opposite the third side surface, with a space therebetween; The opening of the first channel steel is provided at a position opposite to the opening of the second channel steel across the honeycomb material, The fifth non-combustible board is a fire-resistant panel provided in contact with the third non-combustible board and the fourth non-combustible board.

2. The fire-resistant panel of claim 1 , wherein the recessed mating member contacts the third side of the honeycomb material.

3. 3. The fire-resistant panel according to claim 1, wherein the concave fitting member is a channel steel or a setting block.

4. a first decorative material covering the second surface of the first noncombustible board; The fire-resistant panel according to claim 1 , further comprising: a second decorative material covering the second surface of the second noncombustible board.

5. The fire-resistant panel according to claim 1 , wherein the honeycomb material has an inorganic foam material filled in each of a plurality of cell spaces that constitute the honeycomb material.

6. The fire-resistant panel according to claim 1 , further comprising an inorganic foam material sandwiched between the honeycomb material and the third noncombustible board.

7. the first non-combustible board and the second non-combustible board are calcium silicate boards, The fire-resistant panel according to claim 1 , wherein the third noncombustible board and the fourth noncombustible board are fiber-mixed gypsum boards.

8. A joint structure of fire-resistant panels in which a plurality of fire-resistant panels according to any one of claims 1 to 7 are arranged and joined together, A joint structure of fire-resistant panels in which a connecting material is provided between the third non-combustible board and the fourth non-combustible board of one of the adjacent fire-resistant panels, and between the third non-combustible board and the fourth non-combustible board of the other fire-resistant panel.

9. The joint structure of fire-resistant panels according to claim 8, wherein the connecting material is a calcium silicate board, a gypsum board, or a gypsum board.

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