Refractory resin composition

Abstract

To provide a fire-resistant resin composition that can render its residues hard even when filled with a high proportion of a thermal expansion material, and can sufficiently close a partition penetration part.SOLUTION: A fire-resistant resin composition contains a resin, a plasticizer, an additive, and a thermally-expandable laminar inorganic material and is used in the fireproof construction of a building. The resin contains at least one selected from the group consisting of polyvinyl acetal, polybutene, and a rubber component. The additive is at least one selected from the group consisting of a flame retardant, an endothermic agent, a lubricant, and an inorganic filler.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a fire-resistant resin composition, and more particularly to an expandable fire-resistant resin composition capable of sealing compartment penetrations. [Background technology]

[0002] In buildings such as apartment complexes, office buildings, and schools, partitions in walls and other areas may have compartment penetrations to allow long objects such as cables and pipes to pass through. Compartment penetrations are required to have a fire-resistant structure to prevent the spread of fire to other compartments in the event of a fire in one compartment. Partitions typically consist of two wall sections with a hollow space between them, forming a hollow wall.

[0003] One known method for making partition penetrations fire-resistant is to fill the gap between a long through-body and the through-hole with an amorphous filler such as fire-resistant putty. When using an amorphous filler, cylindrical members made of fire-resistant material may also be placed between the through-hole in each wall section and the through-body (see, for example, Patent Documents 1 and 2). [Prior art documents] [Patent Documents]

[0004] [Patent Document 1] Patent No. 6150933 [Patent Document 2] Patent No. 6348320 [Overview of the Initiative] [Problems that the invention aims to solve]

[0005] However, when amorphous fillers are used for fire protection treatment of compartment penetrations, variations in workmanship can occur, sometimes resulting in insufficient fire resistance. Furthermore, when fire-resistant materials and their accessories are installed within the building structure, the extent (quantity, thickness, length, etc.) of their installation may be unclear, or it may be difficult to determine if they are installed according to regulations. Therefore, to confirm whether fire-resistant materials are installed according to regulations, it is necessary to destroy the compartment penetration structure and inspect its internal structure.

[0006] Furthermore, in compartment penetration structures where long insertions such as cables and pipes are inserted, if the insertions are moved after the compartment penetration treatment structure has been applied, the fire-resistant materials installed inside may shift from their proper positions. External forces such as earthquakes can also cause the fire-resistant materials to shift from their proper positions. Moreover, if the fire-resistant material does not expand uniformly but expands unevenly, it may shift from its proper position or fall off. In this way, the shifting of the fire-resistant materials from their proper positions makes it difficult for the fire-resistant structure of the compartment penetration to exhibit the desired fire resistance performance.

[0007] In light of the above issues, a method can be considered in which a thermally expandable sheet with a high expansion ratio is installed at the compartment penetration, without using amorphous filler material within the structure. The thermally expandable sheet can be obtained, for example, by filling it with a high amount of thermal expansion material, which allows it to expand sufficiently due to the flames in the event of a fire, sealing the compartment penetration and suppressing the spread of fire. However, high levels of thermal expansion material tend to make the sheet residue brittle, which can be blown away by flames. Consequently, it was sometimes impossible to adequately seal the compartment penetrations, and the spread of fire could not be suppressed.

[0008] Therefore, the object of the present invention is to provide a fire-resistant resin composition that, in the event of a fire, can appropriately seal compartment penetrations to suppress the spread of fire, and harden the expanded residue to maintain the sealing of compartment penetrations. [Means for solving the problem]

[0009] This invention was made to solve the above problems, and the gist of this invention is as follows. [1] A fire-resistant resin composition for use in the fire-resistant structure of a building, comprising a resin, a plasticizer, an additive, and a thermally expandable layered inorganic material, wherein the resin comprises at least one selected from the group consisting of polyvinyl acetal, polybutene, and rubber components, and the additive comprises at least one selected from the group consisting of flame retardants, heat absorbers, lubricants, and inorganic fillers. [2] The fire-resistant resin composition according to [1], wherein the rubber component is at least one selected from the group consisting of chloroprene rubber, natural rubber, butyl rubber, styrene-butadiene rubber, nitrile-butadiene rubber, ethylene propylene rubber, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, and acrylic rubber. [3] The fire-resistant resin composition according to [1] or [2], wherein the resin further comprises at least one selected from the group consisting of polyphenylene oxide and petroleum resins. [4] The fire-resistant resin composition according to any one of the items [1] to [3], wherein the polyvinyl acetal is polyvinyl butyral. [5] The fire-resistant resin composition according to any one of [1] to [4], wherein the plasticizer content is 0.5 to 100 parts by mass per 100 parts by mass of the resin. [6] The fire-resistant resin composition according to any one of [1] to [5], wherein the content of the thermally expandable layered inorganic is 10 to 50 parts by mass per 100 parts by mass of the fire-resistant resin composition. [7] A fire-resistant resin composition according to any one of items [1] to [6], wherein the ratio of the resin content to the powder content (resin / powder) is 0.2 to 3. [8] The fire-resistant resin composition according to any one of [1] to [7], wherein the thermally expandable layered inorganic material is thermally expandable graphite. A fire-resistant material comprising a fire-resistant resin composition as described in any one of items [9][1] to [8]. The refractory material according to [9], wherein an expansion ratio at 300°C is 5 times or more, and an expansion ratio at 600°C is 20 times or more.

[11] A residue hardness at 300°C is 4 kgf / cm 2 or more, and a residue hardness at 600°C is 0.3 kgf / cm 2 or more, the refractory material according to [9] or

[10] .

[12] The refractory material according to any one of [9] to

[11] , wherein a residue retention rate at 300°C is 80% or more, and a residue retention rate at 600°C is 50% or more.

[13] The refractory material according to any one of [9] to

[12] , wherein a thermal expansion initiation temperature of said fire-resistant resin composition is 100 to 300°C.

[14] The refractory material according to any one of [9] to

[13] , which has a thickness of 0.1 to 10 mm.

[15] A fire-resistant laminate comprising the refractory material according to any one of [9] to

[14] , a base material integrated with said refractory material, and an adhesive layer.

[16] A compartment penetration treatment material comprising the refractory material according to any one of [9] to

[14] , or the fire-resistant laminate according to

[15] .

[17] A compartment penetration treatment structure comprising the compartment penetration treatment material according to

[16] .

[18] A construction method for the compartment penetration treatment structure according to

[17] .

Effect of the Invention

[0010] According to the present invention, there can be provided a fire-resistant resin composition that can block a compartment penetration portion, suppress fire spread when a fire occurs, and can harden expanded residue to maintain blocking of the compartment penetration portion.

Brief Description of Drawings

[0011] [Figure 1] It is a schematic cross-sectional view showing the configuration of a sheet-like member of a compartment penetration treatment structure. [Figure 2] It is a schematic cross-sectional view showing the configuration of a sheet-like member of a compartment penetration treatment structure. [Figure 3] It is a perspective view showing a compartment penetration treatment structure before a compartment penetration treatment material is installed. [Figure 4] It is a cross-sectional view showing a compartment penetration treatment structure. MODE FOR CARRYING OUT THE INVENTION

[0012] Hereinafter, the present invention will be described in detail. The refractory resin composition of the present invention contains a resin, a plasticizer, a specific additive described later, and a thermally expandable layered inorganic material.

[0013] (Resin) The refractory resin composition of the present invention contains a resin including at least one selected from the group consisting of polyvinyl acetal, polybutene, and a rubber component. By using these resins, a refractory material having excellent fire resistance and good residual slag hardness can be obtained. Further, using a rubber component achieves high fire resistance and good residual slag hardness, while using polybutene or polyvinyl acetal facilitates obtaining adequate adhesiveness. Among these, it is preferable for the resin to contain at least one selected from the group consisting of polybutene and a rubber component.

[0014] <Polyvinyl acetal> Polyvinyl acetal is not particularly limited as long as it is obtained by acetalizing polyvinyl alcohol with an aldehyde, but polyvinyl butyral (PVB) is preferable. The use of polyvinyl butyral makes it possible to increase mechanical strength even when the amount of resin relative to the refractory additive is relatively small. Therefore, constant mechanical strength can be ensured even when the thickness of the refractory material is reduced. The amount of hydroxyl groups in the polyvinyl acetal is preferably 20 to 40 mol%. A hydroxyl group content of 20 mol% or more increases the polarity of the polyvinyl acetal, strengthens the bonding force with refractory additives, and improves the mechanical strength of the refractory material. Furthermore, a hydroxyl group content of 40 mol% or less prevents the refractory material from becoming too hard. More preferably, the amount of hydroxyl groups is 23 mol% or more, and even more preferably 26 mol% or more. Also, more preferably, the amount of hydroxyl groups is 37 mol% or less, and even more preferably 35 mol% or less.

[0015] The degree of acetalization of the above polyvinyl acetal is preferably 40 to 80 mol%. By keeping the degree of acetalization within this range, the amount of hydroxyl groups can be kept within the desired range, making it easier to improve the mechanical strength of the refractory material. The degree of acetalization is more preferably 55 mol% or more, even more preferably 65 mol% or more, and even more preferably 76 mol% or less. Furthermore, the amount of acetyl groups in the polyvinyl acetal is preferably 0.1 to 30 mol%. When the amount of acetyl groups is within this range, it exhibits excellent moisture resistance, excellent compatibility with plasticizers, and high flexibility, improving handling. In addition, by keeping the amount of acetyl groups within these ranges, the amount of hydroxyl groups can be kept within the desired range, which makes it easier to improve the mechanical strength of the refractory material. From these viewpoints, the amount of acetyl groups is more preferably 0.2 mol% or more, even more preferably 0.5 mol% or more, even more preferably 15 mol% or less, and even more preferably 7 mol% or less. The degree of acetalization, hydroxyl group content, and acetyl group content can be measured and calculated, for example, by a method conforming to JIS K6728 "Test Method for Polyvinyl Butyral".

[0016] The degree of polymerization of polyvinyl acetal is preferably 200 to 3000. By keeping the degree of polymerization within this range, the refractory additive can be properly dispersed in the refractory material. The degree of polymerization is more preferably 250 or higher, and even more preferably 300 or higher. Lowering the degree of polymerization of polyvinyl acetal reduces its viscosity, making it easier to disperse refractory additives in the refractory material and improving its mechanical strength. From this viewpoint, the degree of polymerization of the polyvinyl acetal resin is preferably 2000 or less, more preferably 1500 or less, and even more preferably 1000 or less. The degree of polymerization of polyvinyl acetal resin refers to the viscosity-average degree of polymerization measured according to the method described in JIS K6728.

[0017] The 10% by mass ethanol / toluene viscosity of the polyvinyl acetal resin is preferably 5 mPa·s or higher, more preferably 10 mPa·s or higher, and even more preferably 15 mPa·s or higher. Furthermore, the 10% by mass ethanol / toluene viscosity is preferably 500 mPa·s or lower, more preferably 300 mPa·s or lower, and even more preferably 200 mPa·s or lower. By setting the 10% by mass ethanol / toluene viscosity of the polyvinyl acetal resin as described above, the refractory additives are more easily dispersed in the refractory material, and the mechanical strength of the refractory material is improved. The viscosity of 10% by mass ethanol / toluene was measured as follows: Take 150 ml of ethanol / toluene (weight ratio 1:1) mixed solvent into an Erlenmeyer flask, add the weighed sample to it, and dissolve the resin at a resin concentration of 10 wt% by shaking in a constant temperature room at 20°C. Maintain the solution at 20°C and measure the viscosity using a BM-type viscometer to determine the 10 mass% ethanol / toluene viscosity.

[0018] The above aldehydes are not particularly limited, but generally, aldehydes having 1 to 10 carbon atoms are preferred. The above aldehydes having 1 to 10 carbon atoms are not particularly limited, and examples include n-butyraldehyde, isobutyraldehyde, n-valeraldehyde, 2-ethylbutyraldehyde, n-hexylaldehyde, n-octylaldehyde, n-nonylaldehyde, n-decylaldehyde, formaldehyde, acetaldehyde, and benzaldehyde. Among these, n-butyraldehyde, n-hexylaldehyde, and n-valeraldehyde are preferred, and n-butyraldehyde is more preferred. These aldehydes may be used individually or in combination of two or more.

[0019] The resin used in the present invention may consist solely of polyvinyl acetal, or it may be used in combination with other resins. The polyvinyl acetal content is preferably 1 to 100 parts by mass, more preferably 5 to 80 parts by mass, and even more preferably 10 to 50 parts by mass, per 100 parts by mass of the resin.

[0020] <Rubber components> The rubber component used in the present invention is preferably at least one selected from the group consisting of chloroprene rubber, natural rubber, butyl rubber, styrene-butadiene rubber, nitrile-butadiene rubber, ethylene-propylene rubber, ethylene-propylene diene rubber and other ethylene-propylene rubbers, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, and acrylic rubber. By using these rubber components in the fire-resistant resin composition, the fire resistance of the fire-resistant material made from the composition is improved. In particular, it is more preferable to include rubber components containing chlorine atoms, such as chloroprene rubber, chlorosulfonated polyethylene rubber, and epichlorohydrin rubber. Furthermore, it is preferable that the rubber component contains at least butyl rubber. Using butyl rubber as the rubber component makes it easier to impart tackiness to the fire-resistant material obtained from the composition. Also, from the viewpoint of improving tackiness, it is preferable to use butyl rubber in combination with polyvinyl acetal, polybutene, petroleum resin (described later), or a combination of two or more of these.

[0021] The content of the rubber component in the present invention is not particularly limited, but is preferably 10 to 100 parts by mass, more preferably 15 to 95 parts by mass, and even more preferably 20 to 93 parts by mass, per 100 parts by mass of resin. Furthermore, the content of the rubber component containing chlorine atoms is not particularly limited, but is preferably 0 to 80 parts by mass, more preferably 5 to 70 parts by mass, and even more preferably 10 to 65 parts by mass, per 100 parts by mass of resin.

[0022] The rubber component used in this invention has a Mooney viscosity ML(1+4) at 100°C that is preferably 10 to 150, more preferably 20 to 140, and even more preferably 30 to 130. Having a Mooney viscosity ML(1+4) within this range results in good processability and moldability, making it easy to produce the desired sheet or molded article. Furthermore, uniform filling ensures good fire resistance. When a rubber component containing chlorine atoms, such as chloroprene rubber, epichlorohydrin rubber, chlorosulfonated polyethylene rubber, or nitrile-butadiene rubber-PVC copolymer, is included, the chlorine content of the chlorine-containing rubber component is preferably 5 to 50, more preferably 8 to 45, and even more preferably 10 to 40. Setting the chlorine content above these lower limits improves the fire resistance of the fireproof material. Setting the chlorine content below these upper limits suppresses the generation of chlorine-derived toxic gases in the event of a fire. Considering these points, it is preferable to include butyl rubber, chloroprene rubber, and nitrile-butadiene rubber.

[0023] <Polybutene> In the present invention, polybutene is not particularly limited, and examples include isobutene homopolymers, isobutene-n-butene copolymers, and polybutene emulsions. By using polybutene in the fire-resistant resin composition, the tackiness of the fire-resistant material made from the composition is improved, and it can be easily attached to building fixtures and the like without using double-sided tape during construction. Among these, isobutene-n-butene copolymers are preferred. Furthermore, the weight-average molecular weight of polybutene, as measured by a method compliant with ASTM D 2503, is, for example, 300 to 5000, preferably 300 to 2000.

[0024] The polybutene content is not particularly limited, but is preferably 3 to 70 parts by mass, more preferably 5 to 65 parts by mass, and even more preferably 10 to 60 parts by mass per 100 parts by mass of resin.

[0025] The above-mentioned resins may be used individually or in combination of two or more types, but it is preferable to use two or more types in combination from the viewpoint of more effectively exhibiting fire resistance and residue hardness.

[0026] In the present invention, when two or more resins are used in combination, examples of resin combinations include polyvinyl acetal and a rubber component, polyvinyl acetal and polybutene, polyvinyl acetal, polybutene and a rubber component, and polybutene and a rubber component. Among these, from the viewpoint of improving the residue hardness and residue retention rate of the refractory material, it is more preferable to use a combination of polybutene and a rubber component.

[0027] In the present invention, when two or more resins are used in combination, the content ratio of each resin is not particularly limited. For example, when polyvinyl acetal and a rubber component are used in combination, the content of polyvinyl acetal is preferably 50 to 300 parts by mass, more preferably 100 to 200 parts by mass, and even more preferably 120 to 180 parts by mass, per 100 parts by mass of the rubber component. When polyvinyl acetal and polybutene are used in combination, the polyvinyl acetal content is preferably 30 to 150 parts by mass, more preferably 40 to 120 parts by mass, and even more preferably 50 to 100 parts by mass, per 100 parts by mass of polybutene content. When polybutene and rubber components are used in combination, the polybutene content is preferably 5 to 300 parts by mass, more preferably 10 to 270 parts by mass, and even more preferably 15 to 240 parts by mass, per 100 parts by mass of the rubber component.

[0028] The resin constituting the fire-resistant resin composition of the present invention preferably includes, in addition to the above-mentioned resin, at least one selected from the group consisting of polyphenylene oxide and petroleum resin. The polyphenylene oxide and petroleum resin may contain one of these, or both.

[0029] <Polyphenylene oxide> The polyphenylene oxide may be an unmodified polyphenylene oxide such as poly(2,6-dimethyl-1,4-phenylene oxide) or a modified polyphenylene oxide. By using polyphenylene oxide, the residue hardness and residue retention rate can be improved. When the resin contains polyphenylene oxide, the polyphenylene oxide content is preferably 1 to 60 parts by mass, more preferably 3 to 50 parts by mass, and even more preferably 5 to 45 parts by mass, per 100 parts by mass of resin, from the viewpoint of adjusting the residue hardness and residue retention rate of the refractory material to a desired range.

[0030] In the present invention, when polyphenylene oxide is used, it is preferable to use it in combination with at least one resin selected from the group consisting of polybutene and rubber components, and more preferably in combination with both polybutene and rubber components. When polyphenylene oxide is used in combination with a rubber component, it may be used in combination with a chlorine-containing rubber component or with other rubber components (chlorine-free rubber components). By using polyphenylene oxide, the residue hardness and residue retention rate of the refractory material can be improved and sufficient refractory properties can be ensured without using a chlorine-containing rubber component.

[0031] <Petroleum resin> Examples of petroleum resins include aliphatic hydrocarbon resins, aromatic hydrocarbon resins, alicyclic saturated hydrocarbon resins, copolymerized petroleum resins, hydrogenated petroleum resins, and petroleum resin emulsions. By using petroleum resins, the adhesiveness of the fire-resistant material can be improved, resulting in good workability. When the resin contains petroleum resin, the petroleum resin content is preferably 2 to 30 parts by mass, more preferably 3 to 20 parts by mass, and even more preferably 4 to 10 parts by mass, per 100 parts by mass of resin, from the viewpoint of improving the adhesiveness of the fire-resistant material and obtaining good workability.

[0032] (Plasticizer) The fire-resistant resin composition of the present invention contains a plasticizer. The inclusion of a plasticizer imparts flexibility to the composition, thereby facilitating the uniform mixing of each component during its manufacture. As a result, the residue hardness and residue retention rate of the fire-resistant material made from the composition can be adjusted to a desired range. In addition, good workability is achieved, and the composition expands easily in the event of a fire, thereby improving fire resistance. Specific examples of plasticizers include phthalate ester plasticizers such as di-2-ethylhexyl phthalate (DOP), dibutyl phthalate (DBP), diheptyl phthalate (DHP), and diisodecyl phthalate (DIDP); adipate esters such as di-2-ethylhexyl adipate (DOA), diisobutyl adipate (DIBA), and dibutyl adipate (DBA); and adipate dibutoxyethyl, adipate di(butoxyethoxyethyl), adipate di(methoxytetraethylene glycol), adipate di(methoxypentaethylene glycol), and Examples include adipic acid ether ester plasticizers such as dipic acid (methoxytetraethylene glycol) (methoxypentaethylene glycol), fatty acid ester plasticizers such as adipic acid polyester, epoxidized ester plasticizers such as epoxidized soybean oil, polyether ester plasticizers, trimellitic acid ester plasticizers such as tory 2-ethylhexyl trimellitate (TOTM) and triisononyl trimellitate (TINTM), phosphate ester plasticizers such as trimethyl phosphate (TMP) and triethyl phosphate (TEP), and process oils such as mineral oil.

[0033] The plasticizer used in this invention is a plasticizer having an ester structure, from the viewpoint of preventing crystallization of the resin and imparting flexibility, etc., i.e., phthalate ester plasticizers such as di-2-ethylhexyl phthalate (DOP), dibutyl phthalate (DBP), diheptyl phthalate (DHP), diisodecyl phthalate (DIDP), adipate esters such as di-2-ethylhexyl adipate (DOA), diisobutyl adipate (DIBA), dibutyl adipate (DBA), and adipate dibutoxyethyl adipate, di(butoxyethoxyethyl) adipate, di(methoxytetraethylene glycol) adipate, di( At least one selected from the group consisting of adipic acid ether ester plasticizers such as methoxypentaethylene glycol, adipic acid (methoxytetraethylene glycol) (methoxypentaethylene glycol), fatty acid ester plasticizers such as adipic acid polyester, epoxidized ester plasticizers such as epoxidized soybean oil, polyether ester plasticizers, trimellitic acid ester plasticizers such as tory 2-ethylhexyl trimellitate (TOTM) and triisononyl trimellitate (TINTM), and phosphate ester plasticizers such as trimethyl phosphate (TMP) and triethyl phosphate (TEP) is preferred.

[0034] Among plasticizers having an ester structure, at least one selected from the group consisting of plasticizers having an ether structure, i.e., polyether ester plasticizers, dibutoxyethyl adipate, di(butoxyethoxyethyl) adipate, di(methoxytetraethylene glycol) adipate, di(methoxypentaethylene glycol) adipate, and adipic acid (methoxytetraethylene glycol) (methoxypentaethylene glycol) is more preferred. In this invention, plasticizers can be used individually or in combination of two or more types.

[0035] When a refractory resin composition contains a plasticizer, the amount of plasticizer in the refractory resin composition is, for example, in the range of 0.5 parts by mass or more and 100 parts by mass or less per 100 parts by mass of the resin component, preferably in the range of 1 parts by mass or more and 80 parts by mass or less, more preferably in the range of 10 parts by mass or more and 70 parts by mass or less, and even more preferably in the range of 20 parts by mass or more and 50 parts by mass or less. If the amount of plasticizer is above these lower limits, flexibility is imparted and moldability tends to be good. If it is below the upper limits, appropriate strength is imparted to the molded article. Furthermore, by staying within the above ranges, it becomes easier to adjust the residue hardness and residue retention rate of the refractory material to the desired range.

[0036] (Thermally expandable layered inorganic material) The thermally expandable layered inorganic material is a conventionally known substance that expands when heated, such as vermiculite and thermally expandable graphite, with thermally expandable graphite being preferred. The thermally expandable layered inorganic material may be in particulate or flaky form. Because the thermally expandable layered inorganic material expands when heated to form large voids, the fire-resistant material using the thermally expandable layered inorganic material of the present invention suppresses the spread of fire and extinguishes it in the event of ignition. Thermally expandable graphite is produced by treating powders of natural flake graphite, pyrolysis graphite, quiche graphite, etc., with inorganic acids such as concentrated sulfuric acid, nitric acid, and selenic acid, and strong oxidizing agents such as concentrated nitric acid, perchloric acid, perchlorates, permanganates, dichromates, and hydrogen peroxide to generate graphite intercalation compounds. The resulting thermally expandable graphite is a crystalline compound that maintains the layered structure of carbon. The thermally expandable graphite used in this invention may also be obtained by neutralizing thermally expandable graphite obtained by acid treatment with ammonia, aliphatic lower amines, alkali metal compounds, alkaline earth metal compounds, etc. Examples of aliphatic lower amines include monomethylamine, dimethylamine, trimethylamine, ethylamine, propylamine, and butylamine. Examples of alkali metal compounds and alkaline earth metal compounds include hydroxides, oxides, carbonates, sulfates, and organic acid salts of potassium, sodium, calcium, barium, magnesium, and other metals.

[0037] The particle size of the thermally expandable graphite is preferably 20 to 200 mesh. When the particle size of the thermally expandable graphite is within this range, it expands easily, creating large voids, which improves fire resistance. It also improves dispersibility in resin. The average aspect ratio of thermally expandable graphite is preferably 2 or more, more preferably 5 or more, and even more preferably 10 or more. There is no particular upper limit to the average aspect ratio of thermally expandable graphite, but from the viewpoint of preventing cracking of the thermally expandable graphite, it is preferably 1,000 or less. An average aspect ratio of 2 or more of thermally expandable graphite makes it easier to expand and create large voids, thus improving flame retardancy. The average aspect ratio of thermally expandable graphite is calculated by measuring the maximum dimension (long axis) and minimum dimension (short axis) of 10 thermally expandable graphite samples, and then taking the average of the values ​​obtained by dividing the maximum dimension (long axis) by the minimum dimension (short axis). The long and short axes of thermally expandable graphite can be measured, for example, using a field emission scanning electron microscope (FE-SEM).

[0038] Furthermore, the content of the thermally expandable layered inorganic material in the fire-resistant resin composition of the present invention is preferably 5 parts by mass or more, more preferably 10 parts by mass or more, even more preferably 20 parts by mass or more, and even more preferably 30 parts by mass or more, per 100 parts by mass of the fire-resistant resin composition. Furthermore, the above content of the thermally expandable layered inorganic material is preferably 60 parts by mass or less, more preferably 50 parts by mass or less, and even more preferably 48 parts by mass or less. If it is above the lower limit, sufficient thermal expansion can be obtained, and it becomes possible to sufficiently seal the compartment penetration. In addition, in the present invention, even if the thermally expandable layered inorganic material is highly filled, the hardness of the expansion residue increases, making it easier to maintain relatively good fire resistance. On the other hand, if it is below the upper limit, moldability is good, and the surface properties, mechanical properties, and flexibility of the sealing member are also good. Furthermore, by selecting the content of thermally expandable graphite within the above range, it becomes easier to adjust the expansion ratio to a desired range.

[0039] (Specific additives) The fire-resistant resin composition of the present invention contains, as a specific additive, at least one selected from flame retardants, heat absorbers, lubricants, and inorganic fillers, in addition to the above-mentioned thermally expandable layered inorganic material. These components may be used individually or in combination of two or more. By containing specific additives, the fire-resistant resin composition of the present invention can achieve high residue hardness and residue retention.

[0040] <Flame retardant> Flame retardants, heat absorbers, and inorganic fillers are fire-resistant additives that improve the fire resistance of fire-resistant resin compositions. Examples of flame retardants used in the present invention include phosphorus-containing compounds. Examples of phosphorus-containing compounds include red phosphorus, various phosphate esters such as triphenyl phosphate, tricresyl phosphate, trixylenyl phosphate, cresyl diphenyl phosphate, and xylenyl diphenyl phosphate, metal phosphate salts such as sodium phosphate, potassium phosphate, and magnesium phosphate, metal phosphate salts such as sodium phosphite, potassium phosphite, magnesium phosphite, and aluminum phosphite, and ammonium polyphosphate. By using these phosphorus-containing compounds, appropriate fire resistance and fire extinguishing performance can be imparted to fire-resistant resin compositions. These flame retardants may be used individually or in combination of two or more. Among these flame retardants, ammonium polyphosphate and aluminum phosphite are particularly preferred from the viewpoint of improving the fire resistance and fire extinguishing performance of the fire-resistant resin composition.

[0041] The flame retardant is preferably solid at room temperature (23°C) and atmospheric pressure (1 atm). The average particle size of the flame retardant is preferably 1 to 200 μm, more preferably 1 to 60 μm, even more preferably 3 to 40 μm, and even more preferably 5 to 20 μm. When the average particle size of the flame retardant is within the above range, the dispersibility of the flame retardant in the fire-resistant resin composition is improved, allowing the flame retardant to be uniformly dispersed in the resin and enabling a higher amount of flame retardant to be blended with the resin.

[0042] The amount of flame retardant in the present invention is not particularly limited, but is preferably 15 to 60 parts by mass, more preferably 20 to 55 parts by mass, and even more preferably 25 to 50 parts by mass per 100 parts by mass of resin.

[0043] <Heat absorbent> Hydrated metal compounds are preferred as heat absorbers used in the refractory resin composition of the present invention. Hydrated metal compounds are compounds that decompose upon contact with a flame, generating water vapor and thus absorbing heat. Examples of hydrated metal compounds include metal hydroxides and hydrates of metal salts. Specifically, examples include aluminum hydroxide, magnesium hydroxide, calcium hydroxide, calcium-magnesium hydroxides, hydrotalcite, boehmite, talc, dawsonite, calcium sulfate hydrate, magnesium sulfate hydrate, and zinc borate [2ZnO·3B2O5·3.5H2O]. Among these, at least one selected from aluminum hydroxide, magnesium hydroxide, calcium sulfate dihydrate, and magnesium sulfate heptahydrate is preferred from the viewpoint of fire resistance and fire extinguishing performance, with aluminum hydroxide and magnesium hydroxide being particularly preferred.

[0044] As a heat absorbent, it is preferable to have a thermal decomposition initiation temperature of 500°C or lower and a heat absorption amount of 500 J / g or more. If either the thermal decomposition initiation temperature or the heat absorption amount falls within the above range, the fire can be quickly extinguished in the event of ignition. From this viewpoint, the thermal decomposition initiation temperature of the heat absorbent is preferably 400°C or lower, and more preferably 300°C or lower. Furthermore, the thermal decomposition initiation temperature of the heat absorbent is usually 100°C or higher, preferably 150°C or higher, and even more preferably 180°C or higher. By setting these lower limits or higher, it is possible to prevent the heat absorbent from malfunctioning due to heating other than fire. The thermal decomposition initiation temperature can be measured using a thermogravimetric differential thermal analyzer (TG-DTA), and specifically, it can be measured by the method described in the examples.

[0045] The heat absorption capacity of the heat absorbent is preferably 600 J / g or more, more preferably 900 J / g or more. When the heat absorption capacity of the heat absorbent is within the above range, the heat absorption capacity is improved, resulting in better fire resistance and fire extinguishing performance. The heat absorption capacity of the heat absorbent is usually 4000 J / g or less, preferably 3000 J / g or less. The amount of heat absorbed can be measured using a thermogravimetric differential thermal analyzer (TG-DTA), and specifically, it can be measured by the method described in the examples.

[0046] Furthermore, the heat absorbent is preferably one with an average particle size of 0.1 to 90 μm. By keeping the average particle size within the above range, the heat absorbent is more easily dispersed in the resin, making it easier to incorporate a large amount of heat absorbent, and thus improving fire resistance and fire extinguishing performance. From the above viewpoint, the average particle size of the heat absorber is more preferably 0.5 to 60 μm, even more preferably 0.8 to 40 μm, and even more preferably 0.8 to 10 μm.

[0047] The amount of heat-absorbing agent in the present invention is not particularly limited, but is preferably 5 to 40 parts by mass, more preferably 10 to 30 parts by mass, and even more preferably 12 to 20 parts by mass per 100 parts by mass of resin.

[0048] <Lubricant> A lubricant may be used in the refractory resin composition of the present invention. By using a lubricant, the composition becomes more fluid, and the thermally expandable layered inorganic material and refractory additives are appropriately dispersed in the composition. As a result, the thermal expandability and residue hardness of the refractory material made from the composition are improved, and the refractory properties of the refractory material are enhanced. Examples of lubricants used in the present invention include resin-based lubricants and phosphate ester-based lubricants. It is preferable to use the lubricant in combination with the refractory additives mentioned above.

[0049] As the resin-based lubricant, known resin-based lubricants can be used, but acrylic oligomers are preferred. As the acrylic oligomer, acrylic acid ester oligomers are preferred. Examples of acrylic acid esters that constitute the oligomer include methyl acrylate, ethyl acrylate, butyl acrylate, cyclohexyl acrylate, and octyl acrylate. Among these, butyl acrylate oligomers are preferred. As the resin lubricant, commercially available products can also be used; for example, "ADEKA Stab FC-113" manufactured by ADEKA Corporation can be used.

[0050] Examples of phosphate ester lubricants include long-chain aliphatic phosphate ester compounds, and long-chain monoalkyl phosphate esters and long-chain dialkyl phosphate esters can be preferably used. The alkyl group constituting the long-chain monoalkyl phosphate ester and the long-chain dialkyl phosphate ester preferably has 12 to 18 carbon atoms. Examples of alkyl groups with 12 to 18 carbon atoms include dodecyl, tridecyl, isotridecyl, tetradecyl, hexadecyl, and octadecyl groups. The long-chain aliphatic phosphate ester compound used in the present invention is preferably at least one selected from the group consisting of monododecyl phosphate, didodecyl phosphate, monooctadecyl phosphate, and dioctadecyl phosphate, and more preferably monooctadecyl phosphate, dioctadecyl phosphate, or a mixture thereof. In the present invention, one type of lubricant may be used alone, or two or more types may be used in combination. For example, a resin-based lubricant and a phosphate ester-based lubricant may be used in combination, and among the above, it is more preferable to use an acrylic oligomer and a long-chain aliphatic phosphate ester compound in combination. The lubricant content in the fire-resistant resin composition of the present invention is preferably 0.1 to 15 parts by mass, more preferably 0.3 to 8 parts by mass, and even more preferably 0.5 to 4 parts by mass, per 100 parts by mass of resin.

[0051] <Inorganic filler> Inorganic fillers that can be used in the fire-resistant resin composition of the present invention include, but are not particularly limited to, inorganic fillers other than the above-mentioned thermally expandable layered inorganic materials, flame retardants, heat absorbers, and lubricants, but include, for example, silica, diatomaceous earth, alumina, zinc oxide, titanium oxide, calcium oxide, magnesium oxide, iron oxide, tin oxide, antimony oxide, ferrites, basic magnesium carbonate, calcium carbonate, magnesium carbonate, zinc carbonate, barium carbonate, dohnite, hydrotalcite, calcium sulfate, barium sulfate, gypsum fiber, calcium silicate, clay, Examples include mica, montmorillonite, bentonite, activated clay, ceviolite, imogolite, sericite, glass fiber, glass beads, silica balloon, aluminum nitride, aluminum phosphite, boron nitride, silicon nitride, carbon black, graphite, carbon fiber, carbon balloon, charcoal powder, various metal powders, potassium titanate, magnesium sulfate, lead zirconia titanate, aluminum borate, molybdenum sulfide, silicon carbide, stainless steel fiber, zinc borate, various magnetic powders, slag fiber, fly ash, and dewatered sludge. Of these, calcium carbonate and carbon black are preferred. These inorganic fillers may be used individually or in combination of two or more.

[0052] The average particle size of the inorganic filler is preferably 0.5 to 100 μm, and more preferably 1 to 50 μm. When the inorganic filler content is small, a smaller particle size is preferred from the viewpoint of improving dispersibility, and when the content is large, a larger particle size is preferred because as the filling progresses, the viscosity of the refractory resin composition increases and moldability decreases. The average particle size of the flame retardant, heat absorber, and inorganic filler mentioned above is the median diameter (D50) value measured using a laser diffraction / scattering particle size distribution analyzer.

[0053] The amount of inorganic filler in the present invention is not particularly limited, but is preferably 5 to 80 parts by mass, more preferably 8 to 70 parts by mass, and even more preferably 10 to 65 parts by mass per 100 parts by mass of resin.

[0054] In the fire-resistant resin composition of the present invention, the content of the specific additive is preferably 3 to 250 parts by mass, more preferably 5 to 200 parts by mass, even more preferably 10 to 150 parts by mass, and even more preferably 50 to 130 parts by mass, per 100 parts by mass of resin. When the content of the specific additive is above the lower limit, flame retardancy can be obtained and mechanical properties can be improved. On the other hand, when it is below the upper limit, the relative amount of thermally expandable layered inorganic material becomes sufficient, and when a fire occurs, it expands due to the flame, seals the compartment penetrations, and can suppress the spread of fire.

[0055] Furthermore, by increasing the amount of polyphenylene oxide, the amount of specific additives can be reduced. In that case, the content of the specific additive is preferably 3 to 50 parts by mass, more preferably 5 to 30 parts by mass, per 100 parts by mass of resin, and the content of polyphenylene oxide is preferably 20 to 60 parts by mass, more preferably 30 to 50 parts by mass, per 100 parts by mass of resin.

[0056] The specific additives mentioned above only need to include at least one selected from flame retardants, heat absorbers, lubricants, and inorganic fillers, as described above. Of these, as a combination of fire-resistant additives, at least one selected from flame retardants, heat absorbers, and inorganic fillers is preferred from the viewpoint of improving the fire resistance of the fire-resistant material, a combination of a flame retardant and a heat absorber, or a combination of a flame retardant and an inorganic filler is more preferred, and it is also preferable to use a combination of a flame retardant, a heat absorber, and an inorganic filler. Furthermore, lubricants may be added to each of these combinations. In particular, the combination of selecting ammonium polyphosphate (APP) as the flame retardant and calcium carbonate as the inorganic filler is preferred. This is thought to be because ammonium polyphosphate and calcium carbonate react when heated by fire or other means, hardening the residue. Furthermore, from the viewpoint of hardening the residue, it is also preferable to use aluminum phosphite as a fire-resistant additive.

[0057] The refractory resin composition of the present invention preferably has a resin-to-powder content ratio (resin / powder) of 0.2 to 3, more preferably 0.5 to 2, and even more preferably 0.5 to 0.7. By setting the resin-to-powder content ratio within the above range, it becomes easier to adjust the residue hardness and residue retention rate of the refractory material to a desired range. Powders are substances that become solid at room temperature (23°C) and normal pressure (1 atm). In fire-resistant resin compositions, they exist in powder, particulate, or fibrous form without dissolving or becoming miscible with the resin. Specifically, among the components described above, solid flame retardants, heat absorbers, inorganic fillers, lubricants, and thermally expandable layered inorganic materials are considered powders.

[0058] The fire-resistant resin composition of the present invention may contain, as necessary, additives commonly used in thermally expandable resin compositions, such as heat stabilizers, processing aids, antioxidants, antistatic agents, pigments, crosslinking agents, and crosslinking accelerators, to the extent that they do not impair its physical properties. Among these, the use of processing aids is preferred.

[0059] [Fireproof material] The fire-resistant material of the present invention consists of the fire-resistant resin composition of the present invention, and is particularly preferably in sheet form. The thickness of the fire-resistant material is preferably 0.1 to 10 mm, more preferably 2 to 8 mm, and even more preferably 3 to 5 mm. If the thickness is above the lower limit, sufficient fire resistance performance is ensured, and if it is below the upper limit, flexibility of the fire-resistant material is ensured.

[0060] The thermal expansion initiation temperature of the fire-resistant material of the present invention is not particularly limited, but is preferably 100 to 300°C, more preferably 120 to 280°C, and even more preferably 130 to 250°C. Setting it above these lower limits prevents the thermally expandable material from expanding unintentionally due to heating other than fire. Setting it below the upper limit makes it easier to reliably expand the thermally expandable material due to heating from a fire. Furthermore, the method for measuring the thermal expansion initiation temperature of the fire-resistant material of the present invention is as described in the examples below.

[0061] The expansion ratio of the refractory material of the present invention at 300°C is preferably 5 times or more, more preferably 10 times or more, and still more preferably 15 times or more. Further, the expansion ratio at 600°C is preferably 20 times or more, more preferably 25 times or more, and still more preferably 30 times or more. When the expansion ratio of the refractory material is not less than the above lower limit, good expansion performance can be obtained when a fire occurs, and the effect of blocking the compartment penetration portion to prevent fire spread can be sufficiently exhibited. Further, although the expansion ratio of the refractory material is not particularly limited, from the viewpoint of ensuring certain residue hardness and residue retention rate and preventing the formation of a gap between the refractory material and the compartment penetration portion when a fire occurs, the expansion ratio at 300°C is preferably 50 times or less, more preferably 40 times or less, still more preferably 35 times or less, and even more preferably 20 times or less. Further, at 600°C, the expansion ratio is preferably 65 times or less, more preferably 60 times or less, still more preferably 50 times or less, and even more preferably 40 times or less.

[0062] The residue hardness of the refractory material of the present invention at 300°C is 3kgf / cm 2 or higher, preferably 4kgf / cm 2 or higher, more preferably 5kgf / cm 2 or higher, even more preferably. Further, the residue hardness at 600°C is 0.1kgf / cm 2 or higher, preferably 0.2kgf / cm 2 or higher, more preferably 0.3kgf / cm 2 or higher, even more preferably. When the residue hardness is not less than the above lower limit, the refractory material can be prevented from being blown away by flame when a fire occurs, and fire spread in the event of a fire can be effectively prevented. Further, although the residue hardness of the refractory material is not particularly limited, at 300°C, it is 50kgf / cm 2 or less, preferably 40kgf / cm 2 or less, more preferably 20kgf / cm 2 or less, even more preferably. Further, at 600°C, it is 10kgf / cm 2 or less, preferably 4kgf / cm 2 or less, more preferably 2kgf / cm2 The following are even more preferable.

[0063] The residue retention rate of the fire-resistant material of the present invention at 300°C is preferably 60% or more, more preferably 70% or more, and even more preferably 80% or more. Furthermore, the residue retention rate at 600°C is preferably 40% or more, more preferably 44% or more, and even more preferably 50% or more. By having a residue retention rate above the above lower limit, excellent fire resistance can be obtained, and the spread of fire in the event of a fire can be effectively prevented. Furthermore, while there are no particular limitations on the residue retention rate of the refractory material, at 300°C, it is preferably 95% or less, and more preferably 93% or less. At 600°C, it is preferably 70% or less, and more preferably 65% ​​or less. Furthermore, the expansion ratio of the refractory material, the hardness of the residue, and the residue retention rate can be measured by the method described in the examples.

[0064] [Fire-resistant laminate] The fire-resistant material of the present invention may be used as a single layer of fire-resistant material, or it may be used as a multilayer (fire-resistant laminate) by laminating two or more layers of fire-resistant material (hereinafter also referred to as fire-resistant material layers), or by laminating other layers other than fire-resistant material. Examples of other layers that can be used include a base material and an adhesive layer. The fire-resistant laminate may have both a base material and an adhesive layer, but it is sufficient to have at least one of them.

[0065] <Base material> The base material used in fire-resistant laminates supports the fire-resistant material and, depending on its material, evenly transfers heat to the fire-resistant material. Examples of base materials include metal foils such as aluminum foil and copper foil, metal foil composites such as glass cloth and aluminum glass cloth, paper, cloth, and resin film. Among these, from the viewpoint of fire resistance, it is preferable to use a non-combustible material, and metal foils and metal foil composites are more preferable. By using metal foils and metal foil composites, it becomes easier to evenly transfer heat to the fire-resistant material, and when a fire occurs, the fire-resistant material expands evenly, making it easier to improve fire resistance. Non-combustible materials are defined in the Building Standards Act and the Building Standards Act Enforcement Order.

[0066] The base material may be provided on one side of the fire-resistant material, or on both sides so as to sandwich the fire-resistant material. However, from the viewpoint of effectively controlling the expansion of the fire-resistant material with the base material and causing it to expand in the direction of the compartment penetration, thereby ensuring that the compartment penetration is reliably sealed in the event of a fire, it is preferable to provide the base material on both sides of the fire-resistant material.

[0067] The thickness of each base material is not particularly limited, but is, for example, 0.01 to 1 mm, preferably 0.05 to 0.5 mm. Having a non-combustible material layer with a thickness below these upper limits provides flexibility to the sheet-like member. Having a thickness above the lower limit makes it easier to ensure fire resistance.

[0068] <Adhesive layer> The adhesive layer used in the fire-resistant laminate is preferably formed by an adhesive, and examples of adhesives that can be used include acrylic adhesives, urethane adhesives, rubber adhesives, and silicone resin adhesives. The adhesive layer may be non-combustible, semi-non-combustible, or flame-retardant, and flame retardants may be added to the adhesive used. The thickness of the adhesive layer is, for example, 5 to 400 μm, preferably 10 to 150 μm. Furthermore, the adhesive layer may be placed on the outermost surface of the fire-resistant laminate so that it can be bonded to other components.

[0069] As described above, multiple sheets of fire-resistant material may be laminated together. When multiple sheets of fire-resistant material are laminated together, if they are adhesive, they may be laminated directly together, or they may be laminated together via an adhesive layer or an adhesive layer made of a known adhesive other than an adhesive layer.

[0070] When multiple sheets of fire-resistant material are laminated, it is preferable that the layers have different expansion ratios, and the expansion ratios should be controlled according to the intended use. When two or more layers of sheet-like fire-resistant material are provided, it is preferable that at least one of them is composed of the fire-resistant resin composition of the present invention and constitutes a fire-resistant layer with a high expansion ratio. Furthermore, in a fire-resistant laminate composed of a base material and a fire-resistant layer, the base material may consist of two or more layers, and if the fire-resistant layer is adhesive, it is preferable to position it on the outermost surface so that it can adhere to other components.

[0071] The fire-resistant laminate preferably comprises a base material and a fire-resistant layer. The fire-resistant laminate may consist of two layers, the base material and the fire-resistant layer, or at least three layers of alternating layers. Furthermore, the fire-resistant laminate is not limited to a three-layer configuration; it may consist of four alternating layers of base material and fire-resistant layer, or even more. The fire-resistant resin composition of the present invention has a high expansion ratio and the residue is hard, so it may constitute some of the multiple fire-resistant layers or all of them. The detailed structure of the fire-resistant laminate will be described later.

[0072] Furthermore, it is preferable that the fire-resistant laminate has at least three layers of alternating base material and fire-resistant material layers having thermal expansion properties. Specifically, as shown in Figure 1(a), the fire-resistant laminate 3 may have three alternating layers of base material 30A, 30B and fire-resistant material layer 31A, or as shown in Figure 1(b), it may have three alternating layers of base material 30A and fire-resistant material layers 31A, 31B. The sheet-like member 3 is not limited to a three-layer configuration, and as shown in Figure 1(c), it may have four alternating layers of base material 30A, 30B and fire-resistant material layers 31A, 31B.

[0073] Furthermore, when the base material and the fire-resistant layer are laminated alternately, the sheet-like member 3 does not need to have the base material and the fire-resistant layer alternately one layer at a time, as long as it has base material / fire-resistant layer / base material or fire-resistant layer / base material / fire-resistant layer in this order. The same type of layer may be laminated continuously, such as base material / base material / fire-resistant layer / fire-resistant layer. For example, as shown in Figure 1(d), base materials 30A and 30B may be laminated continuously, and base materials 30B and 30C and fire-resistant layer 31A may be laminated alternately. Also, as shown in Figure 1(e), there is no limit to the number of layers in the sheet-like member 3, and multiple base materials 30A, ... 30Y, 30Z and multiple fire-resistant layers 31A, ... 31Y, 31Z may be laminated alternately in multiple layers.

[0074] As shown in Figure 2(a), it is also preferable to have an adhesive fire-resistant layer 31A on the outermost surface of the fire-resistant laminate 3. Furthermore, when an adhesive layer is provided, it is also preferable to have a configuration in which the fire-resistant layer 31A, which includes the adhesive layer 33, is placed on the outermost surface, as shown in Figure 2(b). In this case, it becomes easier to improve the fire resistance performance of the fire-resistant layer itself by relatively increasing the content of resins such as chloroprene rubber and polyphenylene oxide, or by increasing the content of thermally expandable layered inorganic materials.

[0075] With the above configuration, the fire-resistant laminate 3 can be easily fixed to other components such as the partition 11 (see Figure 3) described later, without the need to use a fixing member as a separate component from the fire-resistant laminate 3. Furthermore, by making the fire-resistant material layer itself adhesive, it is not necessary to provide an adhesive layer, thus further simplifying the structure of the fire-resistant laminate 3. If the fire-resistant laminate 3 has an adhesive fire-resistant material layer or adhesive layer on its outermost surface, a release sheet may be attached to that outermost surface. The release sheet should be peeled off from the outermost surface when in use.

[0076] Note that the fire-resistant laminate shown in Figure 2 is just one example, and the configuration is not limited to that shown in Figure 2, especially when an adhesive layer is provided as the outermost layer or when an adhesive fire-resistant layer is provided as the outermost layer. It may also be a two-layer structure of fire-resistant layer / base material, or a three-layer structure of fire-resistant layer / base material / adhesive layer, or base material / fire-resistant layer / adhesive layer, etc. Furthermore, in a multilayer structure, the sheet-like member 3 may have the same layer configuration throughout, or it may have a partially different structure. For example, the layer configuration of the base material and the fire-resistant layer may be partially changed.

[0077] <Manufacturing method> The fire-resistant resin composition of the present invention can be manufactured, for example, as follows. First, a predetermined amount of a specific additive such as a fire-resistant additive, a thermally expandable layered inorganic material, a resin, and other additives as needed are mixed in a mixer such as a kneading roll to obtain a fire-resistant resin composition. The mixing temperature is preferably 100 to 150°C. Setting the mixing temperature above the lower limit makes it easier to uniformly mix each component. Setting the mixing temperature below the upper limit prevents the thermally expandable layered inorganic material from expanding during mixing, thereby providing a high-quality fire-resistant material. The fire-resistant resin composition may be diluted by adding a solvent as appropriate.

[0078] The fire-resistant resin composition obtained as described above may be molded into a predetermined shape to form a fire-resistant material. Specifically, it may be formed into a sheet-like fire-resistant material by extrusion molding, press molding, etc. Alternatively, the fire-resistant resin composition diluted with a solvent may be applied to a support such as a substrate or release sheet, and dried as appropriate to form a fire-resistant material on one surface of the support. The fire-resistant material formed on the release sheet may be peeled off the release sheet to obtain a sheet-like fire-resistant material consisting of a single layer of fire-resistant material. Alternatively, a multilayer fire-resistant laminate can be obtained by laminating it onto another layer after peeling it off the release sheet. Alternatively, it may be laminated onto other layers while still laminated on the release sheet or another support.

[0079] The fire-resistant resin composition of the present invention is used in fire-resistant structures of buildings, and is particularly preferred for use in fire-resistant structures of compartment penetrations in partitions such as walls, where long insertions such as cables and pipes are passed through. In other words, it is preferable to use it as a fire-resistant material in compartment penetrations to prevent the spread of fire to other compartments when a fire occurs in one compartment. Furthermore, the fire-resistant resin composition of the present invention can be suitably used as a partition penetration treatment material in a partition penetration treatment structure.

[0080] [Compartment penetration treatment structure] The following describes in detail specific examples of how the fire-resistant resin composition of the present invention is applied as a fire-resistant material to a partition penetration treatment structure, with reference to the drawings. As shown in Figure 3, the compartment penetration treatment structure is a compartment penetration treatment structure in which a compartment penetration 15 is formed in the partition portion 11 of a building and through which a long insertion body 21 is inserted is made of a fire-resistant material. In the compartment penetration treatment structure, the fire-resistant material is applied to the compartment penetration portion 15 as a sheet-like member 3 and is used as at least a part of the compartment penetration treatment material for forming the compartment penetration treatment structure 10. In this specification, as shown in Figure 3, the members (sheet-like members 3 and fixing members for fixing them, etc.) that are installed in the partition penetration section 15 and form the partition penetration treatment structure 10 are collectively referred to as partition penetration treatment materials.

[0081] In the partition penetration structure, the partition section 11 is a member that separates partitions (a first partition A and a second partition B) in the wall surface of a building, and has a partition penetration section 15 that penetrates from one outer surface 11A to the other outer surface 11B of the partition section 11. The partition section 11 shown in Figure 3 is a hollow wall and is composed of two wall materials (partition materials) 12A and 12B arranged with a gap (hollow section 13) between them. Therefore, the partition penetration section 15 is composed of a through hole 13A formed in one wall material 12A, a through hole 13B formed in the other wall material 12B, and a hollow section 13 between them. The outer surface of one wall material 12A constitutes the outer surface 11A of the partition section 11, and the outer surface of the other wall material 12B constitutes the outer surface 11B of the partition section 11. The through holes 13A and 13B may have shapes such as circular, elliptical, or similar shapes. Furthermore, the through holes 13A and 13B on the outer surfaces 11A and 11B respectively constitute the openings 13C and 13D of the partition penetration portion 15 provided in the partition portion 11.

[0082] The following describes the configuration of the partition penetration processing structure on one side of the partition 11, opening 13C. However, in this embodiment, the configuration of the partition penetration processing structure on the other side of the opening 13D is the same, so its description will be omitted.

[0083] The compartment penetration treatment structure 10 comprises a sheet-like member 3 and a cover member 5 as compartment penetration treatment materials, wherein the sheet-like member 3 is a fire-resistant material in which the base material and the fire-resistant material layer are integrated, as described above. The sheet-like member 3 is a member comprising the above-described fire-resistant material, and may consist of a single layer of fire-resistant material, but Figure 3 shows a structure in which it is a fire-resistant laminate.

[0084] [Sheet-like material] As shown in Figure 3, the fire-resistant material (sheet-like member 3) has a slit 32 through which the insertion body 21 is inserted, and at least one of the slits 32 extends to the outer edge of the sheet-like member 3. The slit 32 is formed by cutting. The sheet-like member 3 allows the insertion body 21 to be inserted into the interior of the sheet-like member 3 through the slit 32 that extends to the outer edge. The slit 32 may also have a hole through which the insertion body 21 is inserted, and a slit 32 that extends from the hole to the outer edge of the sheet-like member 3.

[0085] As shown in Figure 4, the sheet-like member 3 into which the insertion body 21 is inserted through the slit 32 is positioned on the outer surface 11A from the outside of the partition 11 so as to cover the gap 13E between the opening 13C and the insertion body 21, thereby closing the gap 13E between the opening 13C and the insertion body 21 with the sheet-like member 3. It is preferable that the sheet-like member 3 be positioned in contact with both the outer surface 11A of the partition 11 and the outer circumference of the insertion body 21. By positioning the sheet-like member 3 in contact with the insertion body 21 and the partition 11, the opening 13C of the partition 11 can be closed, thereby improving and maintaining fire resistance.

[0086] The details of the sheet-like member 3 (fire-resistant material or fire-resistant laminate) are as described above. By using the sheet-like member 3, a fire-resistant structure is formed without placing fillers such as fire-resistant putty or rock wool inside the compartment penetration 15, thus eliminating variations caused by different workers. Furthermore, if multiple fire-resistant material layers are laminated on the sheet-like member 3, the fire-resistant material layer on the expanded partition portion 11 side is embedded inside the gap 13E, preventing the sheet-like member 3 from separating from the partition portion 11 when it expands, thus making the above-mentioned displacement less likely to occur. On the other hand, it is desirable that the fire-resistant material layers located away from the partition portion 11 expand evenly, and that the resulting expansion residue can effectively prevent the spread of fire.

[0087] When the sheet-like member 3 has multiple fire-resistant layers, it is preferable that the expansion ratio of the fire-resistant layer furthest from the outer surface 11A of the partition 11 is higher than that of the fire-resistant layer closest to the outer surface 11A of the partition 11. That is, in the sheet-like member 3 in Figures 1(b) and (c), if the right side of the figure is the partition 11 side, it is preferable that the expansion ratio of the fire-resistant layer 31B is higher than that of the fire-resistant layer 31A. Furthermore, it is preferable that at least the fire-resistant layer 31B is made of the fire-resistant resin composition of the present invention. The fire-resistant resin composition of the present invention is suitable as a material for the fire-resistant layer 31B because it can achieve a high expansion ratio. Thus, when the expansion ratio of the fire-resistant material layer on the partition portion 11 side is low, the strength of the expansion residue is maintained at a high level, the sheet-like member 3 is properly supported by the fire-resistant material layer embedded inside the gap 13E, and displacement becomes even less likely. In addition, the fire-resistant material layer at a position away from the partition portion 11 expands sufficiently when heated, making it easier to exhibit higher fire resistance performance.

[0088] Furthermore, if there are three or more fire-resistant layers, it is preferable to increase the expansion ratio of the fire-resistant layers further away from the outer surface 11A of the partition 11 in order to expand the fire-resistant layers further away from the outer surface 11A of the partition 11 more effectively and almost uniformly.

[0089] As shown in Figure 2(a), if the sheet-like member 3 has an adhesive fire-resistant layer 31A on its outermost surface, it can be bonded to the outer surface 11A of the partition 11 by the adhesive fire-resistant layer. Furthermore, as shown in Figure 2(b), if the fire-resistant material layer 31A, which includes an adhesive layer 33, is placed on the outermost surface, it can be bonded to the outer surface 11A of the partition portion 11 by the adhesive layer. Furthermore, the sheet-like member 3 may be fixed to the outer surface 11A of the partition 11 by fixing members that are separate from the sheet-like member 3, such as staples or screws. Of course, the sheet-like member 3 may also be fixed to the partition 11 by a combination of two or more of these methods.

[0090] [Cover component] The cover member 5 is provided to connect to the sheet-like member 3 and covers the sheet-like member 3 provided in the partition portion 11. For example, as shown in Figure 3, four cover members 5 are used so as to connect to the four edges of the sheet-like member 3, forming four extending portions that extend outward from the sheet-like member 3, and as shown in Figure 4, they cover the sheet-like member 3 provided in the partition portion 11. Means for providing the cover member 5 to connect to at least a part of the sheet-like member 3 include, for example, known fixing means such as adhesives, adhesives and adhesive tapes, and fixing members such as staplers and screws. Here, the adhesives, adhesives and adhesive tapes are preferably non-combustible materials, semi-non-combustible materials, or flame-retardant materials, and it is preferable to incorporate flame retardants into the adhesives, adhesives, etc. The cover member 5 is sheet-like and deformable, making it easy to cover the sheet-like member 3.

[0091] As shown in Figure 4, the cover member 5 surrounds the insertion body 21 so that the portion covering the opening 13C of the partition penetration portion 15 is in contact with it, and is fixed to the insertion body 21 by a string-like member 22 wrapped around it from the outside. The string-like member 22 can be any bendable material, and is preferably a wire member including a wire. The wire member may be a metal wire alone, a resin-coated wire made by coating a metal wire with resin such as Nejiriko (registered trademark), or a wire and fiber intertwined, such as a molding. By using a wire member, the cover member 5 can be fixed to the insertion body 21 simply by twisting or turning it.

[0092] The cover member 5 should cover a portion of the sheet-like member 3, making that portion of the sheet-like member 3 invisible from the outside. Specifically, it is preferable to cover the portion of the sheet-like member 3 through which the insertion body 21 is inserted, thereby improving the design of the compartment penetration 15 and enhancing the fire resistance performance of the compartment penetration 15. On the other hand, the cover member 5 is preferably designed to cover a portion of the sheet-like member 3 so that it is visible from the outside. Specifically, as shown in Figure 4, the cover member 5 is preferably designed to make the end face 3C of the sheet-like member 3 visible from the outside. By making the end face 3C of the sheet-like member 3 visible from the outside when the cover member 5 is installed, it is possible to easily perform a visual inspection to confirm that the sheet-like member 3 is installed in the partition penetration 15.

[0093] It is preferable that the cover member 5 is installed in contact with the sheet-like member 3 and the insertion body 21. By installing the cover member 5 in contact with the sheet-like member 3 and the insertion body 21, the sheet-like member 3 and the cover member 5 can close the opening 13C of the partition 11, thereby improving fire resistance.

[0094] The cover member 5 is installed so as to form a gap 40 between it and the sheet-like member 3. The gap 40 between the sheet-like member 3 and the cover member 5 allows the cover member 5 to be fixed with a margin of error against the axial movement of the insertion body 21. Because the cover member 5 is fixed to the insertion body 21 with a margin of error, even if the insertion body 21, which is positioned inside the sheet-like member 3 and the cover member 5, is moved axially after the sheet-like member 3 and the cover member 5 have been installed, the margin of error of the cover member 5 prevents the sheet-like member 3 and the cover member 5 from moving together with the insertion body 21. By preventing the sheet-like member 3 and the cover member 5 from moving together with the insertion body 21, it is possible to suppress the sheet-like member 3 and the cover member 5 from shifting away from the compartment penetration 15. In other words, with this configuration, the sheet-like member 3 and the cover member 5 can be maintained in the appropriate position within the compartment penetration 15, and the fire resistance of the compartment penetration 15 can be maintained. There is a gap 40 between the sheet-like member 3 and the cover member 5, and various configurations are possible in which the cover member 5 is fixed with a margin of error against the axial movement of the insertion body 21. For example, the cover member 5 may be made of a flexible or stretchable material so that at least a part of it can be bent or curved, and the cover member 5 may be fixed to the insertion body 21 such that at least a part of it has some slack.

[0095] The cover member 5 may consist of a single layer of fire-resistant material, a single layer of non-combustible material, or both a fire-resistant layer and a non-combustible material layer. However, it is preferable to have a non-combustible material layer, and more preferably to consist of a non-combustible material layer. In addition, it may have layers other than the fire-resistant layer and the non-combustible material layer. Examples of such layers include a material layer composed of a material other than a non-combustible material, an adhesive layer, and so on. The cover member 5 preferably includes metal foil such as aluminum foil, glass cloth, or a metal foil composite which is a composite of metal foil and glass cloth such as aluminum glass cloth. These constitute a non-combustible material layer. Among these, aluminum glass cloth is more preferred from the viewpoint of fire resistance. The thickness of the non-combustible material layer is not particularly limited, but is, for example, 0.01 to 1 mm, preferably 0.05 to 0.5 mm. Having a thickness of the non-combustible material layer below these upper limits provides flexibility to the cover member 5. Therefore, even if the cover member 5 has a non-combustible material layer, it can be wrapped around the outer circumference of the insertion body 21 while being in close contact with it. Furthermore, having a thickness above the lower limit makes it easier to ensure fire resistance.

[0096] As described above, the cover member 5 is preferably a sheet that can be deformed to cover the sheet-like member 3, but it is preferable that it is thinner than the sheet-like member 3 in order to provide flexibility and make deformation easier. The thickness of the cover member 5 is not particularly limited, but is, for example, 0.01 to 1 mm, preferably 0.05 to 0.5 mm.

[0097] The fire-resistant layer used in the cover member 5 is preferably a thermally expandable material that expands when heated. The thermally expandable material prevents the spread of fire by expanding during a fire. The thermally expandable material is preferably formed from the thermally expandable resin composition described above. The fire-resistant layer may also be adhesive. The thickness of the fire-resistant layer is not particularly limited, but is, for example, 0.01 to 1 mm, preferably 0.05 to 0.5 mm. Having a fire-resistant layer with a thickness below these upper limits provides flexibility to the cover member 5. Therefore, even though the cover member 5 has a fire-resistant layer, it can be wrapped around the outer circumference of the insertion body 21. Furthermore, having a thickness above the lower limit makes it easier to ensure fire resistance.

[0098] The cover member 5 may have an adhesive fire-resistant layer or an adhesive layer. The adhesive fire-resistant layer and the adhesive layer may constitute the outermost surface of the cover member 5. With the above configuration, the cover member 5 can be fixed to the sheet-like member 3 or the insertion body 21 without using a fixing member as a separate component from the cover member 5. Furthermore, by making the fire-resistant material layer itself adhesive, it is not necessary to provide an adhesive layer, thus further simplifying the structure of the cover member 5. Furthermore, if the cover member 5 has an adhesive fire-resistant layer or adhesive layer on its outermost surface, a release sheet may be attached to that outermost surface. The release sheet should ideally be peeled off from the outermost surface when in use.

[0099] The construction method for the partition penetration treatment structure 10 includes the step of installing the sheet-like member 3 described above so as to close at least a portion of the gap 13E between the opening 13C of the partition penetration portion 15 provided in the partition portion 11 and the insertion body 21. Then, the sheet-like member 3 is covered with a cover member 5 installed on the sheet-like member 3, and a portion of the cover member 5 is fixed to the insertion body 21 to complete the construction. Therefore, the construction is easy.

[0100] The sheet-like member 3 and the cover member 5 used in construction may be separate components. If they are separate, the sheet-like member 3 can be installed in the partition section 11, the cover member 5 can be attached to the sheet-like member 3, and the installed cover member 5 can then cover the sheet-like member 3. Alternatively, the sheet-like member 3 and the cover member 5 used in construction may be a single unit with the sheet-like member 3 and cover member 5 already attached to each other.

[0101] According to the configuration of this embodiment described above, the gap 13E inside the opening 13C of the compartment penetration 15 is sealed by the sheet-like member 3 and the cover member 5, and at least the sheet-like member 3 has fire-resistant material. Therefore, the compartment penetration treatment structure 10 can be given appropriate fire-resistant performance. Furthermore, in this embodiment, since the fire-resistant structure is formed by the sheet-like member 3 and the cover member 5 without placing filler materials such as fire-resistant putty or rock wool inside the compartment penetration 15, variations due to the worker are eliminated.

[0102] Furthermore, in this embodiment, at least a portion of the sheet-like member 3 and the cover member 5 is exposed and visible from the outside. Also, if fixing members are provided to secure the sheet-like member 3 and the cover member 5, it is preferable to position the fixing members in a location that is also visible from the outside. In addition, no members other than the insertion body 21 are provided inside the partition penetration 15. Therefore, it is easy to check whether the partition penetration treatment material has been installed according to the specifications by visual inspection or photography. This also reduces the likelihood of installation errors.

[0103] The adhesive layer is formed by an adhesive, and examples of adhesives that can be used include acrylic adhesives, urethane adhesives, rubber adhesives, and silicone resin adhesives. The adhesive layer may be non-flammable, semi-non-flammable, or flame-retardant, and flame retardants may be added to the adhesive used. The thickness of the adhesive layer is, for example, 5 to 400 μm, preferably 10 to 150 μm. By having an adhesive layer on one surface 5A of the cover member 5, the cover member 5 can be fixed to the insertion body 21 without using a separate fixing member. Furthermore, if the cover member 5 has an adhesive layer on one surface 5A, a release sheet may be attached to that surface 5A. The release sheet should be peeled off from the surface 5A when in use.

[0104] The cover member 5 is made of an elastic foam that has the flexibility to conform to the outer circumference of the insertion body 21. Specifically, examples of elastic foams include olefin-based resin foams and urethane-based resin foams. The thickness of the elastic foam is not particularly limited, but is, for example, 0.1 to 10 mm, preferably 0.15 to 5 mm. Having a thickness of less than or equal to these upper limits provides flexibility to the cover member 5. Therefore, the cover member 5 can be wrapped around the outer circumference of the insertion body 21 while maintaining close contact. Furthermore, having a thickness greater than or equal to the lower limit facilitates the placement of the cover member 5.

[0105] According to the configuration of this embodiment described above, the gap 13E inside the opening 13C of the compartment penetration 15 is sealed by the sheet-like member 3 and the cover member 5, and at least the sheet-like member 3 has a fire-resistant material. Therefore, the compartment penetration treatment structure 10 can be given appropriate fire resistance. Furthermore, as explained above, the partition penetration treatment structure 10 is constructed by preparing a sheet-like member 3 and a cover member 5, first installing the sheet-like member 3 to close the gap 13E between the opening 13C of the partition penetration 15 and the insertion body 21, and then wrapping the cover member 5 around the insertion body 21 at least once, and fixing the cover member 5 so as to cover at least a part of the sheet-like member 3. Therefore, its construction is easy. Furthermore, in this embodiment, since the fire-resistant structure is formed by the sheet-like member 3 and the cover member 5 without placing filler materials such as fire-resistant putty or rock wool inside the compartment penetration 15, variations due to the worker are eliminated.

[0106] Furthermore, although the partition 11 was described as a hollow wall with a hollow section 13 inside, it is not limited to a hollow wall and may be a wall without a hollow section, for example, made of a single wall material. Also, the partition 11 is not limited to the walls of a building, but may be the ceiling or floor of a building. Even in the case of a ceiling or floor, the partition may have a structure with a hollow section between two partition materials, or it may have a structure without a hollow section and may be made of a single partition material, for example.

[0107] The cover member 5 is not limited to the above-described embodiment. For example, in the partition penetration processing structure 10 shown in Figure 3, the cover member 5 is shown as four extending portions that extend outward from the sheet-like member 3, but it may also be a single sheet-like member that is slightly larger than the sheet-like member 3. Furthermore, while the partition penetration treatment structure 10 shown in Figure 4 is shown in which the cover member 5 is adhered only to a portion of the surface 3A of the sheet-like member 3, when using a single sheet-like cover member 5 that is slightly larger than the sheet-like member 3, the cover member 5 can be adhered to the entire surface 3A of the sheet-like member 3. In other words, the cover member 5 may have a structure in which the sheet-like member 3 is laminated on one surface. In such a structure, it is preferable that the cover member 5 has a non-combustible material layer. By combining a non-combustible material layer and a fire-resistant material layer in the sheet-like member 3 and the cover member 5, fire resistance can be improved. In addition, an adhesive layer may be provided on the surface of the cover member 5 to which the sheet-like member 3 is adhered, and this adhesive layer makes it easy to adhere to the sheet-like member 3. Furthermore, the sheet-like member 3 may have a structure in which one layer of the base material extends outward from the other layers. With such a structure, the extended portion of the base material can be used as the cover member 5. Furthermore, although the partition penetration processing structure 10 shown in Figures 3 and 4 is shown to include a sheet-like member 3 and a cover member 5, the cover member 5 may be omitted. Furthermore, in the partition penetration processing structure, the sheet-like member is arranged to cover the opening of the partition portion, but the structure is not limited to this configuration. For example, it may be bent into a sleeve shape and inserted into the partition penetration portion 15 for use. [Examples]

[0108] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to these examples. The components used in the examples and comparative examples are shown below.

[0109] (resin) • PVB (manufactured by Sekisui Chemical Co., Ltd., product name "BH-3", hydroxyl group content 35 mol%, acetalization degree 64 mol%, acetyl group content 1 mol%) • Polybutene (manufactured by ENEOS Corporation, product name "Nisseki Polybutene LV-100", number average molecular weight 500) • Chloroprene rubber (manufactured by Tosoh Corporation, product name "SKYPRENE B-12", Mooney viscosity at 100°C: 35) • Natural rubber (manufactured by Sokutek, product name "HA Latex", Mooney viscosity at 100°C: 121) • Butyl rubber (manufactured by JSR Corporation, product name "JSR BUTYL 365", Mooney viscosity at 125°C: 33) • Styrene-butadiene rubber (manufactured by Asahi Kasei Corporation, product name "Toughden 2003", Mooney viscosity at 100°C: 33) • Nitrile-butadiene rubber (manufactured by JSR Corporation, product name "N520", Mooney viscosity at 100°C: 51) • Ethylene propylene rubber (manufactured by Sumitomo Chemical Co., Ltd., product name "Esplen 532", Mooney viscosity at 100°C: 110) • Chlorosulfonated polyethylene (manufactured by Tosoh Corporation, product name "TOSO-CSM(registered trademark) TS-430", Mooney viscosity at 100°C: 58) • Epichlorohydrin rubber (manufactured by Daiso, product name "Epichromer H", Mooney viscosity 50 at 100°C) • Acrylic rubber (manufactured by Zeon Corporation, product name "Nipol AR51", Mooney viscosity 55 at 100°C) • Polyphenylene oxide (manufactured by Asahi Kasei Corporation, product name "Xyron S202") • Petroleum resin (manufactured by Idemitsu Kosan Co., Ltd., product name "iMarb")

[0110] (Thermally expandable layered inorganic material) ·Thermally expandable graphite 1 (manufactured by ADT, product name "ADT-351", thermal expansion start temperature: 180℃) • Thermally expandable graphite 2 (Air Water Co., Ltd., product name "SS-3N", thermal expansion start temperature: 200℃) • Thermally expandable graphite 3 (manufactured by Fuji Graphite Industry Co., Ltd., product name "EXP-50S 150", thermal expansion start temperature: 150℃)

[0111] (Specific additives) <Flame retardant> • Aluminum phosphite (manufactured by Taihei Chemical Industry Co., Ltd., product name "APA100") • Ammonium polyphosphate (manufactured by Taihei Chemical Industry Co., Ltd., product name "APP") <Heat absorbent> • Aluminum hydroxide (manufactured by Nippon Light Metal Co., Ltd., product name "BF013", average particle size 1 μm, thermal decomposition start temperature 200°C, heat absorption 1000 J / g) • Magnesium hydroxide (manufactured by Kyowa Chemical Industry Co., Ltd., product name "Kisma 10", average particle size 0.9 μm, thermal decomposition start temperature 280°C, heat absorption 1350 J / g) <Lubricant> • Butyl acrylate oligomer (manufactured by ADEKA, product name "ADEKA Stab FC-113") • A mixture of monooctadecyl phosphate and dioctadecyl phosphate (manufactured by ADEKA, product name "ADEKA Stab AX-71") <Inorganic filler> • Calcium carbonate (manufactured by Shiraishi Calcium Co., Ltd., product name "BF300") • Carbon black (manufactured by Mitsubishi Chemical Corporation, product name "Dia Black H")

[0112] (Plasticizer) • Diisodecylphthalate (manufactured by Tokyo Chemical Industry Co., Ltd., product name "DIDP") • Adipic acid ether ester (manufactured by ADEKA, product name "RS-107") • Polyether ester (manufactured by ADEKA, product name "RS-700")

[0113] The measurement and evaluation methods for each physical property are as follows. (Thermal expansion start temperature) A 2cm square piece of fire-resistant material was placed on a hot plate set to 300℃, and the temperature at which its initial thickness doubled was defined as the thermal expansion onset temperature.

[0114] (Expansion ratio) Test specimens (100 mm in length, 100 mm in width, and 2.0 mm in thickness) of refractory materials made from the refractory resin compositions obtained in each example and comparative example were prepared. These test specimens were supplied to an electric furnace and heated at 300°C or 600°C for 30 minutes. The thickness of the test specimens was then measured, and the expansion ratio was calculated as (thickness of the test specimen after heating) / (thickness of the test specimen before heating).

[0115] (Residue hardness) The heated test specimen was fed into a compression testing machine (Kato Tech Co., Ltd., "Finger Feeling Tester"), and 0.25 cm 2 The material was compressed at a speed of 0.1 cm / second using an indenter, and the fracture stress was measured.

[0116] (Residue maintenance rate) The weight of the test specimens after heating was measured to determine the expansion ratio at 300°C and 600°C. The test specimens were heated in a horizontal furnace for 1 hour according to the ISO 834 heating curve. The weight of the test specimens after heating was measured. The percentage of the test specimen weight remaining after heating compared to before heating was calculated and used as a measure of the residue's durability.

[0117] (Fire resistance test) A 160mm diameter opening was made in the concrete structure, and a PVC100 VU pipe (outer diameter 114mm, thickness 3.1mm, JIS standard K6741) was passed through it, extending 300mm under the floor and 500mm above the floor. The refractory material obtained in each example and comparative example was bent into a sleeve shape and installed in the opening. The position of the piping was adjusted so that there was a clearance of 10mm or more between the sleeve and the piping, and it was heated in a horizontal furnace for 2 hours according to the heating curve of ISO834. The test was evaluated as a pass (PASS) if the temperature of the penetrating pipe 25mm above the floor was less than the initial temperature + 180℃ and there was no flame coming out of the penetrating pipe, and as a fail (FAIL) if the temperature was 180℃ or higher than the initial temperature or if flames came out of the pipe above the floor penetrating.

[0118] [Examples 1-6, Comparative Examples 1-4] A fire-resistant resin composition was obtained by mixing a resin, a thermally expandable layered inorganic material, a flame retardant, a heat absorbent, a lubricant, an inorganic filler, a plasticizer, and a petroleum resin in a roll at 130°C for 5 minutes according to the formulation shown in Table 1 below. The obtained fire-resistant resin composition was press-molded at 130°C for 3 minutes to obtain a thermally expandable sheet with a thickness of 1.5 mm (1.3 mm in Example 23). The evaluation results are shown in Table 1.

[0119] [Table 1]

[0120] As shown in each of the above examples, the fire-resistant material using the fire-resistant resin composition of the present invention had a sufficient expansion ratio, and also exhibited good residue hardness and residue retention. Therefore, in fire resistance tests, no penetration and flame emission occurred. On the other hand, the refractory materials prepared in the comparative example showed low residue hardness and residue retention, and did not expand even at high temperatures. In all cases, the refractory tests showed penetration and flame emission. [Explanation of symbols]

[0121] 3 Sheet-like member 5 Cover component 10 Compartment penetration treatment structure 11 Partition section 12A, 12B Wall materials 13 Hollow part 13A,13B through hole 13C,13D opening 13E Gap 15 Compartment penetration 21 Insertion body 22 String-like member 30A,...30Y,30Z Base material 31A,...31Y,31Z Fireproof material layer 32 slits 33 Adhesive layer 40 void

Claims

1. A fire-resistant resin composition for use in fire-resistant structures of buildings, comprising a resin, a plasticizer, an additive, and a thermally expandable layered inorganic material, wherein the resin comprises a rubber component, the thermally expandable layered inorganic material is thermally expandable graphite, the plasticizer comprises a polyether ester-based plasticizer and / or an adipic acid ether ester-based plasticizer, the additive comprises a flame retardant and an inorganic filler, and the flame retardant comprises a phosphorus atom-containing compound.

2. The fire-resistant resin composition according to claim 1, wherein the rubber component is at least one selected from the group consisting of chloroprene rubber, natural rubber, butyl rubber, styrene-butadiene rubber, nitrile-butadiene rubber, ethylene propylene rubber, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, and acrylic rubber.

3. The fire-resistant resin composition according to claim 1 or 2, wherein the resin further comprises at least one selected from the group consisting of polyphenylene oxide and petroleum resins.

4. The fire-resistant resin composition according to any one of claims 1 to 3, wherein the content of the plasticizer is 0.5 to 100 parts by mass per 100 parts by mass of the resin.

5. The fire-resistant resin composition according to any one of claims 1 to 4, wherein the additive comprises at least one selected from the group consisting of heat absorbers and lubricants.

6. A fire-resistant material comprising the fire-resistant resin composition according to any one of claims 1 to 5.

7. A fire-resistant laminate comprising a fire-resistant material according to claim 6, a base material integrated with the fire-resistant material, and an adhesive layer.

8. A partition penetration treatment material comprising the fire-resistant material described in claim 6, or the fire-resistant laminate described in claim 7.

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