Liquid composition, fireproof layer, laminated structure including fireproof layer, and fireproofing method

Abstract

To provide a liquid composition that enables formation of a fireproof layer having high fireproof performance on the surface of a substrate to which a film for wallpaper or the like is applied, a fireproof layer that can be formed using the liquid composition, a laminate structure including the fireproof layer, and a fireproofing method using the liquid composition.SOLUTION: A liquid composition contains a clay including at least one selected from the group consisting of montmorillonite, mica, hectorite and fluorosilicate, and dimer or higher phosphate.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a liquid composition, a fire-resistant layer, a laminated structure including a fire-resistant layer, and a fire-resistant treatment method. [Background technology]

[0002] Decorative films or sheets having a pressure-sensitive adhesive layer provided on a film substrate are used in buildings, vehicles, traffic signs, billboards, packaging materials, etc. For example, wallpaper films used in the interior of buildings are required to be certified as non-combustible materials in accordance with the Building Standards Act of each country.

[0003] Known methods for improving the flame resistance of interior decorative films include adding a flame retardant to the pressure-sensitive adhesive on the back side of the decorative film, and laminating a highly flame-resistant material to the decorative film.

[0004] For example, Patent Document 1 (JP-A-10-501009) describes a "pressure-sensitive adhesive composition comprising an adhesive selected from the group consisting of rubber resin adhesives and acrylic adhesives, which contains about 10 to about 60% by weight of a non-halogen intumescent flame retardant based on the adhesive."

[0005] Patent Document 2 (JP 2013-44983 A) describes a method for manufacturing a micro-fiber laminate comprising: a film layer and an adhesive layer laminated together; a diameter of 20 to 500 μm; and a number density of 2 to 700 particles / cm. 2 The document describes a decorative sheet comprising a decorative film layer having minute holes, and a glass cloth layer. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Special Publication No. 10-501009 [Patent Document 2] Japanese Patent Application Laid-Open No. 2013-44983 Summary of the Invention [Problem to be solved by the invention]

[0007] However, for example, in the test method for non-combustible material certification in Japan, a portion of the heat measured by a cone calorimeter comes from the combustion of the substrate (wall material) to which the wallpaper film is applied, such as the paper covering gypsum board, and not from the combustion of the wallpaper film itself. Therefore, even if the non-combustibility of the wallpaper decorative film alone is improved, it may not be enough to obtain non-combustible material certification. Therefore, it is desirable to improve the non-combustibility of not only the wallpaper film but also the substrate to which it is applied. It is also desirable to further reduce the heat generated by the substrate by forming a fireproof layer on the surface of a substrate such as gypsum board, thereby increasing the design flexibility of the materials applied to the substrate surface, such as the type and thickness of the wallpaper film.

[0008] The present disclosure provides a liquid composition capable of forming a fireproof layer having high fireproofing performance on the surface of a substrate to which a wallpaper film or the like is applied, a fireproof layer that can be formed using the liquid composition, a laminated structure including a fireproof layer, and a fireproofing treatment method using the liquid composition. [Means for solving the problem]

[0009] According to one embodiment, there is provided a liquid composition comprising a clay including at least one selected from the group consisting of montmorillonite, mica, hectorite, and fluorosilicate, and a dimeric or higher phosphate.

[0010] According to another embodiment, there is provided a fire protection layer comprising a clay including at least one selected from the group consisting of montmorillonite, mica, hectorite, and fluorosilicate, and a dimeric or higher phosphate.

[0011] According to yet another embodiment, there is provided a laminated structure comprising: a fire-resistant layer comprising a clay comprising at least one selected from the group consisting of montmorillonite, mica, hectorite, and fluorosilicate; and a dimeric or higher phosphate; and a film disposed on the fire-resistant layer.

[0012] According to yet another embodiment, there is provided a fireproofing treatment method comprising providing a substrate and applying a liquid composition onto the substrate to form a fireproofing layer on the substrate, wherein the liquid composition comprises a clay including at least one selected from the group consisting of montmorillonite, mica, hectorite, and fluorosilicate, and a dimeric or higher phosphate. [Effects of the Invention]

[0013] According to the present disclosure, it is possible to provide a liquid composition capable of forming a fireproof layer having high fireproof performance on the surface of a substrate to which a wallpaper film or the like is applied, a fireproof layer that can be formed using the liquid composition, a laminated structure including a fireproof layer, and a fireproofing method using the liquid composition.

[0014] It should be noted that the above description should not be considered as a disclosure of all embodiments of the present invention and all advantages associated with the present invention. [Brief explanation of the drawings]

[0015] [Figure 1] 1 is a schematic cross-sectional view of a laminated structure according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0016] Hereinafter, the present invention will be described in more detail with reference to the drawings for the purpose of illustrating typical embodiments thereof, but the present invention is not limited to these embodiments.

[0017] In this disclosure, the term "film" also encompasses articles called "sheets."

[0018] In this disclosure, "pressure-sensitive adhesive" refers to the property of a material or composition that has initial tack over a range of temperatures in use, e.g., from 0°C to 50°C, adheres to a variety of surfaces with light pressure, and does not exhibit a phase change (liquid to solid).

[0019] In one embodiment, the liquid composition contains a clay containing at least one selected from the group consisting of montmorillonite, mica, hectorite, and fluorosilicate, and a dimer or higher phosphate. By coating the liquid composition on the surface of a substrate (wall material) to which a wallpaper film or the like is to be applied, a fireproof layer having fireproof properties can be formed on the surface of the substrate.

[0020] Clay is a mineral primarily containing layered silicates. Clay containing at least one selected from the group consisting of montmorillonite, mica, hectorite, and fluorosilicate has a layered structure dispersed and arranged in a planar form in the fireproof layer, thereby imparting oxygen barrier properties to the fireproof layer. This can suppress combustion of the substrate protected by the fireproof layer and the resulting heat generation. Clays can be used alone or in combination of two or more types.

[0021] Montmorillonite is a type of dioctahedral smectite and is classified into Na-type, which primarily contains sodium ions as interlayer cations, and Ca-type, which primarily contains calcium ions. Compared to Ca-type montmorillonite, Na-type montmorillonite has higher swelling, thickening, and suspension stability. The use of Na-type montmorillonite is advantageous in that a small amount can impart oxygen barrier properties to the fireproof layer. The use of Ca-type montmorillonite is advantageous in that the viscosity of the liquid composition can be easily adjusted and the storage stability is high. When the liquid composition contains water glass, the use of Ca-type montmorillonite allows the calcium ions released from the Ca-type montmorillonite to react with the water glass to produce a high-molecular-weight silicate compound, thereby increasing the viscosity of the liquid composition to the desired level. Examples of montmorillonite include KUNIPIA-G (Kunimine Kogyo Co., Ltd., Chiyoda-ku, Tokyo, Japan).

[0022] Mica is classified into trioctahedral mica and dioctahedral mica, and either can be used. Examples of trioctahedral mica include phlogopite (phlogopite) and biotite (biotite), and examples of dioctahedral mica include muscovite (muscovite). It is desirable for mica to have swelling properties. It is desirable for mica to be hydrophilic so that it can be highly dispersed in aqueous compositions and has film-forming properties. An example of mica is Somasif ME-100 (Katakura Co-op Agri Co., Ltd., Chiyoda-ku, Tokyo, Japan).

[0023] Hectorite is a type of trioctahedral smectite. Because of its small average diameter and excellent dispersibility due to its layered structure, synthetic hectorite is advantageous. Examples of hectorite include LAPONITE-SL 25 and LAPONITE-S482 (both from BYK Japan, Shinjuku-ku, Tokyo, Japan), and SUMECTON-SWN (from Kunimine Industries, Chiyoda-ku, Tokyo, Japan).

[0024] Fluorosilicates are minerals with a layered structure in which part of the silicate-containing clay is substituted with fluorine. Because the average diameter of the layered structure is small and the dispersion is excellent, synthetic layered fluorosilicates are advantageous. Examples of fluorosilicates include LAPONITE-JS (BYK Japan, Shinjuku-ku, Tokyo, Japan).

[0025] The clay containing montmorillonite is advantageous in terms of non-combustibility. Without being bound by any theory, it is believed that, in addition to its oxygen barrier properties, montmorillonite promotes carbonization of organic materials that come into contact with the montmorillonite in a high-temperature environment, such as organic materials contained in an adhesive layer of a decorative film attached on a fireproof layer, thereby suppressing heat generation due to combustion.

[0026] In one embodiment, the clay comprises a combination of montmorillonite and at least one selected from the group consisting of mica, hectorite, and fluorosilicate. In this embodiment, the montmorillonite, which has a relatively small layered structure, can fill the voids in the layered structure of the other clays, thereby improving the fire protection performance or adhesion of the fire protection layer to the substrate surface.

[0027] In one embodiment, the average diameter of the clay layer structure is about 5 nm or more, about 10 nm or more, or about 15 nm or more, and about 100 μm or less, about 90 μm or less, or about 80 μm or less. In this disclosure, the average diameter of the layer structure is the average diameter measured by dynamic light scattering.

[0028] In one embodiment, the clay is water-dispersible. Specifically, it is preferable that the clay has fluidity when 2 g of the clay is mixed with 98 g of ion-exchanged water. Such clay promotes dispersion of its layered structure in an aqueous liquid composition, thereby more efficiently enhancing the oxygen barrier properties of the fireproof layer.

[0029] The clay may be modified with a dispersant, a surface modifier, or the like.

[0030] In one embodiment, the clay is contained in the liquid composition in an amount of about 30% by weight or more, about 35% by weight or more, or about 40% by weight or more, and about 85% by weight or less, about 80% by weight or less, or about 75% by weight or less, based on the solid content of the liquid composition. By making the clay content about 30% by weight or more, flame retardancy can be improved. By making the clay content about 85% by weight or less, coatability can be improved.

[0031] Dimer or higher phosphates can promote the dispersion of clay in a liquid composition, reduce the viscosity of the liquid composition, and improve its coating suitability. When the layered structure of clay is dispersed in a liquid composition, a house-of-cards structure (a three-dimensional structure in which the end of one layered structure is coordinated to the plane of another layered structure) may be formed, causing the liquid composition to become excessively viscous. Dimer or higher phosphates can inhibit the formation of a house-of-cards structure by binding or coordinating to the end of the layered structure of clay, thereby improving the dispersibility of the layered structure. Dimer or higher phosphates can themselves function as flame retardants or flame retardants, for example, as flame retardants for cellulose.

[0032] Dimer and higher phosphate salts have the formula: M n+2 P n O 3n+1 M is a monovalent cation, and H + , Li + , Na + , and K + and n is an integer of 2 to 30. M being sodium is advantageous in terms of cost. n being 2 to 21 is advantageous in terms of clay dispersibility. Examples of dimer or higher phosphates include sodium pyrophosphate and sodium hexametaphosphate. When preparing the liquid composition, the phosphate may be in the form of a hydrate, and in this case, the water of hydration is contained as part of the solvent of the liquid composition.

[0033] In one embodiment, the dimer or higher phosphate is contained in the liquid composition in an amount of about 0.1% by mass or more, about 0.5% by mass or more, or about 1% by mass or more, about 10% by mass or less, about 7% by mass or less, or about 5% by mass or less, based on the solid content of the liquid composition. By setting the content of the dimer or higher phosphate to about 0.1% by mass or more, the dispersibility of clay can be improved. By setting the content of the dimer or higher phosphate to about 10% by mass or less, shrinkage, denaturation, etc. of the substrate, particularly the paper covering gypsum board, can be suppressed. This suppresses shrinkage of the substrate during combustion, which is also advantageous in terms of non-combustibility. The content of the dimer or higher phosphate does not include water of hydration.

[0034] The liquid composition may further contain a film-forming binder containing at least one selected from the group consisting of water glass and an organic resin. The liquid composition containing the film-forming binder can form a fireproof layer that is excellent in strength, heat resistance or cold resistance, adhesion to a substrate, adhesion to a material placed on the fireproof layer, etc.

[0035] During the formation of the fireproof layer, water glass condenses to form a silicate film, which functions as a binder for the clay, particularly as a heat-resistant binder. The silicate film itself also has oxygen barrier properties, further enhancing the fireproofing performance of the fireproof layer. Water glass may react with clay to form a geopolymer, which effectively prevents the clay from falling off from the fireproof layer.

[0036] Examples of water glass include lithium silicate, sodium silicate, and potassium silicate. Among these, lithium silicate can be used advantageously in terms of water resistance.

[0037] In one embodiment, the water glass is contained in the liquid composition in an amount of about 0.1% by mass or more, about 0.5% by mass or more, or about 1% by mass or more, and about 70% by mass or less, about 65% by mass or less, or about 60% by mass or less, based on the solid content of the liquid composition. By setting the water glass content to about 0.1% by mass or more, fire resistance can be improved. By setting the water glass content to about 70% by mass or less, excessive viscosity increase of the liquid composition over time can be suppressed, and the storage stability of the liquid composition can be improved.

[0038] The organic resin has an affinity with the organic material placed on the fireproof layer, so that when a decorative film having an adhesive layer is attached on the fireproof layer, for example, the adhesive layer of the decorative film can be attached to the fireproof layer, and the organic resin can be a water-soluble polymer, and can also be used in the form of an aqueous emulsion.

[0039] Examples of organic resins include polyvinyl chloride, polyvinylpyrrolidone, and oxazoline group-containing polymers.

[0040] In one embodiment, the organic resin is contained in the liquid composition in an amount of about 2% by mass or more, about 5% by mass or more, or about 10% by mass or more, and about 55% by mass or less, about 50% by mass or less, or about 45% by mass or less, based on the solid content of the liquid composition. By making the organic resin content about 2% by mass or more, adhesion can be improved. By making the organic resin content about 55% by mass or less, flame retardancy can be improved.

[0041] The liquid composition advantageously comprises, as film-forming binder, a combination of water glass and an organic resin.

[0042] The liquid composition may contain, as optional components, inorganic fillers other than clay such as silica gel and glass fiber, surfactants, pigments, preservatives, and the like, as long as the effects of the present disclosure are not lost.

[0043] The liquid composition may contain water, an organic solvent, or a combination thereof as a solvent. In one embodiment, the liquid composition is an aqueous composition. The aqueous composition is suitable for use in interior applications where the working environment or construction period is limited.

[0044] In one embodiment, the solids content of the liquid composition is about 1% by weight or more, about 3% by weight or more, or about 5% by weight or more, and about 45% by weight or less, about 40% by weight or less, or about 35% by weight or less. By making the solids content of the liquid composition about 45% by weight or less, the suitability for coating can be improved.

[0045] The viscosity of the liquid composition can be appropriately determined depending on the application method. In one embodiment, the viscosity of the liquid composition can be about 1 mPa·s or more, about 10 mPa·s or more, or about 20 mPa·s or more, and about 5500 mPa·s or less, about 5000 mPa·s or less, or about 4500 mPa·s or less, when measured using a rheometer (DISCOVERY HR-2, TA Instruments Japan, Shinagawa-ku, Tokyo, Japan).

[0046] The liquid composition can be used as a primer composition. In this embodiment, for example, a decorative film or sheet having an adhesive layer can be attached onto the fireproof layer formed using the liquid composition.

[0047] In one embodiment, the fireproof layer includes a clay containing at least one selected from the group consisting of montmorillonite, mica, hectorite, and fluorosilicate, and a dimer or higher phosphate. The clay and the dimer or higher phosphate are as described for the liquid composition. The fireproof layer blocks oxygen and can suppress combustion of the substrate or the like covered by the fireproof layer and the resulting heat generation.

[0048] The fireproof layer can be formed using the liquid composition. The fireproof layer can be formed, for example, by applying the liquid composition to the surface of a substrate by spraying, coating, immersion, or the like, and optionally removing the solvent by air drying or heating. If reactive components such as water glass are included, the composition can be heated as needed to react with them. The heating temperature can generally be about 40°C to about 150°C. The heating time can generally be about 1 minute to about 10 minutes.

[0049] In one embodiment, the fire-resistant layer comprises at least 30%, at least about 35%, or at least about 40% by weight clay, up to about 85%, up to about 80%, or up to about 75% by weight clay.

[0050] In one embodiment, the fire-resistant layer comprises at least about 0.1%, at least about 0.5%, or at least about 1% by weight of dimeric or higher phosphate salts, and at most about 10%, at most about 7%, or at most about 5% by weight.

[0051] The fireproof layer further includes a binder containing at least one selected from the group consisting of silicates and organic resins. The silicate may be a water glass condensate as described for the liquid composition. The organic resin is as described for the liquid composition.

[0052] In one embodiment, the fire-resistant layer comprises at least about 0.1%, at least about 0.5%, or at least about 1% by weight of silicate as a binder, up to about 70%, up to about 65%, or up to about 60% by weight.

[0053] In one embodiment, the fire-resistant layer comprises at least about 2%, at least about 5%, or at least about 10% by weight of an organic resin as a binder, up to about 55%, up to about 50%, or up to about 45% by weight.

[0054] Solid content per unit area of ​​fire protection layer (g / m 2 ) is approximately 1 g / m 2 More than about 3g / m 2 or more, or about 5 g / m 2 More than about 40g / m 2 Below, about 35g / m 2 or less, or about 30 g / m 2 It can be as follows:

[0055] One embodiment of the laminated structure includes the fire-resistant layer and a film disposed on the fire-resistant layer. The film may be a decorative film having a base film layer and an adhesive layer on its back surface, and may have a decorative layer such as a printed layer on the base film layer directly or via another layer, or between the base film layer and the adhesive layer. The decorative film may be used for the interior or exterior of a building.

[0056] The base film layer may be at least one selected from the group consisting of polyvinyl chloride, polyurethane, polyethylene, polypropylene, vinyl chloride-vinyl acetate copolymer, acrylic resin, cellulose, and fluororesin. The base film layer may be a single layer or a laminate of multiple layers.

[0057] The adhesive layer may be a pressure-sensitive adhesive layer. Examples of pressure-sensitive adhesive layers include acrylic pressure-sensitive adhesives. The use of acrylic pressure-sensitive adhesives can impart excellent durability and discoloration resistance to the decorative film. Acrylic pressure-sensitive adhesives are easily modified, allowing the adhesive properties to be adjusted to suit the application. The acrylic pressure-sensitive adhesive comprises at least one adhesive acrylic polymer selected from the group consisting of adhesive acrylic homopolymers and copolymers. For example, the acrylic pressure-sensitive adhesive comprises an adhesive homopolymer of a monomer selected from the group consisting of methyl acrylate, butyl acrylate, isoamyl acrylate, isooctyl acrylate, 2-ethylhexyl acrylate, acrylic acid, methacrylic acid, acrylamide, methacrylamide, acrylonitrile, and ethacrylonitrile, or an adhesive copolymer of two or more of these monomers.

[0058] The print layer can be formed by using a printing technique such as gravure printing, electrostatic printing, screen printing, inkjet printing, or offset printing.

[0059] The laminated structure may further include a substrate such as a building wall material, and a fireproof layer may be disposed on the substrate. The laminated structure 100 shown in a schematic cross-sectional view in FIG. 1 has a fireproof layer 10 disposed on a substrate 30, with a film 20 disposed on the fireproof layer 10. In FIG. 1, the substrate 30 is shown as a gypsum board 32 coated on both sides with paper 34. While FIG. 1 shows the fireproof layer 10 disposed on the substrate 30, the components of the fireproof layer may permeate and extend over a portion of the surface layer of the substrate or the entire substrate, and the boundary of the fireproof layer is not necessarily clear.

[0060] Examples of substrates include gypsum board, mortar, cement, concrete, wood, stone, paper, cloth, glass, plastic, porous ceramics, rock wool sound-absorbing board, and calcium silicate board. In one embodiment, the substrate is gypsum board. One or both sides of the gypsum board may be covered with paper. The substrate is not limited to a plate-like shape like a wall material, and may be linear, film-like, spherical, amorphous, three-dimensional, or other shape as long as it is an object to which the liquid composition can be applied.

[0061] The fire protection layer is designed to reduce the total heat release of the laminated structure, measured in accordance with the ISO 5660-1 cone calorimeter test, to approximately 8 MJ / m² for a 20-minute period. 2 Below, approximately 7.2MJ / m 2 or less, or about 6.5 MJ / m 2 It can be as follows:

[0062] The fire protection layer has a heat release rate of 200 kW / m², measured in accordance with ISO 5660-1 Cone Calorimeter test for laminated structures. 2 may be a total of about 10 seconds or less, about 8 seconds or less, or about 5 seconds or less.

[0063] According to the fire prevention material standard, the total heat output is 8MJ / m for 20 minutes. 2 and the heat generation rate is 200 kW / m or less 2 Materials for which the total time exceeding this limit is 10 seconds or less are classified as non-combustible materials.

[0064] In one embodiment, the fire-resistant treatment method includes providing a substrate and applying a liquid composition onto the substrate to form a fire-resistant layer on the substrate, the substrate, the liquid composition, and the fire-resistant layer being as described above.

[0065] The fireproofing method may further include applying a film over the fireproofing layer, as previously described.

[0066] The liquid composition, fireproofing layer, laminated structure, and fireproofing treatment method of the present disclosure can be used in various fields where flame-retardant or non-flammable materials are required, such as buildings, automobiles, airplanes, trains, and electrical and electronic devices. [Example]

[0067] The following examples illustrate specific embodiments of the present disclosure, but the invention is not limited thereto. All parts and percentages are by weight unless otherwise specified.

[0068] The reagents and materials used in this example are shown in Table 1.

[0069] [Table 1]

[0070] Fabrication of decorative sheets A 38% by weight solution of an acrylic copolymer was prepared as an acrylic pressure-sensitive adhesive composition by copolymerizing a butyl acrylate / acrylic acid monomer mixture in ethyl acetate. The resulting pressure-sensitive adhesive composition was applied to an embossed PVC film (3M Japan, Shinagawa-ku, Tokyo, Japan) using a knife coater to a dry thickness of 40 μm to produce a decorative sheet. The PVC film had a composition of polyvinyl chloride resin / plasticizer (including diisononyl phthalate) / additive (acrylic resin, including zinc stearate) = 76 / 17 / 7 (mass ratio).

[0071] Example 1 While stirring 255 g of distilled water, 15 g of KUNIPIA-G was slowly added and thoroughly stirred. After leaving the mixture at room temperature for at least 12 hours, a viscous aqueous dispersion with a solids content of 5.6% by mass was obtained. 0.019 g of sodium diphosphate decahydrate and 4.0 g of distilled water were added to 4.0 g of the resulting aqueous dispersion and thoroughly mixed. 0.93 g of 30% potassium silicate solution was then added to obtain a coating solution. 4.4 g (0.25 g solids) of the resulting coating solution was applied to a 10 cm square gypsum board GB-R, allowed to dry naturally, and then a decorative sheet was attached to obtain an evaluation sample.

[0072] Example 2 While stirring 255 g of distilled water, 30 g of Somasif ME-100 was slowly added and thoroughly stirred. After leaving the mixture at room temperature for at least 12 hours, an aqueous dispersion with a solids content of 11% by mass was obtained. 0.036 g of sodium diphosphate decahydrate and 4.0 g of distilled water were added to 4.0 g of the obtained aqueous dispersion and thoroughly mixed. 1.75 g of 30% potassium silicate solution was then added to obtain a coating solution. 2.6 g (0.25 g solids) of the obtained coating solution was applied to a GB-R gypsum board, allowed to dry naturally, and then a decorative sheet was attached to obtain an evaluation sample.

[0073] Example 3 1.2 g of LAPONITE-SL 25 was mixed with 0.1 g of distilled water and 0.017 g of sodium diphosphate decahydrate and thoroughly mixed. 0.62 g of VINYBLAN 715 was then added to obtain a coating solution. 1.1 g (0.25 g solids) of the resulting coating solution was applied to a gypsum board, allowed to air dry, and then a decorative sheet was attached to obtain an evaluation sample.

[0074] Example 4 0.020 g of sodium diphosphate decahydrate was added to 6.0 g of a 5.6% by mass solids aqueous dispersion of KUNIPIA-G and mixed thoroughly. 0.73 g of VINYBLAN 715 was then added to obtain a coating solution. 3.3 g of the resulting coating solution (0.26 g solids) was applied to a GB-R gypsum board, allowed to air dry, and then a decorative sheet was attached to obtain an evaluation sample.

[0075] Example 5 0.020 g of sodium diphosphate decahydrate was added to 6.0 g of an aqueous dispersion of KUNIPIA-G with a solids content of 5.6% by mass and mixed thoroughly. Next, 0.73 g of VINYBLAN 715 was added. 0.05 g of lithium silicate 75 was then added to obtain a coating solution. 3.4 g of the resulting coating solution (0.27 g of solids) was applied to a GB-R gypsum board, allowed to dry naturally, and then a decorative sheet was attached to obtain an evaluation sample.

[0076] Example 6 While stirring 255 g of distilled water, 20 g of SUMECTON-SWN was slowly added and thoroughly stirred. After leaving the mixture at room temperature for at least 12 hours, a gel with a solids content of 7.3% by mass was obtained. 0.034 g of sodium diphosphate decahydrate and 0.4 g of distilled water were added to 8.2 g of the resulting gel and thoroughly mixed. 1.24 g of VINYBLAN 715 was then added to obtain a coating solution. 2.7 g of the resulting coating solution (0.25 g of solids) was applied to a GB-R gypsum board, allowed to dry naturally, and then a decorative sheet was attached to obtain an evaluation sample.

[0077] Example 7 6.0 g of a 5.6% solids KUNIPIA-G aqueous dispersion was mixed thoroughly with 4.0 g of a 11% solids Somasif ME-100 aqueous dispersion and 0.045 g of sodium diphosphate decahydrate. 1.6 g of VINYBLAN 715 was then added to obtain a coating solution. 2.5 g of the resulting coating solution (0.25 g solids) was applied to a GB-R gypsum board, allowed to air dry, and then a decorative sheet was attached to obtain a sample for evaluation.

[0078] Example 8 3.0 g of a 5.6% solids KUNIPIA-G aqueous dispersion was mixed thoroughly with 2.0 g of an 11% solids Somasif ME-100 aqueous dispersion and 0.022 g of sodium diphosphate decahydrate. Next, 0.44 g of VINYBLAN 715 and 0.12 g of OLFINE EXP.4123 were added. 0.24 g of a 30% potassium silicate solution was then added to obtain a coating solution. 2.5 g (0.27 g solids) of the resulting coating solution was applied to a GB-R gypsum board, allowed to air dry, and then a decorative sheet was attached to obtain an evaluation sample.

[0079] Example 9 While stirring 255 g of distilled water, 45 g of LAPONITE-JS was slowly added and thoroughly stirred. After leaving the mixture at room temperature for at least 12 hours, an aqueous dispersion with a solids content of 15% by mass was obtained. 0.056 g of sodium diphosphate decahydrate was added to 5.0 g of the resulting aqueous dispersion and thoroughly mixed. Next, 0.3 g of KUNIPIA-G powder, 1.5 g of VINYBLAN 715, and 0.12 g of OLFINE EXP.4123 were thoroughly mixed. 0.1 g of lithium silicate 75 was then added to obtain a coating solution. 1.2 g of the resulting coating solution (0.26 g solids) was applied to a GB-R gypsum board, allowed to dry naturally, and then a decorative sheet was attached to obtain an evaluation sample.

[0080] Example 10 While stirring 255 g of distilled water, 45 g of LAPONITE-S482 was slowly added and thoroughly stirred. After leaving the mixture at room temperature for at least 12 hours, an aqueous dispersion with a solids content of 15% by mass was obtained. 0.83 g of sodium diphosphate decahydrate was added to 75 g of the resulting aqueous dispersion and thoroughly mixed. Next, 4.5 g of KUNIPIA-G powder was added with stirring and thoroughly mixed. 23 g of VINYBLAN 715 and 1.8 g of OLFINE EXP.4123 were mixed, followed by 1.5 g of lithium silicate 75 to obtain a coating solution. 1.5 g of the resulting coating solution (0.32 g solids) was applied to a GB-R gypsum board, allowed to dry naturally, and then a decorative sheet was attached to obtain an evaluation sample.

[0081] Comparative Example 1 As an evaluation sample, gypsum board GB-R was used as it was without any treatment.

[0082] Comparative Example 2 2.1 g (solid content 0.25 g) of DP-900N3 was applied to a GB-R gypsum board, and after air drying, a decorative sheet was attached to obtain a sample for evaluation.

[0083] Comparative Example 3 0.84 g of sodium diphosphate decahydrate was added to 20 g of distilled water and stirred thoroughly until dissolved to obtain an aqueous dispersion of sodium diphosphate. 10 g of the aqueous dispersion (0.24 g solid content) was applied to a GB-R gypsum board, allowed to air dry, and then a decorative sheet was attached to obtain a sample for evaluation.

[0084] Comparative Example 4 While stirring 255 g of distilled water, 45 g of SUMECTON-ST was slowly added and thoroughly stirred. After leaving it at room temperature for 12 hours or more, a gel with a solids content of 15% by mass was obtained. 0.052 g of sodium diphosphate decahydrate and 4.0 g of distilled water were added to 4.0 g of the obtained gel and thoroughly mixed. 2.5 g of 30% potassium silicate solution was then added to obtain a coating solution. 1.9 g of the obtained coating solution (0.25 g of solids content) was applied to a GB-R gypsum board, allowed to dry naturally, and then a decorative sheet was attached to obtain an evaluation sample.

[0085] Comparative Example 5 0.035 g of sodium diphosphate decahydrate and 0.2 g of distilled water were added to 4 g of a gel consisting of SUMECTON-ST with a solids content of 15% by mass and mixed thoroughly. 1.24 g of VINYBLAN 715 was then added to obtain a coating solution. 1.5 g of the resulting coating solution (0.25 g of solids) was applied to a GB-R gypsum board, allowed to dry naturally, and then a decorative sheet was attached to obtain an evaluation sample.

[0086] Pyrogenicity test The test was conducted in accordance with ISO5660-1 cone calorimeter test. The heat release rate (kW / m 2 ) and total calorific value (MJ / m 2 ) was measured using a cone calorimeter (Toyo Seiki Seisakusho Co., Ltd., Kita-ku, Tokyo, Japan). A test specimen (10 cm × 10 cm) was placed horizontally in the sample installation position of the cone calorimeter, and a cone-shaped electric heater was used to heat the specimen from above at 50 kW / m 2 The test was carried out for 20 minutes. The heat generation rate was determined based on the oxygen consumption rate by combustion gas analysis. The total heat generation rate for the first 20 minutes after the start of heating was 8 MJ / m 2or less and 200 kW / m 2 If the total time during which the heat generation rate exceeded 10 seconds was 10 seconds or less, the test was judged as passing, and if not, the test was judged as failing.

[0087] [Table 2-1]

[0088] [Table 2-2]

[0089] [Table 2-3]

[0090] It will be apparent to those skilled in the art that the above-described embodiments and examples may be modified in various ways without departing from the basic principles of the present invention, and that various improvements and modifications of the present invention may be made without departing from the spirit and scope of the present invention. [Explanation of symbols]

[0091] 10 Fire protection layer 20 Film 30 Base material 32 Gypsum board 34 Paper 100 Laminated structure

Claims

1. A film-forming binder comprising montmorillonite, a dimer or higher phosphate, and at least one selected from the group consisting of water glass and an organic resin. A primer composition for application as a fire-resistant layer to an object to which a decorative film having an adhesive layer is to be attached.

2. The primer composition of claim 1, wherein the film-forming binder comprises at least one selected from the group consisting of polyvinyl chloride, polyvinylpyrrolidone, and oxazoline group-containing polymers.

3. The primer composition of claim 1 , wherein the film-forming binder comprises at least one selected from the group consisting of lithium silicate, sodium silicate, and potassium silicate.

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