Manufacturing methods for building materials

Abstract

To provide a primer that can give a substrate flame retardancy, and a method for producing building materials.SOLUTION: A primer comprises a silane compound represented by the formula (1), or a polymer of the silane compound. In the formula (1): (R1O)xSiR2y (x is a number from 1 to 3. y is a number from 1 to 3. The sum of x and y is 4. R1 is H, CH3, or C2H5. R2 is an organic substituent. At least some R2 included in the primer are C1-3 organic substituents, R2a. In the primer, the mol number of R2a is four or more times higher than the mol number of R2, which is not R2a).SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a primer and a method for manufacturing a building material. [Background technology]

[0002] One method of making wood flame retardant is to impregnate wood with a flame retardant. This method of impregnating wood with a flame retardant is disclosed in Patent Document 1. One method of making plastic flame retardant is to change the composition of the plastic. This method of changing the composition of the plastic is disclosed in Patent Document 2. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-137805 [Patent Document 2] Japanese Patent Application Laid-Open No. 2000-273298 Summary of the Invention [Problem to be solved by the invention]

[0004] Special equipment is required to penetrate the wood with a flame retardant. It also takes a lot of time and energy to penetrate the wood with a flame retardant. In the case of the method of changing the composition of the plastic, the composition of the plastic is limited.

[0005] In one aspect of the present disclosure, it is desirable to provide a primer that can impart flame retardancy to a substrate, and a method for producing a building material. [Means for solving the problem]

[0006] One aspect of the present disclosure is a primer containing a silane compound represented by the following formula (1) or a polymer of the silane compound: Equation (1) (R 1 O) x SiR 2y (x is a number between 1 and 3, inclusive. y is a number between 1 and 3, inclusive. The sum of x and y is 4. R 1 is H, CH3, or C2H5. 2 is an organic substituent. 2 At least a part of the organic substituents R 2a In the primer, R 2a The number of moles of is R 2a Not R 2 ) The flame retardancy of a substrate can be increased by applying a primer, which is one aspect of the present disclosure, to the substrate.

[0007] Another aspect of the present disclosure is a method for producing a building material, comprising applying a primer to a substrate to form a primer layer, and forming a coating layer on the primer layer, wherein the primer is a primer containing a silane compound represented by the following formula (1) or a polymer of the silane compound:

[0008] Equation (1) (R 1 O) x SiR 2 y (x is a number between 1 and 3, inclusive. y is a number between 1 and 3, inclusive. The sum of x and y is 4. R 1 is H, CH3, or C2H5. 2 is an organic substituent. 2 At least a part of the organic substituents R 2a In the primer, R 2a The number of moles of is R 2a Not R 2 ) A building material produced by the building material production method according to another aspect of the present disclosure has high flame retardancy. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a cross-sectional view showing the configuration of a building material. [Figure 2] FIG. 1 is a cross-sectional view showing the configuration of a building material. [Figure 3] FIG. 1 is a cross-sectional view showing the configuration of a building material. [Figure 4] FIG. 1 is an explanatory diagram showing a manufacturing method of a building material. [Figure 5] FIG. 2 is an explanatory diagram showing the mechanism by which a primer layer suppresses wood combustion. [Figure 6] 10 is a graph showing the measurement results of the heat release amount and heat release rate in Example 12. [Figure 7] 10 is a graph showing the measurement results of the heat release amount and heat release rate in Comparative Example 5. DETAILED DESCRIPTION OF THE INVENTION

[0010] Exemplary embodiments of the present disclosure will now be described with reference to the drawings. 1. Composition of building materials (1) Base material Building materials include a base material. Examples of the base material include a flammable base material. Examples of the flammable base material include wood. Examples of wood include cedar lumber with a thickness of 12 mm, a width of 100 mm, and a length of 2000 mm.

[0011] The substrate is not limited to wood and can be selected arbitrarily. Examples of the substrate include plastic, wooden building materials, paper, cloth, etc. Examples of plastic include polyethylene resin, polypropylene resin, acrylic resin, phenolic resin, vinyl chloride resin, and expanded polystyrene resin. Examples of wooden building materials include lumber, laminated lumber, plywood, laminated veneer lumber (LVL), cross-laminated timber (CLT), and medium-density fiberboard (MDF). The form of the substrate is not particularly limited. Examples of the form of the substrate include a pillar, a board, a sheet, and a cloth.

[0012] Examples of the substrate include wooden structural members, such as pillars, beams, walls, and floors. The pillar may be, for example, a rectangular pillar. The cross-sectional shape of the rectangular pillar in a cross section perpendicular to the longitudinal direction is, for example, a square. The length of one side of the square is, for example, 90 mm or more and 1100 mm or less.

[0013] An example of a beam is a rectangular beam. The cross-sectional shape of a rectangular beam in a cross section perpendicular to the longitudinal direction is, for example, a rectangle. 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 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 is, for example, 3000 mm or more and 10000 mm or less.

[0014] The shape of the wall is, for example, a rectangle. 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.

[0015] The substrate may be, for example, a piece of wood with a plate- or sheet-like member attached to its surface. Examples of the plate- or sheet-like member include gypsum board, fireproof sheet, decorative material, etc. (2) Composition of the coating layer The building material includes a coating layer. The coating layer is formed on a primer layer, which will be described later. The coating layer includes, for example, a coating film and a glass fiber portion. The coating film foams upon heating. The glass fiber portion is made of glass fiber cloth or glass fiber nonwoven fabric. At least a portion of the glass fiber portion is embedded in the coating film.

[0016] For example, as shown in FIG. 1, a building material 1 includes a substrate 3, a primer layer 4, and a coating layer 5. The coating layer 5 is formed on the primer layer 4. The coating layer 5 includes a coating film 7 and a glass fiber portion 9. In the embodiment shown in FIG. 1, the entire glass fiber portion 9 is embedded in the coating film 7. The coating film 7 is impregnated into the interior of the glass fiber portion 9.

[0017] In the thickness direction, the glass fiber portion 9 is preferably located closer to the surface 5B of the coating layer 5 than to the center 5A in the thickness direction of the coating layer 5. When the glass fiber portion 9 is located closer to the surface 5B than to the center 5A, the foaming suppression effect is even higher. The foaming suppression effect is the effect of suppressing excessive foaming of the coating film 7.

[0018] The coating layer 5 preferably has a portion (hereinafter referred to as non-containing portion 5C) that does not contain the glass fiber portion 9 on the primer layer 4 side. The non-containing portion 5C is made up of, for example, only the coating film 7. When the coating layer 5 has the non-containing portion 5C, the foaming suppression effect is further enhanced.

[0019] For example, as shown in FIG. 2, building material 1 includes a substrate 3, a primer layer 4, and a coating layer 5. Coating layer 5 is formed on primer layer 4. Coating layer 5 includes a coating film 7 and a glass fiber portion 9. In the embodiment shown in FIG. 2, surface 9A of glass fiber portion 9 coincides with surface 5B of coating layer 5. Coating film 7 is impregnated into the glass fiber portion 9. Coating layer 5 preferably has a non-containing portion 5C on the primer layer 4 side. When coating layer 5 has non-containing portion 5C, the foaming suppression effect is even higher.

[0020] Examples of glass constituting the glass fiber cloth or glass fiber nonwoven fabric include alumina borosilicate glass, soda-lime glass, and quartz glass. Alumina borosilicate glass has a low thermal expansion coefficient and is resistant to thermal shock, making it preferable as the glass constituting the glass fiber cloth or glass fiber nonwoven fabric. Of the glass constituting the glass fiber cloth or glass fiber nonwoven fabric, it is preferable that 97 mass % or more is alumina borosilicate glass.

[0021] Examples of sizing agents contained in the glass fiber cloth or glass fiber nonwoven fabric include starch, acrylic resin, PVA, EVA, etc. The content of the sizing agent in the glass fiber cloth or glass fiber nonwoven fabric is preferably 3 mass % or less.

[0022] The weave 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, more preferably 53 threads / 25 mm.The weave 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, more preferably 48 threads / 25 mm.

[0023] When the weave density in the longitudinal or transverse direction is 70 threads / 25 mm or less, the penetration of the coating composition into the glass fiber cloth is improved, and when the weave density in the longitudinal or transverse direction is 30 threads / 25 mm or more, the foam-inhibiting effect is improved.

[0024] The preferred weaving method for the glass fiber cloth is plain weave. The mass per unit area of ​​the glass fiber cloth or glass fiber nonwoven fabric is 70 g / m 2 More than 150g / m 2 Less than 92 g / m 2 is more preferable.

[0025] The thickness of the glass fiber cloth or 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 of the glass fiber cloth or glass fiber nonwoven fabric in the longitudinal direction is preferably 300 N / 25 mm or more and 1000 N / 25 mm or less, more preferably 510 N / 25 mm, and the tensile strength of the glass fiber cloth or glass fiber nonwoven fabric in the transverse direction is preferably 300 N / 25 mm or more and 1000 N / 25 mm or less, more preferably 451 N / 25 mm.

[0026] The mass per unit area of ​​the coating film 7 is, for example, 250 g / m 2 More than 550g / m 2 The mass per unit area of ​​the coating film 7 that is impregnated into the glass fiber portion 9 or that is closer to the surface 5B than the glass fiber portion 9 is 75 g / m 2 More than 275g / m 2 In this case, the foaming suppression effect is further enhanced.

[0027] For example, as shown in FIG. 3, the coating layer 5 does not include a glass fiber portion, but includes a coating film 7. For example, the coating layer 5 is made of only the coating film 7. The mass per unit area of ​​the coating film 7 is, for example, 250 g / m 2 More than 550g / m 2 The following is the result. (3) Composition of the paint composition The coating film 7 is formed by applying a 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 condensation-polymerized phosphate ester, and (c) one or more of phosphoric acid, boric acid, ammonium salt, and ammonia water. The specific coating composition may further contain one or more of (d) a compound having an amino group in its molecular structure, (e) kaolin, and (f) glass fiber.

[0028] The coating composition used to form the coating film 7 may be any other coating composition as long as it can form a coating film that foams when heated. It is preferable that the coating film 7 formed by applying the other coating composition has transparency.

[0029] (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 an aldehyde with melamine in the presence of an alkaline catalyst. Methods for producing water-soluble melamine resins are disclosed, for example, in Japanese Patent No. 257115, Japanese Patent Laid-Open No. 51-114492, and Japanese Patent Laid-Open No. 2006-124457.

[0030] Examples of water-soluble melamine resins include methylol melamine resins, alkoxylated methylol melamine resins, etc. Examples of methylol melamine resins include monomethylol melamine resins, dimethylol melamine resins, trimethylol melamine resins, etc. Examples of alkoxylated methylol melamine resins include methylol melamine resins, methylated methylol melamine resins, methoxymethylolated melamine resins, butylated methylol melamine resins, etc.

[0031] The alkoxylated methylol melamine resin may be completely alkoxylated, or may have a residual methylol group or an residual imino group. The specific coating composition may also contain a copolymer of a water-soluble melamine resin and a phenolic resin, etc. Among the water-soluble melamine resins, methylol melamine resins are more preferred.

[0032] When the specific coating composition contains a methylol melamine resin, the flame retardancy of the substrate 3 and the transparency of the coating film 7 become even more pronounced. In this specification, "transparent" is not limited to complete transparency, and may be, for example, semi-transparent.

[0033] (3-2)(b) Polycondensed phosphate ester The specific coating composition contains a condensation-polymerized phosphate ester. The condensation-polymerized phosphate ester is an ester obtained by a condensation reaction between polyphosphoric acid and an alcohol. Examples of the alcohol include aliphatic alcohols, glycols, polyhydric alcohols, and glycerin.

[0034] Examples of the aliphatic alcohol include methanol, ethanol, butanol, and propanol. Examples of the glycol include ethylene glycol and propylene glycol. Examples of the polyhydric alcohol include pentaerythritol, dipentaerythritol, and the like. Examples include erythritol and tripentaerythritol.

[0035] The condensation polymerization phosphate ester is preferably a condensation polymerization phosphate ester obtained using a polyhydric alcohol. When the specific coating composition contains a condensation polymerization phosphate ester obtained using a polyhydric alcohol, the flame retardancy of the substrate 3 and the transparency of the coating film 7 become even more pronounced. The condensation polymerization phosphate ester is more preferably a condensation polymerization phosphate ester obtained using pentaerythritol. When the specific coating composition contains a condensation polymerization phosphate ester obtained using pentaerythritol, the flame retardancy of the substrate 3 and the transparency of the coating film 7 become even more pronounced.

[0036] The blending ratio of the condensation polymerization phosphate ester per 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.

[0037] When the blending ratio of the condensation polymerization phosphate ester 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 substrate 3 and the transparency of the coating film 7 become more pronounced. When an excess of the condensation polymerization phosphate ester is mixed with the water-soluble melamine resin, the flame retardancy of the substrate 3 and the transparency of the coating film 7 become more pronounced.

[0038] (3-3)(c) component The specific coating composition includes component (c). Component (c) includes one or more of phosphoric acid, boric acid, ammonium salt, and aqueous ammonia. Component (c) includes, for example, both phosphoric acid and boric acid. Examples of ammonium salts include ammonium phosphate salts and ammonium borate salts.

[0039] Ammonia gradually evaporates from the ammonium salt and aqueous ammonia, and the volatilized ammonia retards the hardening of the water-soluble melamine resin. The blending ratio of component (c) per 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.

[0040] When the blending ratio of component (c) relative 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 substrate 3 and the transparency of the coating film 7 become even more pronounced. When component (c) contains an excess of phosphoric acid or boric acid relative to the water-soluble melamine resin, the curing of the water-soluble melamine resin is accelerated.

[0041] Furthermore, when component (c) contains an excess of phosphoric acid or boric acid relative to the water-soluble melamine resin, the excess phosphoric acid or boric acid chemically bonds with the hydroxyl groups of the primer layer 4, improving adhesion between the coating film 7 and the primer layer 4. Furthermore, the excess phosphoric acid or boric acid chemically bonds with the water-soluble melamine resin decomposed by the heat of combustion in the event of a fire, further enhancing the flame retardancy of the substrate 3. 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.

[0042] (3-4)(d) Compounds with an amino group in the molecular structure The specific coating composition contains (d) a compound having an amino group in its molecular structure (hereinafter also referred to as component (d)). By containing component (d), the specific coating composition cures faster at room temperature. The faster the specific coating composition cures at room temperature, the less sagging occurs when the specific coating composition is applied to a vertical surface.

[0043] Examples of the 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, and amantadine.

[0044] Examples of aromatic amines include aniline, phenethylamine, toluidine, catecholamine, and 1,8-bis(dimethylamino)naphthalene. 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, and 4-dimethylaminopyridine.

[0045] Component (d) is preferably a compound having two or more amino groups or urea. Examples of component (d) having two or more amino groups include ethylenediamine and hexamethylenediamine.

[0046] When the specific coating composition contains a compound having two or more amino groups or urea as component (d), the specific coating composition cures more quickly at room temperature. The reason why the specific coating composition cures more quickly at room temperature is presumed to be because the polycondensation product of component (d) and formaldehyde remaining in the water-soluble melamine resin reduces the fluidity of the specific coating composition. The polycondensation product of component (d) and formaldehyde is component (D), which will be described later.

[0047] The blending ratio of component (d) per 100 parts by mass of the water-soluble melamine resin is preferably 0.05 to 5 parts by mass, more preferably 0.5 to 5 parts by mass, and particularly preferably 2.5 parts by mass. When the blending ratio of component (d) per 100 parts by mass of the water-soluble melamine resin is 0.05 to 5 parts by mass, the curing of the specific coating composition at room temperature becomes even faster.

[0048] (3-5)(e) Kaolin The specific coating composition further contains, for example, (e) kaolin. As the 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 is acidic.

[0049] When the specific coating composition contains kaolin, the specific coating composition hardens faster. When the specific coating composition contains halloysite, the specific coating composition hardens even faster. The particle size of the kaolin is preferably 1 μm or more and 10 μm or less. When the particle size of the kaolin is 1 μm or more and 10 μm or less, the specific coating composition hardens more quickly.

[0050] The blending ratio of kaolin per 100 parts by mass of water-soluble melamine resin is preferably from 20 to 250 parts by mass, more preferably from 50 to 200 parts by mass, and most preferably from 150 to 180 parts by mass. When the blending ratio of kaolin per 100 parts by mass of water-soluble melamine resin is 250 parts by mass or less, it is possible to prevent the coating film 7 from becoming cloudy.

[0051] (3-6)(f) Glass fiber The specific coating composition further contains, for example, (f) glass fibers. The glass fibers are, for example, in the form of powder. When the specific coating composition contains glass fibers, the shape retention of the heat insulating layer after heat foaming is improved. The diameter of the glass fibers is preferably 5 μm or more and 20 μm or less. The length of the glass fiber is preferably 10 μm or more and 300 μm or less and more preferably 30 μm or more and 50 μm or less. The aspect ratio of the glass fiber is the value obtained by dividing the length of the glass fiber by the diameter of the glass fiber. The aspect ratio of the glass fiber is preferably 1.5 or more and 5.5 or less.

[0052] Glass fiber is sometimes called powder or milled. Preferably, the glass fiber is not surface-treated. Commercially available glass fiber products include milled fiber (Central Glass Fiber Co., Ltd.), milled fiber (Asahi Fiber Glass Co., Ltd.), PF cut fiber (Nitto Boseki Co., Ltd.), and milled fiber (Nippon Electric Glass Co., Ltd.).

[0053] (3-7) Other ingredients The specific coating composition may contain additives, pigments, etc. used in ordinary coatings, to the extent that the flame retardancy, transparency of the coating film 7, and speed of curing of the coating film 7 are not significantly impaired. Examples of additives include thickeners, pH adjusters, dispersants, wetting agents, preservatives, dyes, antifoaming agents, pigments, etc.

[0054] Examples of thickeners include polyvinyl alcohol, urethane-modified polyether, and carboxymethyl cellulose. Examples of pH adjusters include aqueous ammonia and amines. Examples of pigments include inorganic pigments, organic pigments, and extender pigments. Examples of inorganic pigments include carbon black, titanium oxide, and iron oxide. Examples of organic pigments include quinacridone and azo pigments. Examples of extender components include silica, barium sulfate, talc, and mica.

[0055] 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 and carboxylic acid. Examples of the sulfonic acid include p-toluenesulfonic acid. Examples of the carboxylic acid include acetic acid, citric acid, maleic acid, and acrylic acid.

[0056] The specific coating composition contains, for example, components of the intumescent fire-resistant coating to the extent that the transparency of the coating film 7 is not significantly impaired. Examples of the components of the intumescent fire-resistant coating include ammonium polyphosphate, melamine, and polyhydric alcohols. Examples of the polyhydric alcohol include pentaerythritol.

[0057] (3-8) Form of specific paint composition The specific coating composition may be in the form of a two-component composition consisting of a first component and a second component, for example. The first component contains a water-soluble melamine resin. The second component contains a condensation-polymerized phosphate ester and component (c). The first and second components are mixed before use. When the specific coating composition is in the form of a two-component composition, the storage stability of the specific coating composition is high.

[0058] Component (d) is preferably contained in the second part and not in the first part. When component (d) is contained in the second part and not in the first part, the storage stability of the specific coating composition is even higher. (4) Coating 7 The coating film 7 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. The coating film 7 further contains, for example, one or more of (D) a polycondensate of formaldehyde and a compound having an amino group in its molecular structure, (E) kaolin, and (F) glass fiber.

[0059] The (A) water-soluble melamine resin is, for example, the same as the (a) water-soluble melamine resin contained in the specific coating composition. The (B) condensation-polymerized phosphate ester is, for example, the same as the (a) water-soluble melamine resin contained in the specific coating composition. (b) Polycondensed phosphate esters are the same as those included in the above.

[0060] In the coating film 7, the blending ratio of the condensation polymerized phosphate ester per 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.

[0061] When the blending ratio of the condensation polymerization phosphate ester to 100 parts by mass of the water-soluble melamine resin in the coating film 7 is 120 parts by mass or more and 350 parts by mass or less, the flame retardancy of the building material 1 and the transparency of the coating film 7 become even more pronounced. When an excess of the condensation polymerization phosphate ester is mixed with the water-soluble melamine resin, the flame retardancy of the building material 1 and the transparency of the coating film 7 become even more pronounced.

[0062] Component (C) is basically the same as component (c) contained in the specific coating composition, except that one option for component (C) is ammonia rather than aqueous ammonia. In the coating film 7, the blending ratio of component (C) per 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.

[0063] When the blending ratio of component (C) to 100 parts by mass of water-soluble melamine resin in coating film 7 is 15 parts by mass or more and 90 parts by mass or less, the flame retardancy of building material 1 and the transparency of coating film 7 become even more pronounced. When component (C) contains an excess of phosphoric acid or boric acid relative to the water-soluble melamine resin, the curing of the water-soluble melamine resin is accelerated.

[0064] Furthermore, when component (C) contains an excess of phosphoric acid or boric acid relative to the water-soluble melamine resin, the excess phosphoric acid or boric acid chemically bonds with the hydroxyl groups of the primer layer 4, improving adhesion between the coating film 7 and the primer layer 4. Furthermore, the excess phosphoric acid or boric acid chemically bonds with the water-soluble melamine resin decomposed by the heat of combustion during a fire, further enhancing the flame retardancy of the building material 1. 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.

[0065] The compound having an amino group in its molecular structure in component (D) is, for example, the same as component (d) contained in the specific coating composition. In the coating film 7, the blending ratio of component (D) per 100 parts by mass of water-soluble melamine resin is preferably from 0.05 to 5 parts by mass, more preferably from 0.5 to 5 parts by mass. When the blending ratio of component (D) per 100 parts by mass of water-soluble melamine resin is from 0.05 to 5 parts by mass, the curing of coating film 7 at room temperature during production of building material 1 becomes even faster.

[0066] The coating film 7 contains, for example, (E) kaolin. (E) Kaolin is, for example, the same as the component (e) contained in the specific paint composition. In the coating film 7, the blending ratio of kaolin per 100 parts by mass of water-soluble melamine resin is preferably from 20 to 250 parts by mass, more preferably from 50 to 200 parts by mass, and most preferably from 150 to 180 parts by mass. When the blending ratio of kaolin per 100 parts by mass of water-soluble melamine resin is 250 parts by mass or less, it is possible to prevent the coating film 7 from becoming cloudy.

[0067] The coating film 7 contains, for example, (F) glass fiber. The (F) glass fiber is, for example, the same as the component (f) contained in the specific coating composition. The coating film 7 may also contain, for example, "other components" in the specific coating composition.

[0068] The coating film 7 may be formed by applying a coating composition other than the specific coating composition, as long as it has the effect of foaming when heated. The coating film 7 is preferably transparent. (5) Primer and primer layer 4 The building material 1 has a primer layer 4. The primer layer 4 is formed by applying a primer to the surface of the substrate 3. The primer contains a silane compound represented by the following formula (1) or a polymer of the silane compound.

[0069] Equation (1) (R 1 O) x SiR 2 y (x is a number between 1 and 3, inclusive. y is a number between 1 and 3, inclusive. The sum of x and y is 4. R 1 is H, CH3, or C2H5. 2 is an organic substituent. 2 At least a part of the organic substituents R 2a In the primer, R 2a The number of moles of is R 2a Not R 2 ) The organic substituent refers to an alkyl group. Examples of the organic substituent include CH, C, H, C, H, C, H, NH, and phenyl groups. R 2a Examples of the alkyl group include CH3, C2H5, C3H7, C3H6NH2, etc. Examples of the polymer include oligomers and resins.

[0070] Examples of silane compounds represented by formula (1) include methyltrimethoxysilane, 3-aminopropyltrimethoxysilane, and the hydrolysis product of methyltrimethoxysilane. The chemical formula of the hydrolysis product of methyltrimethoxysilane is (HO)3SiCH3.

[0071] Examples of polymers of silane compounds represented by formula (1) include methyl silicone oligomers having methoxy groups, methyl silicone resins, etc. As a component of the primer, methyltrimethoxysilane or its hydrolysis product is most preferred.

[0072] The amount of primer to be applied is 10 to 200 g / m2 in terms of active ingredient. 2 is preferable, and 30 to 100 g / m 2 The active ingredient is the silane compound represented by formula (1) contained in the primer, or a polymer of the silane compound. The coating amount calculated as the active ingredient is the mass of the active ingredient per unit area.

[0073] The amount of primer applied is 10 to 200 g / m2 in terms of active ingredient. 2 When the amount of the primer applied is 30 to 100 g / m2 in terms of the active ingredient, the flame retardancy of the substrate 3 is further increased. 2 In this case, the flame retardancy of the base material 3 is particularly high.

[0074] A silane compound where x is 1 is called an M unit. A silane compound where x is 2 is called a D unit. A silane compound where x is 3 is called a T unit. A polymer of a silane compound is composed of, for example, M units and D units. In this case, the polymer of the silane compound is a linear polymer. The polymer of a silane compound contains, for example, T units. In this case, the molecular structure of the polymer of the silane compound is a branched structure, and the polymer of the silane compound is a resin.

[0075] Commercially available ethoxysilanes such as methyltrimethoxysilane, methyltriethoxysilane, dimethyldiethoxysilane, and dimethyldiethoxysilane include, for example, KBM (manufactured by Shin-Etsu Chemical Co., Ltd.), WACKER SILANE (manufactured by Wacker Asahi Kasei Silicones), XIAMETER, DOWSIL (manufactured by Dow-Toray Industries, Inc.), and Silquest (manufactured by Momentive).

[0076] Commercially available methylsilicone oligomers and methylsilicone resins having a methoxy group include, for example, KR-251, KR-242A, X-40-2406M, KR-220L, and KR-255 (manufactured by Shin-Etsu Chemical Co., Ltd.), SILRES MSE 100, SILRES KX, SILRES HK46, SILRES BS45, and SILRES (manufactured by Asahi Kasei Wacker Silicone Co., Ltd.). Examples include: DOWSIL US-CF-2403 Resin (manufactured by Dow-Toray Industries, Inc.), M120XB, SS4267, and SR1000 (manufactured by Momentive Corporation). 2. Manufacturing method of building material 1 The building material 1 can be produced, for example, by the following method: First, as shown in S1 of FIG.

[0077] Next, a coating layer 5 is formed on the primer layer 4. When the coating layer 5 includes a glass fiber portion 9, the method for forming the coating layer 5 is, for example, as follows. As shown in S2, a coating composition is applied on the primer layer 4 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 harden and lose its fluidity. The leaving time is, for example, several hours to several weeks.

[0078] Next, as shown in S3, the glass fiber part 9 is placed on the first coating film 11. Next, as shown in S4, a coating composition is applied onto the glass fiber part 9 to form a second coating film 13. The coating composition applied in S4 is, for example, the same type of coating composition as the coating composition applied in S2. At least a portion of the coating composition applied to form the second coating film 13 soaks into the glass fiber part 9. Next, the second coating film 13 is cured.

[0079] Through the above steps, the coating layer 5 is formed, and 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 coating layer 5. The first coating film 11 becomes the non-containing portion 5C. When a sufficient amount of coating composition is applied in S4, the entire glass fiber portion 9 is embedded in the coating film 7, as shown in Figure 1. When a small amount of coating composition is applied in S4, the surface 9A of the glass fiber portion 9 and the surface 5B of the coating layer 5 coincide, as shown in Figure 2. The second coating film 13 is the portion of the coating film 7 that is impregnated into the glass fiber portion 9 or is located closer to the surface 5B than the glass fiber portion 9.

[0080] When the coating layer 5 does not include the glass fiber portion 9, a coating composition is applied onto the primer layer 4 to form the coating film 7. In this case, the coating film 7 corresponds to the coating layer 5. 3. Effects of the manufacturing method of the primer and building materials (3-1) The primer layer 4 formed using a primer suppresses the combustion of the substrate 3. The reason for this is presumed to be as follows. Under normal circumstances, as shown in FIG. 5, the OH groups of the cellulose contained in the substrate 3 and the R groups of the silane compound contained in the primer layer 4 are bonded to each other. 1 The O group or the OH group generated by hydrolysis of the O group forms a hydrogen bond. The silane compound contained in the primer layer 4 also bonds to the coating film 7 by dehydration condensation.

[0081] In the event of a fire, the OH groups of the substrate 3 and the OH groups of the primer layer 4 undergo dehydration condensation to generate SiO groups on the surface of the substrate 3. As a result, the flame retardancy of the substrate 3 is improved. R 2a When the carbon number of R is 1 to 3, the flame retardancy of the base material 3 is further improved. 2a The number of moles of R 2a Not R 2 When the number of moles is four or more times the number of moles of the base material 3, the flame retardancy of the base material 3 is further improved.

[0082] (3-2) When a fire breaks out around the building material 1 and the coating layer 5 is heated, the coating film 7 included in the coating layer 5 foams. As a result, the coating layer 5 forms a heat insulating layer. The formed heat insulating layer suppresses combustion of the substrate 3. When the coating layer 5 includes a glass fiber part 9, the glass fiber part 9 exerts a foam suppression effect.

[0083] (3-3) The coating film 7 is, for example, a coating film formed by applying a specific coating composition. In this case, the building material 1 can further suppress the combustion of the substrate 3. (3-4) The mass per unit area of ​​the coating film 7 is, for example, 250 g / m 2 More than 550g / m 2 or less, and the coating film 7 is impregnated into the glass fiber portion 9 or is The mass per unit area of ​​the portion on the surface 5B side is, for example, 75 g / m 2 More than 275g / m 2 In this case, the foaming suppression effect of the building material 1 is even higher.

[0084] (3-5) The coating layer 5 includes, for example, a non-containing portion 5C. In this case, the foaming suppression effect of the building material 1 is further enhanced. 4. Working Example (4-1) Preparation of primers Primers P1 to P4 were produced. Primer P1 is made of methyl methoxy silane. In Primer P1, the active ingredient is methyl methoxy silane. Primer P2 has the following composition:

[0085] (Primer P2) 3-aminopropyltrimethoxysilane: 100 parts by mass Isoparaffin: 200 parts by mass Antifoaming agent: 1 part by mass In primer P2, the active ingredient is 3-aminopropyltrimethoxysilane.

[0086] Primer P3 is composed of a methylsilicone oligomer having a methoxy group. The methylsilicone oligomer having a methoxy group is a polymer of a first silane compound and a second silane compound. The first silane compound is represented by the formula (1), where R 1 is CH3 and R 2 is CH3, x is 3, and y is 1. The second silane compound is a silane compound represented by the formula (1) where R 1 is CH3 and R 2 is a phenyl group, x is 3, and y is 1. The methylsilicone oligomer having a methoxy group is produced by hydrolyzing and condensing a first silane compound and a second silane compound in the presence of an acid. The methylsilicone oligomer having a methoxy group contains 0.25 moles of the second silane compound per mole of the first silane compound. The weight-average molecular weight of the methylsilicone oligomer having a methoxy group is 800 to 1300. In Primer P3, all components are active ingredients.

[0087] Primer P4 is made of a methylsilicone resin. The methylsilicone resin is a polymer of a third silane compound and a fourth silane compound. The third silane compound is represented by the formula (1) where R 1 is H and R 2 is CH3, x is 2, and y is 2. The fourth silane compound is a silane compound represented by the formula (1) in which R 1 is H and R 2 is CH3, x is 3, and y is 1. The methylsilicone resin is produced by hydrolyzing and condensing the third and fourth silane compounds in the presence of an acid. The weight-average molecular weight of the methylsilicone resin is 700. In Primer P4, all components are active ingredients.

[0088] (4-2) Manufacturing of specific paint compositions The following components were mixed to prepare the first and second parts of the specific coating composition. <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> Polycondensation phosphate ester: 30 parts by mass Phosphoric acid: 5 parts by mass Urea: 0.5 parts by mass The first and second agents each contained water as a solvent. In each case, the mass ratio of the nonvolatile content to the total mass was 76 mass %. The diameter of the glass fibers contained in the first agent was 10 μm, and the fiber length was 30 to 50 μm.

[0089] (4-3) Manufacturing of Building Material 1 (i) Example 1 A rectangular board of cedar laminated wood was prepared as the substrate 3. The dimensions of the substrate 3 were 99 mm in length, 99 mm in width, and 15 mm in thickness. As shown in S1 of FIG. 4, the primer P1 produced in (4-1) above was applied to the surface of the substrate 3 by a brush coating method to form a primer layer 4. The application amount of primer P1 in terms of the active ingredient was 35 g / m 2 The primer may be applied using a roller or a spray.

[0090] Next, as shown in S2 of Fig. 4, a specific coating composition was applied to form a first coating film 11. The specific coating composition was a mixture of 100 parts by mass of a first agent and 100 parts by mass of a second agent. 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 228 g / m 2 The mass per unit area of ​​the first coating film 11 is the mass per unit area of ​​the non-volatile components.

[0091] Next, as shown in S3 of FIG. 4, a glass fiber part 9 made of glass fiber cloth was placed on the first coating film 11. Of the glass constituting the glass fiber cloth, 97% by mass or more was alumina borosilicate glass. The sizing agent contained in the glass fiber cloth was acrylic resin. The content of the sizing agent in the glass fiber cloth was 13% by mass. The content of glass in the glass fiber cloth was 87% by mass.

[0092] The weave density in the longitudinal direction of the glass fiber cloth was 53 threads / 25 mm. The weave density in the transverse direction of the glass fiber cloth was 48 threads / 25 mm. The weave of the glass fiber cloth was plain weave. The mass per unit area of ​​the glass fiber cloth was 150 g / m 2 The thickness of the glass fiber cloth was 0.1 mm.

[0093] Next, as shown in S4 of FIG. 4, a specific coating composition was applied onto the glass fiber portion 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 114 g / m 2 The mass per unit area of ​​the second coating film 13 is the mass per unit area of ​​the non-volatile components.

[0094] 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 that constitutes the coating layer 5. The first coating film 11 became the non-containing portion 5C. As shown in FIG. 1, the entire glass fiber portion 9 was embedded in the coating film 7. The second coating film 13 became the portion of the coating film 7 that either impregnated the glass fiber portion 9 or was located closer to the surface 5B than the glass fiber portion 9.

[0095] (ii) Examples 2 to 6 Building materials 1 of Examples 2 to 6 were produced basically in the same manner as in Example 1. However, the types of primers and the amounts of primer applied were as shown in Table 1.

[0096] [Table 1]

[0097] (iii) Comparative examples 1 and 2 Building materials 1 of Comparative Examples 1 and 2 were manufactured basically in the same manner as in Example 1. However, In Comparative Example 1, no primer layer 4 was formed. In Comparative Example 2, the primer layer 4 was formed by applying an acrylic resin instead of the primers P1 to P4.

[0098] (iv) Example 7 Building material 1 of Example 7 was produced in essentially the same manner as in Example 1, except that the amount of primer P1 applied was 50 g / m2 in terms of active ingredient. 2 Furthermore, no glass fiber cloth was used when forming coating layer 5. Coating layer 5 consists only of coating film 7. When forming coating layer 5, the specific paint composition was applied twice. The coating film formed by the first application is designated as coating film A. The coating film formed by the second application is designated as coating film B. The masses per unit area of ​​coating films A and B are shown in Table 2.

[0099] [Table 2]

[0100] (v) Examples 8 to 11 Building materials 1 of Examples 8 to 11 were produced basically in the same manner as in Example 7. However, the type of primer and the amount of primer applied were as shown in Table 2.

[0101] (vi) Comparative examples 3 and 4 Building materials 1 of Comparative Examples 3 and 4 were manufactured basically in the same manner as in Example 7. However, in Comparative Example 3, a primer layer 4 was not formed. In Comparative Example 4, a primer layer 4 was formed by applying an acrylic resin instead of the primers P1 to P4.

[0102] (vii) Example 12, Comparative Example 5 The building material 1 of Example 12 was produced basically in the same manner as in Example 7. However, in Example 12, the thickness of the substrate 3 was 30 mm. Also, in Example 12, the coating amount of the coating film 7 was 228 g / m 2 The building material 1 of Comparative Example 5 was produced basically in the same manner as in Example 12. However, in Comparative Example 5, the primer layer 4 was not formed. (4-3) Evaluation of Building Materials 1 of Examples 1 to 11 and Comparative Examples 1 to 4 Tests were carried out on the building materials 1 of Examples 1 to 11 and Comparative Examples 1 to 4. The test specimens were subjected to a heat load of 50 kW / m using the cone calorimeter method specified in ISO 5660-1. 2 The total heat release amount and maximum heat release rate were measured when heated for 10 minutes at a radiation intensity of 100 psi. The measured values ​​were applied to the following evaluation criteria to evaluate flame retardancy. The evaluation results are shown in Tables 1 and 2. The reference sample is Comparative Example 1 for Examples 1 to 6 and Comparative Example 2, and Comparative Example 3 for Examples 7 to 11 and Comparative Example 4.

[0103] (Evaluation criteria for flame retardancy based on total heat generation) ◎: The total calorific value was reduced compared to the reference sample. The reduction was more than 20%. ○: The total calorific value was reduced compared to the reference sample. The reduction was more than 10% but less than 20%.

[0104] △: The total calorific value was reduced compared to the reference sample. The reduction was greater than 0% and less than 10%. ×: The total calorific value was equal to or greater than that of the reference sample. (Flame retardancy rating based on maximum heat release rate) ◎: The maximum heat release rate was reduced compared to the reference sample by more than 20%.

[0105] ○: The maximum heat release rate decreased compared to the reference sample. The decrease was more than 10% but less than 20%. △: The maximum heat release rate was reduced compared to the reference sample. The reduction was greater than 0% and less than 10%.

[0106] ×: The maximum heat release rate was equal to or greater than that of the reference sample. (4-4) Evaluation of Building Material 1 of Example 12 and Comparative Example 5 The calorific value and heat release rate of the building materials 1 of Example 12 and Comparative Example 5 were measured by the cone calorimeter method. The measurement results of Example 12 are shown in Figure 6. The measurement results of Comparative Example 5 are shown in Figure 7. In Example 12, the heat release peak was suppressed compared to Comparative Example 5. Furthermore, in Example 12, the ignition time was slower compared to Comparative Example 5.

[0107] 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 in various modified forms.

[0108] (5-1) The mass of the isoparaffin contained in the primer P2 can be adjusted appropriately within the range of 0 to 500 parts by mass. The mass of the antifoaming agent contained in the primer P2 can be adjusted appropriately within the range of 5 parts by mass or less.

[0109] (5-2) For example, another coating film may be formed on the second coating film 13. [Explanation of symbols]

[0110] 1...building material, 3...substrate, 4...primer layer, 5...coating layer, 5A...center, 5B...surface, 5C...non-containing portion, 7...coating film, 9...glass fiber portion, 9A...surface, 11...first coating film, 13...second coating film

Claims

1. A primer is applied to a substrate containing cellulose to form a primer layer, forming a coating layer having a coating film that foams upon heating on the primer layer; The primer contains a silane compound represented by the following formula (1) or a polymer of the silane compound: Manufacturing methods for building materials. Equation (1) (R) １ O) ｘ SiR ２ ｙ (x is a number between 1 and 3, inclusive. y is a number between 1 and 3, inclusive. The sum of x and y is 4. R １ is H, CH ３ , or C ２ H ５ It is. ２ is an organic substituent. ２ At least a part of the organic substituents R ２ａ In the primer, R ２ａ The number of moles of is R ２ａ Not R ２ (More than four times the number of moles of

2. A method for manufacturing the building material according to claim 1, The substrate is made of wood. Manufacturing methods for building materials.

3. A method for manufacturing the building material according to claim 1 or 2, The polymer is an oligomer or a resin. Manufacturing methods for building materials.

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