Fire-resistant structural materials and buildings

Abstract

To provide a fire resistant structural material that can improve fire resistance, and a building.SOLUTION: A fire resistant structural material 10 comprises: an outer shell material 11 formed into a long cylindrical shape using a metal material; and a core material 12 inserted into the interior of the outer shell material 11. The core material 12 comprises: a non-combustible portion 13 in which at least one type of combustion inhibitor among a phosphorus-based combustion inhibitor, a boron-based combustion inhibitor and a halogen-based combustion inhibitor, and a silicate compound are impregnated and which is formed with a wood material hardened with the silicate compound; and an insulating portion 14 including an inorganic fiber aggregate 21 and a heat resistant composition 22 contained within the inorganic fiber aggregate 21.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a fire-resistant structural material with enhanced fire resistance, and a building provided with columns and beams using the fire-resistant structural material.

Background Art

[0002] Regarding structural materials for constructing buildings such as houses and buildings, the one described in Patent Document 1 has been proposed. Patent Document 1 describes a fire-resistant composite member configured by integrating a steel material having a substantially H-shaped cross-sectional portion with a plurality of through-holes and concrete, and the steel material has a yield strength at 600°C of 155N / mm for 400N standard steel 2 or more, and 215N / mm for 490N standard steel 2 or more of fire-resistant steel is used.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] Buildings are supported by structural materials such as columns and beams, and in the event of a fire, the structural materials lose their strength, causing the building to collapse. In order to prevent such collapse of buildings during fires, as disclosed in Patent Document 1, attempts have been made to improve fire resistance by using fire-resistant steel as the steel material for structural members, or by integrating steel materials and concrete. However, the temperature during a fire reaches 500°C or higher in about 5 minutes after the start of the fire, and 1100 to 1200°C in about 7 to 8 minutes, but the fire resistance performance of fire-resistant steel is about 500 to 600°C, and the fire resistance performance of concrete is about 400°C, which is less than 1000°C. Therefore, sufficient fire resistance performance cannot be obtained with the conventional use of fire-resistant steel or the like, and in particular, fire resistance performance such as 2-hour fire resistance or 3-hour fire resistance cannot be satisfied.

[0005] The present invention solves the above-mentioned problems of the prior art, and aims to provide a fire-resistant structural member and a building that can achieve improved fire resistance performance. [Means for Solving the Problems]

[0006] As means for solving the above problems, the present invention is as described below. [1] The fire-resistant structural member of the present invention is a fire-resistant structural member comprising an outer shell member formed in a long cylindrical shape using a metal material, and a core member inserted into the interior of the outer shell member, The core member is a non-combustible portion formed of a wood material that is impregnated with at least one combustion inhibitor selected from a phosphorus-based combustion inhibitor, a boron-based combustion inhibitor, and a halogen-based combustion inhibitor, and a silicic acid compound, with the silicic acid compound cured; and a heat insulating portion including an inorganic fiber aggregate and a heat-resistant composition contained in the inorganic fiber aggregate. The gist of the fire-resistant structural member is as described above. [2] The core member may further comprise a rigid portion formed of a steel pipe or a shaped steel, the non-combustible portion is disposed inside the rigid portion, and the heat insulating portion may be disposed between the rigid portion and the outer shell member. [3] The non-combustible portion may be formed in a columnar shape from one or a plurality of the wood materials, and filled inside the rigid portion. [4] The heat insulating portion may cover the rigid portion from the outside. [5] In the heat insulating portion, the inorganic fiber aggregate may contain one or more types of glass fibers selected from E-glass, S-glass, T-glass, and silica glass. [6] The gist of the present invention is that the building comprises columns and / or beams formed using the fire-resistant structural material described in [1] or [2]. [Effects of the Invention]

[0007] According to the fire-resistant structural material and building of the present invention, a core material having a non-combustible part and an insulating part can maintain its strength even when exposed to high temperatures during a fire by suppressing heat transfer due to fire in the insulating part and suppressing combustion due to fire in the non-combustible part, thereby improving fire resistance performance. [Brief explanation of the drawing]

[0008] [Figure 1] This is a partial cross-sectional perspective view showing a column as a fire-resistant structural material. [Figure 2] This is a partial cross-sectional perspective view showing a beam as a fire-resistant structural material. [Figure 3] (a) is a perspective view showing flame-retardant treated wood material, and (b) is a cross-sectional view along the line 6B-6B in Figure 1(a). [Figure 4] This is a perspective view showing a partially broken section of a wooden building. [Figure 5] This is a magnified perspective view showing a portion of the floor structure and ceiling panels. [Modes for carrying out the invention]

[0009] The present invention will now be described with reference to the drawings. The matters described herein are illustrative and illustrative to illustrate embodiments of the present invention, and are intended to provide what is considered to be the most effective and straightforward explanation of the principles and conceptual features of the present invention. In this regard, it is not intended to describe structural details of the present invention beyond what is necessary for a fundamental understanding of the invention, but rather to make it clear to those skilled in the art, through the description and drawings, how some forms of the present invention are actually realized.

[0010] [1] Fireproof structural materials The fire-resistant structural material 10 of the present invention comprises an outer shell material 11 formed in a long cylindrical shape using a metal material, and a core material 12 inserted inside the outer shell material 11 (see Figures 1 and 2). The fire-resistant structural material 10 is a structural material used in the construction of a building, and is a structural material that has been given fire-resistant properties. A structural material refers to a material used in the framework of a building with a structure such as wood, steel frame, reinforced concrete, or steel-reinforced concrete, and which bears and supports the loads and other forces applied to the building. Specifically, structural members include vertical members that extend in a roughly vertical direction (perpendicular direction), such as columns, studs, through columns, and braces, and horizontal members that extend in a horizontal direction, such as beams, girders, foundations, joists, purlins, and girder beams.

[0011] The outer shell material 11 is provided for purposes such as protecting the core material 12 and adding aesthetic appeal to the fire-resistant structural material 10. The outer shell material 11 is formed in a long, cylindrical shape using a metal material, and covers and protects the core material 12 inserted inside it from the outside. The outer shell material 11 can be given aesthetic appeal to the fire-resistant structural material 10 by decorating or painting it, such as by spraying a spray material such as mortar or urethane onto its outer surface, painting the outer surface with paint, applying cloth or wallpaper to the outer surface, or installing panel material or board material on the outer surface.

[0012] Furthermore, for the panel material or board material provided on the outer surface of the outer shell material 11, structural plywood as defined by the Japanese Agricultural Standards (JAS), or board material or panel material having strength equivalent to that structural plywood, can be used. In this case, the strength of the fire-resistant structural material 10 can be increased. In addition, so-called "fire-resistant panels" such as gypsum board, calcium silicate board, cement board, and ALC panels (autoclaved lightweight concrete panels) can be used for the panel or board materials provided on the outer surface of the outer shell material 11. In this case, the fire resistance performance of the fire-resistant structural material 10 can be further improved. Among these fire-resistant panels, gypsum board and calcium silicate board are preferred from the viewpoint of being lightweight. Furthermore, for the panel material or board material provided on the outer surface of the outer shell material 11, for example, a laminated board made by laminating multiple wood-based boards, or by laminating multiple fire-resistant panels, or by laminating wood-based boards and fire-resistant panels can be used.

[0013] The material of the outer shell 11 is not particularly limited as long as it is a metallic material, and examples include iron, copper, fire-resistant steel, nickel alloy, chromium alloy, nickel-chromium alloy, stainless steel, etc. Among these, if fire-resistant steel is used for the outer shell 11, the fire resistance performance of the fire-resistant structural material 10 can be further improved. The shape of the outer shell material 11 is not particularly limited as long as it is cylindrical through which the core material 12 can be inserted. Examples of cross-sectional shapes include polygonal rings such as square rings, triangular rings, and hexagonal rings, as well as circular rings and elliptical rings. The shape of the outer shell material 11 shown in Figures 1 and 2 is a cylindrical shape with a square ring cross-section.

[0014] The core material 12 is provided to provide the strength and rigidity required for the fire-resistant structural material 10 as part of the building's framework, and to impart fire resistance to the fire-resistant structural material 10. The core material 12 is inserted into the interior of the outer shell material 11 and constitutes the core of the fire-resistant structural material 10. When the fire-resistant structural material 10 supports loads and other forces applied to the building, it is the main part that bears the force. Preferably, the outer diameter of the core material 12 is approximately the same as the inner diameter of the outer shell material 11, as shown in Figures 1 and 2. In this case, the core material 12 can be filled without any gaps inside the outer shell material 11, and the core material 12 and the outer shell material 11 will be substantially integrated to bear the loads and other forces applied to the building, thereby improving the strength and rigidity of the fire-resistant structural material 10.

[0015] The core material 12 is equipped with a non-combustible portion 13 and an insulating portion 14. By providing these non-combustible portion 13 and insulating portion 14 in the core material 12, the fire-resistant structural material 10 can exhibit excellent fire resistance. In other words, the non-combustible part 13 does not burn even in the event of a fire, suppressing the combustion of the core material 12 and maintaining the shape, strength, etc. of the core material 12, thereby preventing the fire-resistant structural material 10 from burning, breaking, being destroyed, collapsing, etc. The heat-insulating section 14 prevents heat transfer from the outside to the inside of the core material 12 without cracking or otherwise breaking during a fire, thereby suppressing the core material 12 from reaching high temperatures (combustion temperatures). This prevents the fire-resistant structural material 10 from burning, breaking, being destroyed, or collapsing during a fire.

[0016] The core material 12 may further comprise a rigid portion 15 formed from a steel pipe and / or structural steel. The rigid section 15 is provided to improve the strength and rigidity of the core material 12. The material used for the rigid part 15 is usually steel such as stainless steel, but iron, copper, fire-resistant steel, nickel alloy, chromium alloy, nickel-chromium alloy, etc. can also be used. In particular, when fire-resistant steel, nickel alloy, chromium alloy, nickel-chromium alloy, etc. are used for the material of the rigid part 15, the fire resistance performance of the fire-resistant structural material 10 can be further improved.

[0017] The steel pipe forming the rigid section 15 is not particularly limited in shape, and its cross-sectional shape can include polygonal rings such as quadrangular rings, triangular rings, and hexagonal rings, as well as circular rings, elliptical rings, etc. The structural steel forming the rigid section 15 is not particularly limited in shape, and examples of cross-sectional shapes include H-shape, I-shape, Z-shape (crank shape), T-shape, L-shape (mountain shape), C-shape (channel shape), etc. The rigid part 15 can be made from only a rigid part 15 made from a steel pipe (see Figure 1), or only a rigid part made from a structural steel (not shown), or a rigid part 15A made from a steel pipe and a rigid part 15B made from a structural steel can be used in combination (see Figure 2).

[0018] If the core material 12 includes a rigid part 15, it is preferable that the non-combustible part 13 is arranged inside the rigid part 15, and the heat insulating part 14 is arranged between the rigid part 15 and the outer shell material 11. When the non-combustible portion 13 is located inside the rigid portion 15, it is preferable that the non-combustible portion 13 is formed in a columnar shape from one or more wood materials and filled inside the rigid portion 15. In this case, the non-combustible part 13 can constitute the core of the core material 12, which is the core of the fire-resistant structural material 10. By making the core of the core material 12 of the fire-resistant structural material 10, which bears forces such as loads applied to the building, so-called "non-combustible" material, the strength and rigidity of the fire-resistant structural material 10 (core material 12) can be maintained for a long period of time in the event of a fire. Furthermore, the non-combustible portion 13 can be filled without any gaps inside the rigid portion 15, and the non-combustible portion 13 and the rigid portion 15 become almost one, thereby improving the strength and rigidity of the core material 12.

[0019] Furthermore, if the non-combustible part 13 is formed in a columnar shape from a single piece of wood, it will be necessary to cut, shave, or otherwise process the wood to match the size of the rigid part 15 in order to fill it completely without gaps inside the rigid part 15. In contrast, if the non-combustible part 13 is formed in a columnar shape from multiple pieces of wood, it is possible to combine pieces of wood of various sizes to match the size of the rigid part 15, thus eliminating the need to process the wood and improving work efficiency.

[0020] When the heat insulating section 14 is positioned between the rigid section 15 and the outer shell material 11, it is preferable that the heat insulating section 14 covers the rigid section 15 from the outside. In this case, since the rigid part 15 is covered by the heat insulating part 14, the transfer of high heat during a fire to the rigid part 15 is suppressed, thereby preventing the rigid part 15 from softening, and the strength and rigidity of the fire-resistant structural material 10 (core material 12) can be maintained for a long period of time during a fire. Furthermore, by adjusting the thickness of the heat insulating portion 14 covering the rigid portion 15, the core material 12 can be filled without any gaps inside the outer shell material 11, and the core material 12 and the outer shell material 11 become almost one, thereby improving the strength and rigidity of the fire-resistant structural material 10. The heat insulating portion 14 can be formed in a sheet shape and wrapped around the outer surface of the rigid portion 15, or formed in a plate shape, box shape, cylindrical shape, etc. and attached to the rigid portion 15, thereby covering the rigid portion 15 from the outside.

[0021] (1) Non-combustible parts The non-combustible part 13 described above is formed from wood material that has been impregnated with at least one combustion inhibitor from among phosphorus-based combustion inhibitors, boron-based combustion inhibitors, and halogen-based combustion inhibitors, and a silicate compound, and the silicate compound has been hardened (gelled). In other words, the wood material used in the non-combustible part 13 is treated with a flame retardant using a combustion inhibitor and a silicate compound. This flame retardant treated wood material does not burn and burn away even when exposed to high temperatures during a fire, and instead carbonizes, thus maintaining its shape, strength, etc. In other words, the non-combustible part 13, formed from wood treated with flame retardant, can maintain its shape, strength, etc., by carbonizing even when exposed to high temperatures during a fire. In this way, even when exposed to high temperatures during a fire, the non-combustible part 13 carbonizes and maintains its shape, strength, etc., allowing the fire-resistant structural material 10 (core material 12) to maintain its strength and rigidity for a long period of time. In particular, it can meet the requirement of 2-hour fire resistance under the Building Standards Act, and more preferably, it can meet the requirement of 3-hour fire resistance.

[0022] (1-1) Flame retardant treatment Flame retardant treatment is a process to make wood-derived materials, such as wood and wood-based boards, flame-retardant. Therefore, "wood" and "wood-based boards" are not particularly limited to wood-derived materials, and can include all natural wood, processed wood, or laminated wood, plywood, medium-density fiberboard (MDF), hard fiberboard, soft fiberboard (insulation board), particleboard, etc. The form of the wood or wood-based board is not particularly limited; for example, it could be a square timber, a rod, a column, a board, etc. The type of wood (tree species) that is the origin of the material is not particularly limited, but when natural wood or processed wood is used, from the viewpoint that a higher density (ρ) leads to better retention of shape, strength, etc. due to carbonization during a fire, the density (ρ) is 260 kg / m 3 or more is preferred. Specifically, examples of tree species include Sugi (ρ; 270 to 330 kg / m 3 or so), Abies firma (ρ; 630 to 640 kg / m 3 or so), Japanese beech (ρ; 650 to 670 kg / m 3 or so), or cypress species such as Hiba (Asunaro), Japanese cypress, and Sawara cypress (ρ; 370 to 460 kg / m 3 or so), oak species such as Mizunara, Kunugi, Konara, Kashiwa, Naragashiwa, and Abemaki (ρ; 800 kg / m 3 or more), and oak species such as Akagashi and Ubamegashi (ρ; 1000 kg / m 3 or more), and the like can be mentioned.

[0023] Wood, wood boards, and the like to be subjected to flame retardant treatment can be used as they are, or those sufficiently dried before treatment can be used. In particular, dried ones can have improved strength by eliminating shrinkage, warpage, and the like. The degree of drying is not particularly limited. Normally, the moisture content of wood or wood boards is about 15% by mass as the equilibrium moisture content when stored outdoors, 8 to 15% by mass when stored indoors, and about 12% by mass on average, but the wood or wood board before treatment can be dried, for example, so as to have a moisture content of 0 to 5% by mass. The drying method is not particularly limited, and examples thereof include high-frequency heating, superheated steam heating, hot plate heating, and the like.

[0024] The flame retardant treatment includes the steps shown below. First impregnation step: a step of impregnating wood, wood boards, or the like with a silicic acid compound and a gelling agent. Curing step: a step of curing (gelling) the silicic acid compound with a gelling agent. Second impregnation step: a step of impregnating wood, wood boards, or the like with at least one combustion inhibitor selected from a phosphorus-based combustion inhibitor, a boron-based combustion inhibitor, and a halogen-based combustion inhibitor. The first and second impregnation processes can be carried out separately as two processes, but they can also be carried out together as a single process.

[0025] The order of each step in the flame-retardant treatment is not particularly limited, as long as the curing step is performed after the first impregnation step. Specific examples of the order of each step include the following sequences A to D. Sequence A; First impregnation step, curing step, second impregnation step Sequence B; First impregnation step, second impregnation step, curing step Sequence C; First impregnation step and second impregnation step, curing step Sequence D; Second impregnation step, first impregnation step, curing step

[0026] Among the above-mentioned sequences A to D, sequence A is preferred because it allows for the impregnation of wood or other materials with a silicate compound, followed by hardening (gelling), and then impregnation with a combustion inhibitor. In other words, the hardened (gelled) silicate compound has excellent adsorption properties, and the combustion inhibitor is adsorbed onto the hardened (gelled) silicate compound and firmly fixed inside the wood or other material. Therefore, it is possible to prevent the combustion inhibitor from leaching onto the surface of the wood or other material, and to improve water resistance. Furthermore, in case A, since the silicate compound is impregnated and hardened (gelled) inside the wood, etc., it is possible to reduce the amount of combustion inhibitor used that is impregnated later.

[0027] In the flame retardant treatment, in the case of sequence A described above, a silicate compound and a gelling agent can be impregnated into the wood, etc., and after the silicate compound has hardened (gelled), a combustion inhibitor can be impregnated into the wood, etc. In this case, the wood, etc. can be dried both before impregnation with the silicate compound and gelling agent, and before impregnation with the combustion inhibitor. In particular, when the silicic acid compound is hardened (gelled) and the wood is dried before impregnating it with the combustion inhibitor, the hardened (gelled) silicic acid compound shrinks inside the wood, creating voids. This improves the penetration of the liquid used for impregnation with the combustion inhibitor.

[0028] (1-2) Liquid preparation Flame retardation treatment is a process that makes wood and wood-based boards flame-retardant by impregnating them with a silicate compound and at least one of the following combustion inhibitors: phosphorus-based, boron-based, and halogen-based combustion inhibitors, and then hardening the silicate compound. This flame-retardant treatment involves using liquid agents to impregnate wood or wood-based boards with silica compounds, combustion inhibitors, and other substances. The liquid formulation contains a silicate compound, a combustion inhibitor, and a gelling agent for hardening the silicate compound. The silicate compound used can be a silicate compound that can be gelled (hardened) by a gelling agent. Specifically, examples of silicate compounds include silica contained in colloidal silica and alkali silicates. The combustion inhibitor may be at least one of the following: a phosphorus-based combustion inhibitor, a boron-based combustion inhibitor, and a halogen-based combustion inhibitor.

[0029] (1-3) Silicate compounds Colloidal silica, as a silicic acid compound, is represented by the general formula: Me₂O·nSiO₂ [where Me is Na, R₃N, or R₄N (where R is a hydrogen atom or an organic group such as choline or monomethyltriethanolammonium), and n is between 50 and 300]. Colloidal silica is a colloid in which silica is dispersed in a medium. Unlike alkali silicates, this silica has a high molar ratio of SiO2, ranging from 50 to 300. The particle size of the silica is usually 5 nm or larger, with an upper limit of 50 μm or less, preferably 20 μm or less. In colloidal silica, the silica concentration is not particularly limited, but is preferably 20 to 50% by mass, and more preferably 20 to 40% by mass, in terms of SiO2 concentration. Furthermore, colloidal silica comes in two forms: aqueous dispersions (hereinafter also referred to as "aqueous colloidal silica") and organic media dispersions (hereinafter also referred to as "organocolloidal silica"). Either one may be used alone, or both may be used in combination.

[0030] When using aqueous colloidal silica, a low-viscosity product with a silica particle size of preferably 20 μm or less, more preferably 15 μm or less, can be used. Furthermore, when aqueous colloidal silica is used, the SiO2 concentration is preferably 20-50% by mass, more preferably 20-40% by mass, and even more preferably 20-35% by mass. Aqueous colloidal silica is preferred when the Me in the general formula described above is R4N (ammonium silicate) because, compared to other colloids, it has advantages such as low viscosity even at relatively high SiO2 concentrations and strong bonding force.

[0031] When using organocolloidal silica, a low-viscosity product with a silica particle size of preferably 20 μm or less, more preferably 15 μm or less, can be used. Furthermore, when organocolloidal silica is used, the SiO2 concentration is preferably 20-40% by mass, more preferably 20-30% by mass. Organocolloidal silica is preferable because, when the medium is methanol, isopropanol, or a xylene-butanol mixture, it can be formed into a colloid with low viscosity and high SiO2 concentration.

[0032] Aqueous colloidal silica and organocolloidal silica are preferably low-viscosity materials with a viscosity of 1 to 50 cps / 25°C, more preferably 1 to 30 cps / 25°C. Low viscosity allows for good penetration into wood and other materials. The silica dispersed in colloidal silica is preferably small in size, for example, with a particle size of 20 μm or less. When the particle size is 20 μm or less, it is about the same size as the pores in the cell walls of wood, etc., and the silica compound can be impregnated into the interior of the cell walls of wood, etc.

[0033] If alkali silicates that are prone to discoloration are included, it is preferable to use colloidal silica in combination. This significantly suppresses discoloration caused by alkali metals. When alkali silicates and colloidal silica are used in combination, it is preferable that the alkali silicate (percentage in solid content) is 50% by mass or less, particularly 30% by mass or less, and even more preferably 10% by mass or less, when the total amount of silicate compounds is 100% by mass.

[0034] Alkali silicates, as silicic acid compounds, are salts of silicic acid compounds represented by the general formula; Me2O·nSiO2 (where Me is Na, K, Li, R3N, or R4N (where R is an organic group such as choline or monomethyltriethanolammonium, or a hydrogen atom), and n is a number from 0.5 to 10). Specifically, examples of alkali silicates include sodium silicate, potassium silicate, lithium silicate, tertiary amine silicate, and quaternary ammonium silicate. Of these, it is preferable that at least one of sodium silicate, lithium silicate, and potassium silicate be used, and more preferably at least one of sodium silicate and lithium silicate. Furthermore, the use of sodium silicate and lithium silicate in combination is particularly preferable because it results in low viscosity and excellent penetration into wood. Furthermore, from the viewpoint of suppressing discoloration of modified wood, lithium silicate, tertiary amine silicate, and quaternary ammonium silicate are preferred. These alkali silicates may be used individually or in combination of two or more.

[0035] The alkali silicate content is not particularly limited, but is preferably 10 to 50% by mass, and more preferably 15 to 30% by mass, when the total amount of the liquid is 100% by mass. In this case, the concentration is sufficiently high while maintaining a moderate viscosity, and it has excellent penetration into wood. Furthermore, in this case, the viscosity can be reduced by heating to a degree that does not cause gelation, thereby further improving penetration. In other words, a larger amount of silicate compound can be impregnated into wood, etc., in a single treatment. Furthermore, to impregnate wood and other materials with even more silicate compounds, the process can be repeated by applying and removing pressure.

[0036] When using sodium silicate as the alkali silicate and water as the medium, it is preferable to use lithium silicate in combination. In particular, it is preferable to use sodium silicate of JIS No. 3 or JIS No. 4 as the alkali silicate because it contains more silicon than alkali metal elements and can efficiently impregnate the wood with silicon. However, if one attempts to prepare a solution of the aforementioned alkali silicate concentration using only sodium silicate, the viscosity will be high. In this case, the viscosity can be reduced by using lithium silicate, which has low viscosity when used with water as a medium. In this case, the viscosity of the solution can be, for example, 5 to 250 cps / 25°C, and especially 10 to 150 cps / 25°C.

[0037] (1-4) Gelling agent The gelling agent only needs to be able to gel, or harden, the silicate compound, and can be appropriately selected and used depending on the type of silicate compound. This gelling agent may be solid or liquid. Examples of gelling agents include acidic reagents and metal salt reagents.

[0038] Examples of acidic reactants include sulfuric acid, phosphoric acid, boric acid, oxalic acid, acetic acid, carbonic acid, formic acid and its salts, compounds that exhibit acidity, boric acid and its salts, compounds that exhibit acidity, phosphates or borates that become acidic through thermal decomposition, etc. Specific examples include sodium phosphate, sodium dihydrogen phosphate, ammonium dihydrogen phosphate, calcium hydrogen phosphate, alkyl-stabilized aluminum biphosphate, and others.

[0039] As metal salt reagents, metal salts such as alkali metals and alkaline earth metals can be used. Specific examples include sodium chloride, calcium chloride, magnesium chloride, magnesium sulfate, and aluminum sulfate.

[0040] When the silicate compound is silica (when using colloidal silica), the pH of the liquid is adjusted to a stable range, either acidic or alkaline, that avoids the most unstable pH range of 4.0 to 7.0 and allows for a longer pot life. Then, the liquid is impregnated into the wood, and subsequently, the gelling agent is decomposed, or the gelling agent is impregnated in the next step to cause gelation. Furthermore, when using alkali silicates, such as water glass, the most unstable neutral pH range of 6.5 to 8.5 can be avoided, and the wood can be impregnated as an acidic silica sol dispersion in an acidic range that allows for a longer pot life. Subsequently, the gelling agent contained in the solution can be decomposed, and the pH can be adjusted to the unstable neutral range to induce gelation, or the gelling agent can be impregnated in the next step to induce gelation. Furthermore, when alkali silicates are used, gelling agents other than metal salt reagents, such as acidic reagents, are used as gelling agents.

[0041] (1-5) Combustion inhibitors The combustion inhibitor is used to suppress the burning of wood, and at least one of the following can be used: a phosphorus-based combustion inhibitor, a boron-based combustion inhibitor, and a halogen-based combustion inhibitor. Furthermore, the combustion inhibitor can be, for example, a compound that can be in the form of a solution or dispersion, that is, a compound that can be liquefied. It is preferable to use a combination of phosphorus-based and boron-based combustion inhibitors, as this allows for higher heat resistance and flame retardancy compared to using either one alone. This can be understood from the fact that differential thermal analysis of wood impregnated with the combustion inhibitors shows a higher residual weight at higher temperatures when used in combination compared to when used individually.

[0042] (1-6) Phosphorus-based combustion inhibitors Phosphorus-based combustion inhibitors contain compounds with the element phosphorus, and typically exert their combustion-inhibiting effect through the dehydration and carbonization action of these phosphorus-containing compounds. Dehydration and carbonization is the process by which, upon heating, the cellulose that makes up wood is dehydrated, separating it into water and carbon. Furthermore, phosphorus-based combustion inhibitors may also contain other compounds besides those containing the element phosphorus, in addition to compounds containing the element phosphorus.

[0043] Specific examples of phosphorus-based combustion inhibitors include phosphoric acid and phosphates. Examples of phosphoric acids include metaphosphoric acid and polyphosphoric acid. Examples of phosphates include ammonium phosphate, guanidine phosphate, guanylurea phosphate, melamine phosphate, sodium hydrogen ammonium phosphate, ammonium hydrogen phosphate, sodium phosphate, and sodium hydrogen phosphate. Only one of these phosphoric acids or phosphates may be used, or two or more may be used in combination. Phosphorus-based combustion inhibitors can be synthetic, natural, processed natural, or mixtures thereof.

[0044] Phosphorus-based combustion inhibitors can exert a more effective combustion inhibitory effect when used in combination with other compounds, particularly nitrogen-based combustion inhibitors. Nitrogen-based combustion suppression aids consist of compounds containing the element nitrogen. Examples of nitrogen-based combustion suppression aids include various compounds containing the element nitrogen, such as ammonium nitrate, urea, guanidine, dicyandiamide, and ammonium chloride. These may be used individually or in combination of two or more. Nitrogen-based combustion suppression aids can be synthetic, natural, processed natural, or mixtures thereof.

[0045] (1-7) Boron-based combustion inhibitors Boron-based combustion inhibitors contain compounds that include the element boron. Typically, the compounds containing the element boron are dehydrated and decomposed by heating, then melt and become glassy, ​​which covers the surface of the wood and thereby suppresses combustion. Specific examples of boron-based combustion inhibitors include boric acid and borates. Examples of borates include sodium borate (sodium borate, borax). These boric acid and borates can be used individually or in combination of two or more. Boron-based combustion inhibitors can be synthetic, natural, processed natural, or mixtures thereof. Furthermore, boron-based combustion inhibitors may contain not only boron-containing compounds but also other compounds other than boron-containing compounds.

[0046] (1-8) Halogenated combustion inhibitors Halogen-based combustion inhibitors contain compounds with halogen elements, and typically, during the thermal decomposition of wood, the compounds with halogen elements combine with the decomposed components to form non-combustible or flame-retardant components, thereby suppressing combustion. The halogen elements are not particularly limited, but among them, bromine and chlorine are preferred. Specific examples of halogenated combustion inhibitors include various halides, such as ammonium chloride, ammonium bromide, calcium chloride, zinc chloride, antimony chloride, and paraffin chloride. Halogen-based combustion inhibitors can be synthetic, natural, processed natural, or mixtures thereof. Furthermore, halogen-based combustion inhibitors may also contain other compounds besides those containing halogen elements, in addition to compounds containing halogen elements.

[0047] (1-9) Media etc. The liquid formulation is one of the following: a liquid in which silicate compounds, combustion inhibitors, gelling agents, etc., are dissolved in a medium, a liquid in which these are dispersed in a medium, or a mixture thereof. This liquid formulation can be in a single formulation in which the silicate compound, combustion inhibitor, and gelling agent are all dissolved or dispersed in the same medium; or it can be in a two-form formulation in which one and two selected from the silicate compound, combustion inhibitor, and gelling agent are dissolved or dispersed in different media; or it can be in a three-form formulation in which the silicate compound, combustion inhibitor, and gelling agent are dissolved or dispersed in different media. The method for preparing the liquid formulation is not particularly limited, as long as the silicate compound, combustion inhibitor, and gelling agent can be dissolved or dispersed in the medium, respectively. Specifically, the liquid formulation can be prepared by mixing three components: a dispersion of a silicic acid compound such as colloidal silica or a solution of a silicic acid compound such as an alkali silicate, a dispersion or solution of a combustion inhibitor, and a gelling agent. The liquid agent can be in one, two, or three formulations, and can be appropriately selected depending on, for example, which of the above sequences A to D is used to carry out each step of the flame retardant treatment. For example, if the steps of the flame retardant treatment are carried out in sequence A, the liquid agent can be in two formulations, comprising agent A containing a silicate compound and a gelling agent, and agent B containing a combustion inhibitor. If the steps of the flame retardant treatment are carried out in sequence C, the liquid agent can be in one formulation, comprising a silicate compound, a combustion inhibitor, and a gelling agent.

[0048] The medium used in the liquid formulation is not particularly limited; it may be water, an organic medium, or a mixture of water and an organic medium. The medium is preferably an aqueous medium, and preferably water or a mixed medium of water and a highly hydrophilic organic medium. In the case of a mixed medium, the organic medium used is preferably an alcohol with 1 or 2 carbon atoms, particularly methanol with 1 carbon atom, in which case the permeability can be further improved. The content of the alcohol with 1 or 2 carbon atoms in the mixed medium is not particularly limited, but is preferably 50% by mass or less, and more preferably 10 to 40% by mass, when the total amount of the medium is 100% by mass.

[0049] The pot life of the liquid agent is not particularly limited, as long as it is longer than the time required to impregnate the wood with the silicate compound and combustion inhibitor. This pot life is usually 2 to 50 days, preferably 10 days or more, and more preferably 50 days or more. A pot life of 10 days or more offers the advantages of excellent operability, sufficient time for the liquid agent to be thoroughly impregnated into the wood, and the ability to be used repeatedly. Furthermore, this pot life can be controlled by adjusting the pH. The gel can be applied to wood or other materials, impregnated, and then dried to remove moisture and concentrate, causing it to gel (harden); the gelling agent can be heated and decomposed to adjust the pH to a neutral range to cause gel (harden); or the gelling agent can be impregnated in the next step to cause gel (harden).

[0050] The specific usable time is as follows: [1] When colloidal silica containing 30% by mass of silica and alkyl-stabilized aluminum biphosphate are used, and a liquid preparation containing 70 parts by mass of colloidal silica, 30 parts by mass of alkyl-stabilized aluminum biphosphate and 10 parts by mass of water is prepared, it is stable for more than 6 months at room temperature (e.g., 20-30°C). When a liquid preparation containing 50 parts by mass of colloidal silica and 50 parts by mass of alkyl-stabilized aluminum biphosphate is prepared, it is stable for 5-6 days.

[0051] [2] When colloidal silica containing 30% by mass of silica and oxalic acid dihydrate are used, and a liquid preparation containing 100 parts by mass of colloidal silica and 4 parts by mass of oxalic acid dihydrate is prepared, gelation begins on the 4th day at room temperature, and when the sol is heated at 2°C / min, gelation begins at 84°C. [3] When colloidal silica containing 30% by mass of silica and 1K potassium silicate are used, and a liquid preparation containing 100 parts by mass of colloidal silica and 10 parts by mass of 1K potassium silicate is prepared, gelation begins on the 17th day at room temperature. When a liquid preparation containing 100 parts by mass of colloidal silica and 25 parts by mass of 1K potassium silicate is prepared, gelation begins on the 3rd day.

[0052] [4] When colloidal silica containing 30% by mass of silica and 2K potassium silicate are used, and a liquid preparation containing 80 parts by volume of colloidal silica and 20 parts by volume of 2K potassium silicate is prepared, it begins to gel on the second day at room temperature. When a liquid preparation containing 50 parts by volume of colloidal silica and 50 parts by volume of 2K potassium silicate is prepared, it begins to gel in 16 hours. The pot life is slightly shorter, but it is still practical. [5] When colloidal silica containing 30% by mass of silica and ammonium formate are used, and a liquid preparation containing 100 parts by mass of colloidal silica and 0.5 parts by mass of ammonium formate is prepared, it begins to gel at room temperature on the third day. [6] When colloidal silica containing 30% by mass of silica and ammonium acetate are used to make a liquid preparation containing 100 parts by mass of colloidal silica and 0.5 parts by mass of ammonium acetate, gelation begins on the 6th day at room temperature, and gelation also begins when the sol is heated at 100°C for 5 minutes.

[0053] Furthermore, when the silicic acid compound is colloidal silica, the pot life is short, unstable, and extremely difficult to use in the pH range of 8.0 to 11.0, and especially 8.5 to 10.0. Therefore, it is preferable to adjust the pH with a basic compound-based gelling agent to control the pot life before use. Furthermore, when the silicate compound is an alkali silicate, it is preferable to convert it into an acidic sol (pH 1.0-2.5) using sulfuric acid, phosphoric acid, etc., which is highly stable, has low viscosity, and a long pot life. This sol is then impregnated into wood or the like, and the pH is adjusted to 6.0-8.0 to induce gelation.

[0054] (1-10) Impregnation method and impregnation conditions The method of impregnating wood with the liquid agent is not particularly limited, but examples include pressurized impregnation, which involves impregnation under pressure using nitrogen gas, and atmospheric pressure impregnation, which involves impregnation without pressure. Among these, pressurized impregnation is preferred, as the pressurization allows for the impregnation of a larger amount of silicate compounds, combustion inhibitors, and gelling agents into the tissues of the wood (such as the vessels and cell walls). During impregnation, the liquid agent can be applied to the surface of wood, wood-based boards, etc., but it is preferable to create pore-like or slit-like recesses on the surface of wood, wood-based boards, etc. For example, when impregnating a wooden material 111, which is made of square timber, with a liquid agent as the wooden material used to form the non-combustible part 13, as shown in Figures 3(a) and (b), a plurality of perforated recesses 111A are provided on the surface of the wooden material 111, and the liquid agent is injected or pressed into these recesses 111A to impregnate it with a silicate compound, a combustion inhibitor, and a gelling agent.

[0055] The method for forming the recess 111A is not particularly limited. For example, the hole may be made by laser light, by a woodworking machine such as a drill, or by other methods, and two or more of these methods may be used in combination. The type of laser light is not particularly limited, but a carbon dioxide laser is preferred. The wavelength and output of the laser light are also not limited and are preferably set according to the type of wood, the shape and depth of the recess, etc. When using laser light, it is possible to form recesses with high dimensional accuracy more easily than with other methods, such as when using a woodworking machine.

[0056] The recess 111A is a hole formed in the wood material 111, and this hole may penetrate the wood material or may be a closed-bottom hole that does not penetrate. In other words, the depth of the recess (hole) is not particularly limited, and it is preferable to set it considering that the liquid agent will be impregnated in a range of 30 to 50 mm around the recess. The shape of the recess 111A is not particularly limited. For example, as shown in Figures 3(a) and 3(b), a cylindrical hole with a roughly circular opening and a straight cross-section, and a conical hole with a roughly circular opening and a cross-section that narrows inward can be used. Other examples include polygons such as quadrilaterals for the opening shape, and folded lines, curves, etc. for the cross-section.

[0057] The direction of extension of the recess 111A is not particularly limited, and examples include a direction intersecting the wood grain and a direction substantially parallel to the wood grain. The size of the recess 111A is not particularly limited; for example, the opening diameter of the recess 111A can be 0.5 mm to 1 mm. The recesses 111A can be impregnated by diffusing the liquid agent over a range of 30 to 50 mm around each recess.

[0058] The formation location, number, and density of the recesses 111A are not particularly limited. These formation locations, number, and density can be set according to the properties and application of the wood material. For example, forming recesses in inconspicuous locations such as the back surface, end face, or periphery of the wood material can suppress deformation and strength reduction of the wood material, and prevent deterioration of its appearance. The position, number, and density of the recesses 111A can be appropriately set according to the hardness of the wood material, the density of the wood grain (annual rings), the grain pattern (flat grain, straight grain, etc.).

[0059] When the recess 111A is provided, the liquid agent not only impregnates the surface layer of the wood material, but also penetrates into the interior of the wood material through the recess 111A, allowing for the impregnation of a larger amount of silicate compounds, combustion inhibitors, and gelling agents into the wood material. In other words, the formation of the recess 111A contributes to improving the penetration of the liquid agent into wood materials. Therefore, even if the wood material is long like the wood material 111, or large in size such as a large area, or hard with a tight grain, making it difficult to penetrate and impregnate with the liquid agent deep inside even with pressure or heat, the formation of the recess allows the liquid agent to penetrate and impregnate easily (for example, at low pressure and in a short time).

[0060] The impregnation conditions are not particularly limited, but it is preferable to impregnate the liquid agent while taking into consideration its pot life. During impregnation, there are no particular limitations regarding whether or not the liquid agent and / or wood, wood-based boards, etc., are heated. However, heating can increase the penetration rate, and in particular, a sufficient penetration rate can be achieved even at normal pressure or low pressure. However, when heating liquids, especially those with a short pot life, caution is necessary because the silicate compounds may harden (gel) during impregnation.

[0061] The method of pressurization is not particularly limited. For example, pressurization may be achieved by injecting a gas into the reaction vessel, by heating, or by combining these methods. The pressurization conditions are not particularly limited, but it is preferable to set them appropriately depending on the type of wood, moisture content, vacuum level, grain condition and type, dimensions and shape of the wood, etc. Typically, the pressure should be 10 MPa or less, preferably 8 MPa or less, and even more preferably 6 MPa or less (usually 0.2 MPa or more). This ensures sufficient prevention of warping, deformation, and cracking, regardless of the type and shape of the wood.

[0062] In particular, for wood and wood-based materials where annual rings are not visible, pressure can be increased up to 10 MPa, regardless of whether they are soft or hard. For softwoods and woody materials with visible growth rings, it is preferable to set the pressure to 3 MPa or less (usually 0.5 MPa or more). For hardwoods and woody materials with visible growth rings, it is preferable to set the pressure to 5 MPa or less (usually 1.5 MPa or more). Furthermore, softwoods and wood-based materials are defined as those with a density of 0.56 kg / m³ at a temperature of 25°C and a moisture content of 7% or less, as measured according to JIS Z2101. 3 This refers to wood and wood-based materials that are less than [amount missing]. Examples of softwood include coniferous woods such as cedar, cypress, and lauan.

[0063] The liquid agent can also be impregnated by heating. When heating, the liquid agent may be heated, the entire container of the liquid agent may be heated, or a combination of these heating methods may be used. The liquid agent can be heated, for example, using a separate heating container from the container into which the liquid agent is impregnated. The liquid agent can also be circulated between containers. The temperature of the heated liquid is not particularly limited, but is preferably less than 180°C, particularly 40-150°C, and even more preferably 60-120°C. Within this temperature range, the penetration rate can be sufficiently improved, and damage to the wood and deterioration of the liquid can be prevented. Furthermore, by raising the liquid temperature in this way, the penetration rate can be increased by 2 to 5 times compared to impregnation at room temperature (e.g., 20-30°C), and the time required for the silicate compound impregnation process (first step) can be significantly reduced.

[0064] (1-11) Impregnation amount of silicate compound The amount of silica compound impregnated into wood is not particularly limited, but in order to obtain a sufficient flame retardant effect, the SiO2 content can be preferably 40 to 200 parts by mass, more preferably 50 to 150 parts by mass, and even more preferably 60 to 120 parts by mass, with the mass of the wood before impregnation being 100 parts by mass.

[0065] (1-12) Amount of gelling agent to be mixed The amount of gelling agent mixed in the liquid formulation varies depending on the type of gelling agent and is not particularly limited, but it can be set to an amount that is sufficient to gel the silicate compound. For example, with ammonium formate, ammonium acetate, etc., 0.2 to 1.0 parts by mass (with 100 parts by mass of the silicate compound; the same applies hereinafter), particularly around 0.3 to 0.7 parts by mass, is sufficient. With alkyl-stabilized aluminum biphosphate, oxalic acid, 1K (2K) potassium silicate, etc., 1 to 40 parts by mass, particularly 2 to 30 parts by mass, can be used. Thus, the amount of gelling agent to be mixed needs to be set according to the type, but 0.2 to 40 parts by mass, particularly 0.3 to 30 parts by mass, and more preferably 0.5 to 25 parts by mass, is preferable. Furthermore, since each combination of silicate compound and gelling agent has a preferred mixing range, it is preferable to use a mixing amount that provides a sufficient pot life. Furthermore, the amount of gelling agent refers to the mass ratio of the acidic reagent to 100 parts by mass of the silicate compound in the case of a liquid preparation containing only the acidic reagent (and not the metal salt reagent). Furthermore, for liquid formulations containing only metal salt reagents (without acidic reagents), the expression represents the mass ratio of the metal salt reagent to 100 parts by mass of the silicate compound. Furthermore, in the case of a liquid preparation containing an acidic reagent and a metal salt reagent, the total mass ratio of the acidic reagent and the metal salt reagent is expressed relative to 100 parts by mass of the silicate compound.

[0066] (1-13) Amount of combustion inhibitor impregnation The amount of combustion inhibitor impregnated into wood, etc., is not particularly limited, but from the viewpoint of obtaining a suitable combustion inhibitory effect, it is usually 1 m³ of wood, etc. 3 The lower limit for the amount of impregnation inside is 100 kg / m³ of solids. 3 The above is possible. The amount of combustion inhibitor impregnated is preferably 150 kg / m³. 3 The above is more than 200 kg / m³. 3 More preferably 300 kg / m 3 The above is acceptable. Furthermore, there is no particular upper limit to the amount of combustion inhibitor impregnated, but it is usually 700 kg / m³. 3 The following is possible: Furthermore, the combustion inhibitor used shall be at least one of the following: phosphorus-based combustion inhibitors, boron-based combustion inhibitors, and halogen-based combustion inhibitors. However, the impregnation amount mentioned above shall be the total amount of the material impregnated as a combustion inhibitor; that is, if two or more of the following are used as combustion inhibitors, the total amount of those materials shall be used.

[0067] Specifically, from the viewpoint of obtaining a sufficient combustion suppression effect, the amount of phosphorus-based combustion inhibitor impregnated is preferably 100 kg / m³ in solid content as a lower limit. 3 The above is more comfortable at 120 kg / m³. 3 More preferably 200 kg / m 3 In particular, 300 kg / m³ is preferred. 3 The above may be the case. The upper limit of the impregnation amount of phosphorus-based combustion inhibitor is not particularly limited, and is usually 500 kg / m³ in terms of solid content. 3 The following is possible: From the viewpoint of obtaining a sufficient combustion suppression effect, the amount of boron-based combustion inhibitor impregnated is preferably 100 kg / m³ in solid content as a lower limit. 3 The above is more comfortable at 120 kg / m³. 3 More preferably 200 kg / m 3 The above may be the case. The upper limit of the impregnation amount of boron-based combustion inhibitor is not particularly limited, but is usually 400 kg / m³ in terms of solid content. 3 The following is possible: From the viewpoint of obtaining a sufficient combustion suppression effect, the amount of halogen-based combustion inhibitor impregnated is preferably 50 kg / m³ in solid content as the lower limit. 3 Above, a comfortable 100 kg / m² 3 More preferably 120 kg / m 3 The above may be the case. The upper limit of the impregnation amount of boron-based combustion inhibitor is not particularly limited, but is usually 300 kg / m³ in terms of solid content. 3 The following is possible:

[0068] (2) Insulation section The above-mentioned heat insulating section 14 includes an inorganic fiber aggregate 21 and a heat-resistant composition 22 contained within the inorganic fiber aggregate 21 (see Figures 1 and 2). In other words, the material used for the heat insulating section 14 is a heat-resistant heat insulating material containing an inorganic fiber aggregate 21 and a heat-resistant composition 22. The heat insulating section 14 includes an inorganic fiber aggregate 21 composed of multiple inorganic fibers derived from the heat-resistant heat insulating material, and a heat-resistant composition 22 contained within the inorganic fiber aggregate 21. The heat-insulating section 14, which includes an inorganic fiber aggregate 21 derived from a heat-resistant heat-insulating material and a heat-resistant composition 22, is difficult to melt and burn even at high temperatures during a fire, and therefore exhibits excellent heat resistance.

[0069] In other words, the heat-insulating section 14 is made of a heat-resistant heat-insulating material having excellent heat resistance, and this heat-resistant heat-insulating material is a so-called fiber-reinforced heat-resistant ceramic that includes an inorganic fiber aggregate 21 and a heat-resistant composition 22. In other words, the heat-resistant insulating material is a ceramic material with improved strength through fiber reinforcement, formed by a composite of an inorganic fiber aggregate 21, which is a fiber, and a heat-resistant composition 22, which is a ceramic, and possesses extremely high toughness, rigidity, and heat resistance. The insulation section 14, made of heat-resistant insulation material (fiber-reinforced heat-resistant ceramics), can prevent cracking in high-temperature ranges such as during a fire. Furthermore, the heat-insulating section 14, which is made of heat-resistant insulating material (fiber-reinforced heat-resistant ceramics), is a material that can be nailed or screwed in, just like the steel, wood, and fire-resistant panel materials commonly used in buildings, and is therefore suitable as a building material.

[0070] Specifically, the heat-insulating section 14, which is made of a heat-resistant heat-insulating material (fiber-reinforced heat-resistant ceramics), preferably has heat resistance that prevents melting at temperatures of 1000°C or higher. In other words, the heat-insulating section 14 preferably does not melt even at temperatures of 1000°C or higher, and therefore has fire-resistant properties that prevent combustion at temperatures of 1000°C or higher. Furthermore, it can be said that the fire resistance performance of the heat-insulating section 14, which prevents combustion at temperatures of 1000°C or higher, preferably satisfies the requirement of 2-hour fire resistance under the Building Standards Act, and more preferably satisfies the requirement of 3-hour fire resistance.

[0071] The density (bulk density) of the heat-insulating section 14, which is made of heat-resistant heat-insulating material (fiber-reinforced heat-resistant ceramics), is not particularly limited, but is preferably 62.5 kg / m³. 3 More than 700Kg / m 3 More preferably, 187.5 kg / m² 3 More than 660Kg / m 3 More preferably, 312.5 kg / m³ 3 More than 600Kg / m 3 The following is possible: In this case, a suitable balance can be achieved between the strength of the heat-insulating section 14 and weight reduction and heat insulation performance. The heat insulating portion 14 may have a skin layer on its surface. This skin layer is formed in a film-like manner by the heat-resistant composition 22 and contains substantially no inorganic fiber aggregates 21.

[0072] The heat-insulating section 14, made of a heat-resistant heat-insulating material (fiber-reinforced heat-resistant ceramics), is formed in a porous manner with multiple air bubbles 23 inside. Therefore, the weight of the core material 12 (fire-resistant structural material 10) equipped with the heat-insulating section 14 can be reduced. Furthermore, the insulation section 14 can exhibit good insulation performance by retaining air in the internal air bubbles 23. This insulation performance by the insulation section 14 affects heat transfer to the non-combustible section 13 and rigid section 15 of the core material 12 in the event of a fire. In other words, the heat-insulating section 14, through its heat-insulating performance, suppresses or prevents the transfer of heat during a fire to the non-combustible section 13 and rigid section 15 of the core material 12, thereby delaying the carbonization of the non-combustible section 13 and the softening of the rigid section 15, and improving the fire resistance performance of the fire-resistant structural material 10.

[0073] In the aforementioned heat-insulating section 14, the heat-resistant composition (ceramics) contained in the heat-resistant heat-insulating material is formed by firing and hardening (ceramicizing) the reactive heat-resistant composition (slurry) which is the material. In other words, the heat-resistant insulating material (fiber-reinforced heat-resistant ceramics) is obtained by impregnating an inorganic fiber aggregate with a reactive heat-resistant composition (slurry), which is the material for the heat-resistant composition (ceramics), and then firing it. The insulating part 14 is formed by shaping this heat-resistant insulating material (fiber-reinforced heat-resistant ceramics) into a predetermined shape (for example, a cylindrical shape). The firing process is not particularly limited, as long as a heat-resistant composition (ceramics) can be obtained by firing a reactive heat-resistant composition (slurry). For example, the heat insulating part 14 can be formed by forming an inorganic fiber aggregate 21 impregnated with a reactive heat-resistant composition (slurry) into a sheet, strip, etc., wrapping it around the outer surface of the rigid part 15, and firing it in a heating furnace or the like in that state.

[0074] (2-1) Inorganic fiber aggregate The inorganic fiber aggregate 21 is formed by intertwining multiple inorganic fibers, and by reinforcing the heat-resistant composition 22, which is made of ceramics, with fibers, the heat insulating portion 14 can be given strength and heat insulating properties. Inorganic fibers are not particularly limited, but non-combustible fibers are preferred. Specifically, examples of inorganic fibers include glass fibers, slag fibers, alumina fibers, asbestos fibers, and others such as carbon fibers, steel wool, and stainless steel fibers. Among these, glass fibers, slag fibers, alumina fibers, and asbestos fibers are more preferred as inorganic fibers from the viewpoint of availability, heat insulation, and fire resistance. Only one type of inorganic fiber selected from those listed above may be used, or two or more types may be used in combination. For example, the inorganic fibers may consist only of glass fibers, or they may consist of glass fibers and one or more types selected from slag fibers, alumina fibers, and asbestos fibers. Examples of glass fibers include E-glass, S-glass, T-glass, and silica glass. For inorganic fibers, one or more types of glass fibers selected from these can be used. However, the higher the softening point, the better the heat resistance of the insulation part using it. Therefore, those with a softening point of 800°C or higher are preferred, those with a softening point of 900°C or higher are more preferred, and those with a softening point of 1000°C or higher are even more preferred. Specifically, glass fibers with a softening point of 800°C or higher include E glass (softening point: approximately 840°C), S glass (softening point: approximately 970°C), T glass (softening point: 1000°C or higher), and silica glass (softening point: approximately 1700°C or higher). Glass fibers with a softening point of 900°C or higher include S glass, T glass, and silica glass. Glass fibers with a softening point of 1000°C or higher include T glass and silica glass.

[0075] The fiber diameter and fiber length of the inorganic fiber are not particularly limited. The fiber diameter of inorganic fibers is typically 2 μm to 30 μm, preferably 5 μm to 30 μm, more preferably 5 μm to 20 μm, and even more preferably 5 to 15 μm. The lower limit of the fiber length of inorganic fibers is usually 10 mm or more, preferably 20 mm or more, more preferably 30 mm or more, and even more preferably 50 mm or more. The upper limit of the fiber length of inorganic fibers is usually 100 mm or less, preferably 80 mm or less.

[0076] The shape and form of the inorganic fiber aggregate 21 are not particularly limited. Examples of shapes and forms of the inorganic fiber aggregate 21 include sheets, needle mats, boards, felt, nonwoven fabrics, film-like materials, paper-like materials, and woven fabrics. The inorganic fiber aggregate 21 has different densities and bulkiness depending on its shape and form.

[0077] When the shape and form of the inorganic fiber aggregate 21 is that of a nonwoven fabric, paper-like material, or woven fabric, the inorganic fiber aggregate 21 will be of high density. In this case, the inorganic fiber aggregate 21 tends to have superior fire resistance due to its higher inorganic fiber content. Specifically, the basis weight of the inorganic fiber aggregate 21 in this case is preferably 150 g / m². 2 More than 900g / m 2 More preferably 200g / m 2 More than 600g / m 2 The following is possible:

[0078] When the shape and form of the inorganic fiber aggregate 21 is a sheet, needle mat, board, felt, etc., the inorganic fiber aggregate 21 will be bulky. In this case, the insulating section 14 containing the inorganic fiber aggregate 21 will contain more air bubbles 23 and tend to have superior heat insulation properties. Specifically, in this case, the basis weight of the inorganic fiber aggregate 21 can be about 1 / 4 to 1 / 2 of the basis weight of the high-density material described above.

[0079] The density (bulk density) of the inorganic fiber aggregate 21 is not particularly limited, but the lower limit of the density (bulk density) when the heat insulating portion 14 is formed is preferably 50 kg / m³. 3 Above, a comfortable 150 kg / m² 3 More preferably 250 kg / m 3The above is possible. Furthermore, the upper limit of density (bulk density) is preferably 350 kg / m³. 3 More preferably, 330 kg / m³ 3 More preferably, 300 kg / m 3 The following is possible. In this case, a suitable balance can be achieved between the strength of the heat-insulating section 14 and weight reduction and heat insulation performance. The density (bulk density) of the inorganic fiber aggregate before compression is not particularly limited, but is preferably 20 kg / m³. 3 More than 250Kg / m 3 More preferably 65 kg / m 3 More than 230Kg / m 3 More preferably 80 kg / m 3 More than 200Kg / m 3 The following is possible:

[0080] The inorganic fiber aggregate 21 may be included in the heat insulating section 14 as a single layer, or it may be included in the heat insulating section 14 as a laminated form of two or more layers. The thickness of the inorganic fiber aggregate 21 is not particularly limited. Its thickness can be preferably 0.5 mm to 200 mm, more preferably 2 mm to 150 mm, and even more preferably 5 mm to 100 mm, when the heat insulating portion 14 is formed. The thickness of the inorganic fiber aggregate before the heat insulating portion 14 is formed is not particularly limited, but is preferably 1 mm to 300 mm, more preferably 4 mm to 200 mm, and even more preferably 10 to 150 mm. The thickness of the inorganic fiber aggregate 21 described above refers to the total thickness of the inorganic fiber aggregate 21. That is, if two or more layers of inorganic fiber aggregate 21 are stacked and included in the heat insulating section 14, the thickness of the inorganic fiber aggregate 21 is the total thickness of the two or more layers of inorganic fiber aggregate 21.

[0081] (2-2) Heat-resistant composition The heat-resistant composition 22 is a ceramic obtained by hardening (ceramizing) a reactive heat-resistant composition (slurry) by firing, and also serves to bind the inorganic fibers of the inorganic fiber aggregate 21 in the heat insulating section 14. The heat-resistant composition 22 is not particularly limited as long as it has heat resistance. Specifically, the heat-resistant composition 22 can be selected from, for example, kaolin-based heat-resistant materials, mullite-based heat-resistant materials, alumina-based heat-resistant materials, silicon-based heat-resistant materials, chamotte-based heat-resistant materials, chromium-based heat-resistant materials, carborundum-based heat-resistant materials, and magnesia-based heat-resistant materials, and from the viewpoint of reactivity and heat resistance, kaolin-based heat-resistant materials, mullite-based heat-resistant materials, and alumina-based heat-resistant materials are preferred.

[0082] The ratio of the inorganic fiber aggregate 21 to the heat-resistant composition 22 in the heat-insulating section 14 is not particularly limited, but when the mass of the inorganic fiber aggregate 21 is M1 and the mass of the heat-resistant composition 22 is M2, the ratio of M1 to M2 (M1 / M2) can preferably be 1.0 to 4.0, more preferably 1.2 to 3.5, and even more preferably 1.5 to 3.0. The bulk density (density) of the heat-resistant composition 22 contained in the heat-insulating section 14 is not particularly limited, but from the viewpoint of imparting excellent fire resistance to the heat-insulating section 14, such that it does not melt in the temperature range of 1000°C or higher, the lower limit is preferably 12.5 kg / m³ in the state in which the heat-insulating section 14 is formed (i.e., in the ceramicized state). 3 More preferably, 37.5 kg / m² 3 More preferably 62.5 kg / m 3 The above is possible. Furthermore, the upper limit of bulk density is preferably 350 kg / m³. 3 More preferably, 330 kg / m³ 3 More preferably, 300 kg / m 3 The following is possible: Furthermore, depending on the type used in the reactive heat-resistant composition, the ceramicized heat-resistant composition 22 may contain crystalline water in its crystalline structure, or hydroxyl groups may be generated during the oxidative decomposition by weathering that results in micronization. The action of this crystalline water and hydroxyl groups enables the composition to exhibit excellent heat resistance.

[0083] (2-3) Reactive heat-resistant compositions The reactive heat-resistant composition is a material for obtaining a heat-resistant composition 22, which is a ceramic. This reactive heat-resistant composition contains clayey minerals, heat-resistant ceramics, inorganic oxide sols, etc., and is in slurry form. The reactive heat-resistant composition reacts with the inorganic fibers of the inorganic fiber aggregate 21 during firing to form the heat-resistant composition 22, thereby significantly improving the heat resistance of the inorganic fiber aggregate 21. For example, when the inorganic fibers are glass fibers, the inorganic fiber aggregate 21 made of glass fibers usually has a heat resistance of 400°C to 800°C, but by using the reactive heat-resistant composition, its heat resistance can be improved to 1000°C or higher. The mass ratio of the reactive heat-resistant composition to the inorganic fiber aggregate 21 when impregnation is not particularly limited, but the ratio of M1 to M3 (M1 / M3), where M1 is the mass of the inorganic fiber aggregate 21 and M3 is the mass of the reactive heat-resistant composition, can be preferably 1.0 to 4.0, more preferably 1.2 to 3.5, and even more preferably 1.5 to 3.0.

[0084] The inorganic fiber aggregate 21 used together with the reactive heat-resistant composition (heat-resistant composition 22) can be used in a compressed state in the thickness direction as described above, and in that state, its density (bulk density) can be, for example, 250 kg / m³. 3 ~300 kg / m 3 It can be improved to that extent. When an inorganic fiber aggregate 21 with increased density (bulk density) is used together with a reactive heat-resistant composition (heat-resistant composition 22), the resulting heat-insulating portion 14 is extremely lightweight, possesses toughness and rigidity, and has extremely high heat resistance of 1100°C to 1250°C. These insulating sections 14 offer superior heat resistance, heat insulation, toughness, and workability compared to conventional fire-resistant panels such as gypsum board, cement board, calcium silicate board, and ALC panels (autoclaved lightweight concrete panels). Furthermore, they are lightweight, making them useful as building materials for high-rise buildings and apartment complexes. They are particularly useful as heat-resistant insulation and fire-resistant materials for high-rise buildings and apartment complexes with pure wood construction or hybrid wood-and-steel structures.

[0085] (2-4) Clay-based minerals The clayey minerals described above act on the heat-resistant ceramics contained in the reactive heat-resistant composition, imparting viscosity to the composition and making it easier to form into a slurry. The clayey mineral is not particularly limited, and crystalline clay minerals, amorphous clay minerals, quasicrystalline clay minerals, etc., can be used. Among these, crystalline clay minerals such as sepiolite and halloysite are preferred, and sepiolite is particularly preferred. Sepiolite mainly consists of hydrated magnesium silicate, and its viscosity does not change easily even when the temperature changes, and it can maintain high viscosity even at high temperatures. For this reason, by suitably adhering the reactive heat-resistant composition (slurry) to the surface of the inorganic fibers of the inorganic fiber aggregate 21 and causing a solid-phase reaction, the heat-resistant composition suitably bonds the inorganic fibers together, and a high-strength heat-insulating part 14 can be obtained.

[0086] The composition of the sepiolite is not particularly limited, but it is preferably 50 to 70 parts by weight of SiO2 and 25 parts by weight or less of MgO2. Furthermore, it may also contain 2 to 4 parts by weight of Al2O3, 1 to 2 parts by weight of CaO, etc. The average particle size of the sepiolite is not particularly limited, but 5 μm to 10 μm is preferred. In this case, it not only adheres well to the surface of the inorganic fibers but also penetrates into the interior of the inorganic fiber aggregate 21, making it easier to undergo solid-phase reactions. The specific surface area of ​​sepiolite is not particularly limited, but is 200m². 2 ~400m 2 Preferably, 250m 2 ~350m 2 It is even more preferable that this is the case. In this case, the efficiency of the solid-phase reaction can be maintained at a high level.

[0087] Clay-based minerals are useful in preventing precipitation of heat-resistant ceramics when only heat-resistant ceramics and inorganic oxide sols are mixed. Clay-based minerals, especially clay minerals, increase the viscosity of reactive heat-resistant compositions, thereby enhancing their reactivity with inorganic fibers. Furthermore, when silica sol is used as the inorganic oxide sol, by using sepiolite as the clayey mineral, the combination of sepiolite, which can maintain high viscosity even at high temperatures, and silica sol, which is low molecular weight and highly reactive, with heat-resistant ceramics results in a heat-resistant composition that can withstand high temperatures.

[0088] (2-5) Heat-resistant ceramics The heat-resistant ceramics described above react with the inorganic fibers of the inorganic fiber aggregate 21, improving the heat resistance of the inorganic fibers and thereby contributing to improved fire resistance. In the heat-insulating section 14, which is made of heat-resistant insulating material (fiber-reinforced heat-resistant ceramics), the heat resistance can be adjusted depending on the type of heat-resistant ceramic used. The heat-resistant ceramics are not particularly limited. Specifically, the heat-resistant ceramics are preferably one or more selected from natural minerals such as clay, as well as kaolin-based ceramics (kaolinite, etc.), mullite-based ceramics (mullite, etc.), alumina-based ceramics (alumina, etc.), silicon-based ceramics (silicates such as calcium silicate, magnesium silicate, silica (silicic acid), silica-alumina (aluminum silicate)), chamotte-based ceramics, chromium-based ceramics, carborundum-based ceramics, magnesia-based ceramics, and phosphate-based ceramics.

[0089] Among the heat-resistant ceramics mentioned above, silicon-based ceramics (silicates such as calcium silicate, magnesium silicate, and aluminum silicate), kaolin-based ceramics (such as kaolinite), mullite-based ceramics (such as mullite), and alumina-based ceramics (such as alumina) are preferred. Among these, fibrous ceramics (for example, hydroxyapatite) and silicates (for example, calcium silicate) can be suitably used. Furthermore, hydrated silicates are preferred, such as hydrated calcium silicate, hydrated aluminum silicate, and hydrated magnesium silicate. Heat-resistant ceramics can be appropriately selected from the above-mentioned options to achieve the desired heat resistance temperature (1000°C or higher, especially 1100°C or higher, even further 1200°C or higher, especially 1400°C to 1800°C). The particle size of the heat-resistant ceramics is not particularly limited. From the viewpoint of improving reactivity, the particle size is preferably small, and specifically, it is preferably 15 μm or less.

[0090] (2-6) Inorganic oxide sols The inorganic oxide sol described above, when mixed with the clayey mineral contained in the reactive heat-resistant composition, makes the reactive heat-resistant composition a uniform slurry. When the reactive heat-resistant composition, made into a uniform slurry by this inorganic oxide sol, is impregnated into the inorganic fiber aggregate 21 and fired, a uniform hardening reaction (ceramization) can be achieved. Furthermore, because the inorganic oxide sol has good dispersibility and extremely small particles, it exhibits high reactivity in solid-phase reactions and has excellent entanglement with inorganic fibers, thus enabling the formation of a strong heat-resistant and bonding insulating section 14. The inorganic oxide sol is not particularly limited, but a dispersion containing an inorganic oxide in an aqueous medium can be used. Specifically, examples of inorganic oxide sols include silica sol (colloidal silica), alumina sol, titania sol, zirconia sol, and the like. The inorganic oxide content in the inorganic oxide sol is not particularly limited. The inorganic oxide content is preferably 20 to 40 parts by weight, more preferably 25 to 35 parts by weight, when the inorganic oxide sol is 100 parts by weight. In this case, the inorganic fibers of the inorganic fiber aggregate 21 can be easily and sufficiently bound together.

[0091] Among the inorganic oxide sols mentioned above, silica sol (colloidal silica) and alumina sol are preferred. Silica sol (colloidal silica) and alumina sol offer a wide range of particle sizes, particle size distributions, and shapes, and can be adapted to meet the required physical properties such as heat resistance, bonding properties, and hardness. For example, when silica sol is fired, the silanol groups [Si-OH] on the surface of the silica sol contribute to chemical bonding, creating numerous contact points between the bonded inorganic fibers, thereby greatly improving the strength of the heat insulating section 14. In particular, when the inorganic fibers are glass fibers, silica sol accumulates in the gaps between the glass fibers by capillary action, and the dehydration condensation reaction of the silanol groups can firmly bond the glass fibers together. In particular, fibrous silica sols (such as alumina nanofiber sols) can be combined with fibrous minerals (such as sepiolite) as clayey minerals, and further combined with fibrous ceramics (such as hydroxyapatite) as heat-resistant ceramics, thereby further improving heat resistance.

[0092] [Other ingredients] The reactive heat-resistant composition may contain, as desired, other components such as thickeners, curing accelerators, and penetrating agents, in addition to the three components of clayey minerals, heat-resistant ceramics, and inorganic oxide sols. Thickening agents are used as auxiliary agents to increase the viscosity of reactive heat-resistant compositions, and examples include carboxymethylcellulose (CMC), sodium polyacrylate, and gelling agents. The amount of thickening agent is not particularly limited, but is usually 2 to 5 parts by weight when the total solid content of the reactive heat-resistant composition is 100 parts by weight. A curing accelerator is used to accelerate the curing of the reactive heat-resistant composition, and examples include sodium hexametaphosphate. The content of the curing accelerator is not particularly limited, but is usually 0.2 to 0.5 parts by weight when the total solid content of the reactive heat-resistant composition is 100 parts by weight. Penetrating agents are used to facilitate the penetration of the reactive heat-resistant composition into the inorganic fiber aggregate 21, and examples include sodium dialkyl sulfosuccinate. The amount of penetrating agent is not particularly limited, but is usually 0.2 to 1.0 parts by weight when the total solid content of the reactive heat-resistant composition is 100 parts by weight.

[0093] [2] Building The building of the present invention comprises columns and / or beams formed using the fire-resistant structural material 10 described above. Figure 1 shows a column 10A formed using the fire-resistant structural material 10, and Figure 2 shows a beam 10B formed using the fire-resistant structural material 10. In a typical building, the framework is formed by combining vertical and horizontal members. Columns are vertical members that support the building by bearing the loads, while beams are horizontal members that support the building by bearing the loads. In other words, columns and beams are important structural members that support the building, and their load-bearing capacity, rigidity, and strength are related to the building's resilience, such as earthquake resistance and wind pressure resistance. In the case of wooden buildings, the horizontal structural members that support the building are called ridge beams, those that support the roof are called girders, those that extend in the same direction as the ridge beam are called purlins, and those that extend in a direction intersecting the ridge beam are called beams. However, in this specification, all horizontal members that support a building, such as ridge beams, girders, and beams, are included in the term "beams." In the case of steel-framed buildings, in this specification, all vertical members that form the framework are included in the term "columns," and all horizontal members that form the framework are included in the term "beams."

[0094] As shown in Figure 1, the column 10A comprises an outer shell material 11 and a core material 12 inserted inside the outer shell material 11, and is formed in the shape of a rectangular column. The outer shell material 11 is formed from heat-resistant steel into a long, rectangular tube shape. The core material 12 comprises a non-combustible portion 13, a heat insulating portion 14, and a rigid portion 15. This core material 12 is formed in the shape of a rectangular prism having an outer diameter approximately the same as the inner diameter of the outer shell material 11, and is filled without any gaps inside the outer shell material 11.

[0095] The non-combustible section 13 is formed in a rectangular prism shape by combining multiple (four in Figure 1) pieces of wood. Each of the multiple pieces of wood forming the non-combustible section 13 has been treated to be flame-retardant and has excellent fire resistance. Furthermore, by combining the multiple pieces of wood, the non-combustible section 13 is formed to have an outer diameter that is approximately the same as the inner diameter of the rigid section 15, and is filled without any gaps inside the rigid section 15.

[0096] The heat insulating section 14 covers the outer surface of the rigid section 15 and is filled without any gaps between the outer shell material 11 and the core material 12. The heat insulating section 14 includes an inorganic fiber aggregate 21 and a heat-resistant composition 22 contained within the inorganic fiber aggregate 21, and can exhibit excellent heat resistance performance. It also has air bubbles 23 formed within the inorganic fiber aggregate 21, and can exhibit excellent heat insulating performance.

[0097] The rigid section 15 is formed from a rectangular tubular steel pipe, and heat-resistant steel is used as the material for the steel pipe. The rigid section 15 brings together the non-combustible section 13, which is formed by combining multiple pieces of wood material. Furthermore, because the non-combustible section 13 is filled without any gaps inside the rigid section 15, it becomes almost one with the non-combustible section 13, and can exhibit excellent strength and rigidity.

[0098] As shown in Figure 2, the beam 10B comprises an outer shell material 11 and a core material 12 inserted inside the outer shell material 11, and is formed in the shape of a vertically elongated rectangular prism. The outer shell material 11 is formed from heat-resistant steel into a long, vertically elongated rectangular tube shape. The core material 12 comprises a non-combustible portion 13, an insulating portion 14, a first rigid portion 15A, and a second rigid portion 15B. This core material 12 is formed in the shape of a rectangular prism having an outer diameter approximately the same as the inner diameter of the outer shell material 11, and is filled without any gaps inside the outer shell material 11.

[0099] The non-combustible section 13 is formed by combining multiple (eight in Figure 2) pieces of timber. Each of the pieces of timber forming the non-combustible section 13 has been treated to be flame-retardant and has excellent fire resistance. Furthermore, by combining the multiple pieces of timber, the non-combustible section 13 is formed together with the second rigid section 15B to form a vertically elongated rectangular prism shape and is filled without any gaps inside the first rigid section 15A.

[0100] The heat insulating section 14 covers the outer surface of the first rigid section 15A and is filled without any gaps between the outer shell material 11 and the core material 12. The heat insulating section 14 includes an inorganic fiber aggregate 21 and a heat-resistant composition 22 contained within the inorganic fiber aggregate 21, and can exhibit excellent heat resistance performance. It also has air bubbles 23 formed within the inorganic fiber aggregate 21, and can exhibit excellent heat insulating performance.

[0101] The first rigid section 15A is formed from a rectangular tubular steel pipe, and heat-resistant steel is used as the material for the steel pipe. The first rigid section 15A brings together the non-combustible section 13 and the second rigid section 15B, which are formed by combining multiple wood materials. The second rigid section 15B is formed from an H-shaped steel section, and heat-resistant steel is used as the material for the steel section. The second rigid section 15B has concave recesses on both sides, and multiple pieces of wood that form the non-combustible section 13 are housed in these recesses. In Figure 2, four pieces of wood that form the non-combustible section 13 are housed in each recess of the second rigid section 15B. The second rigid section 15B is substantially integrated with the non-combustible section 13 by having the non-combustible section 13 housed without gaps in the recesses on both sides, and the first rigid section 15A is filled without gaps with the substantially integrated second rigid section 15B and the non-combustible section 13 inside, thereby exhibiting excellent strength and rigidity.

[0102] When the columns 10A and beams 10B described above are exposed to high temperatures during a fire, the outer shell material 11 loses strength and rigidity in a relatively short time (about 10 minutes). However, the core material 12 has an insulating section 14 that can withstand the high temperatures during a fire, and its insulating performance prevents and delays the transfer of high-temperature heat during a fire to the rigid section 15 (first rigid section 10A and second rigid section 10B) and the non-combustible section 13. Furthermore, even if the heat insulation section 14 cannot withstand the high temperatures during a fire, and the high heat from the fire is transferred to the rigid section 15 (first rigid section 10A and second rigid section 10B) and the non-combustible section 13, the rigid section 15 (first rigid section 10A and second rigid section 10B) will first withstand the high temperatures during the fire, thereby maintaining the strength and rigidity of the column 10A and beam 10B.

[0103] Furthermore, since the non-combustible part 13 is made of wood material that has been treated to be flame-retardant, it will not burn up even when exposed to high temperatures during a fire, and will maintain its shape and strength for a long period of time by carbonizing. Even when exposed to high temperatures during a fire, the columns 10A and beams 10B can maintain their strength and rigidity for a long period of time because at least one of the insulating portion 14, rigid portion 15 (first rigid portion 10A and second rigid portion 10B), and non-combustible portion 13 of the core material 12 can withstand the high temperatures during a fire. Therefore, the columns 10A and beams 10B can maintain their strength and rigidity for a long period of time during a fire, and in particular, they can have the performance to meet the requirement of 2-hour fire resistance under the Building Standards Act, and more preferably, the performance to meet the requirement of 3-hour fire resistance.

[0104] (1) Wooden building A concrete example of a building equipped with columns and / or beams formed using the fire-resistant structural material 10 described above is a wooden building. Wooden buildings typically belong to the low-rise or mid-rise building categories, and specifically include 1-3 story houses, residences (including apartment buildings), warehouses, parking lots, and 3-5 story apartment buildings, office buildings, warehouses, etc. As an example of a wooden building, we can cite building 60, as shown in Figure 4. This building 60 has a so-called "wall structure," in which external forces applied to the building (frame) are supported by planar structural members such as load-bearing walls 61 and rigid floors 62. In other words, the building 60 has a foundation 63 and a base plate 64 as a substructure that supports the building on the ground, and on the base plate 64, a box-shaped structural frame is constructed using load-bearing walls 61 and rigid floors 62, thereby configuring the building as a wall-type structure in which these load-bearing walls 61 and rigid floors 62 support the external forces applied to the frame.

[0105] (1-1) Floor If a wall-type building 60 has multiple floors (two in the figure) vertically, it may have through columns 65 that extend vertically across the multiple floors (see Figure 4). The through columns 65 are important structural members (vertical members) that support the weight of the building 60, and may be made of the fire-resistant structural material described above (see Figure 1). In other words, when a fire-resistant structural material 10 (see Figure 1) is used for a continuous column 65, the fire-resistant structural material 10 has high rigidity and possesses the performance (load pressure) required to support the weight of the building 60 as a continuous column 65. Furthermore, even if a fire occurs in the building 60, the continuous column 65 using the fire-resistant structural material 10 (see Figure 1) will exhibit excellent fire resistance and will not be burned or destroyed, thus preventing the collapse of the building 60 due to fire for a long period of time.

[0106] Furthermore, if the through-column 65 using the fire-resistant structural material 10 has a rigid section 15 formed from a steel pipe and / or shaped steel core material 12, the ability to support the weight of the building 60 (load pressure) is dramatically improved. In particular, if the material of the steel pipe and / or shaped steel forming the rigid section 15 is fire-resistant steel, nickel alloy, chromium alloy, nickel-chromium alloy, etc., the fire resistance performance can also be improved. In the event of a fire, the through-columns 65 made of fire-resistant structural material 10 can withstand the fire themselves and prevent the rigid parts 15 from being directly exposed to heat for an extended period of time. As a result, the through-columns 65 made of fire-resistant structural material 10 can maintain the increased load pressure provided by the rigid parts 15 for an extended period of time even under fire conditions, and a building 60 supported by such through-columns 65 can suppress collapse due to fire, even if it has multiple floors. Specifically, a building 60 having through-columns 65 made of fire-resistant structural material 10 can meet the requirement of 2-hour fire resistance under the Building Standards Act, and can also meet the requirement of 3-hour fire resistance.

[0107] (1-2) Load-bearing wall The load-bearing wall 61 is constructed of a frame member 120 formed by combining vertical frames 121 and horizontal frames 122, and panels 150 fixed to the frame member 120. The vertical frame 121 can be treated as a column 10A, and the above-mentioned fire-resistant structural material 10 (see Figure 1) can be used. Similarly, the horizontal frame 122 can be treated as a beam 10B, and the above-mentioned fire-resistant structural material (see Figure 2) can be used. When the load-bearing wall 61 has vertical frames 121 and horizontal frames 122 made of the fire-resistant structural material 10 described above, it will have excellent fire resistance and can be considered a so-called fire-resistant wall. Specifically, a load-bearing wall 61 that is a fire-resistant wall can meet the requirement of 2-hour fire resistance under the Building Standards Act, and can also meet the requirement of 3-hour fire resistance.

[0108] (1-3) Floor structure The wooden building 60 has a floor structure constructed of multiple joists 621 assembled in a frame-like manner and floorboards 622 attached to the top of the joists 621 (see Figure 5). In the floor structure, the joists 621 and floorboards 622 form a rigid floor 62, which constitutes a so-called "wall structure" that supports external forces applied to the building (frame).

[0109] The rigid floor 62 may have a fire-resistant structure, in which case the floor structure may be constructed as a fire-resistant floor structure. In other words, in a rigid floor 62, the joists 621 are the main structural members (horizontal members) that support the weight of the building 60, and can be made of the fire-resistant structural material described above (see Figure 2). The joists 621 made of fire-resistant structural material 10 (see Figure 2) have excellent fire resistance, so even if a fire breaks out in the building 60, they can be spared from burning or destruction. In this case, it is possible to prevent the building 60 from collapsing due to the floor collapsing during a fire. Specifically, the rigid floor 62 with a fire-resistant floor structure can meet the requirement of 2-hour fire resistance under the Building Standards Act, and can also meet the requirement of 3-hour fire resistance.

[0110] (1-4) Frame structure In addition to the aforementioned "wall structure," wooden buildings can also be categorized as having a so-called "frame structure," where external forces acting on the building (framework) are supported by columns and beams. In other words, a framed building has a foundation and base as the substructure that supports the building on the ground, and on the base, a framework (framework) is constructed of columns (including through columns that run vertically across multiple floors) and beams (including ridge beams and girders), and this framework (framework) is configured to support the external forces applied to the building. In a wooden building with a frame structure, for example, the fire-resistant structural material 10 shown in Figure 1 can be used as a column, and the fire-resistant structural material 10 shown in Figure 2 can be used as a beam. Columns and beams made with fire-resistant structural material 10 possess excellent fire resistance, allowing them to withstand fire and avoid burning even in the event of a fire in the building. They can also support the building for extended periods, preventing its collapse. Specifically, a wooden building with a frame structure using fire-resistant structural material 10 for its columns and beams can meet the 2-hour fire resistance requirement and even the 3-hour fire resistance requirement under the Building Standards Act.

[0111] (2) Steel frame buildings A concrete example of a building equipped with columns and / or beams formed using the fire-resistant structural material 10 described above is a steel-framed building. A steel-framed building can be classified as a low-rise, mid-rise, or high-rise building, and specifically includes houses, residences (including apartment buildings), warehouses, parking lots, and houses, apartment buildings, warehouses, parking lots, and other buildings of three stories or more. Regarding steel-framed buildings, the structural forms include rigid frame structures, braced structures, and truss structures. A rigid frame structure is a structure in which columns and beams are completely fixed (rigidly connected) to form a rectangular frame. A braced structure is a structure in which columns and beams form a rectangular frame and this frame is reinforced with diagonal braces. A truss structure is a structure in which multiple structural members form a triangular frame and many of these triangular frames are combined, with structural members extending horizontally in the combined frame being called beams, and structural members extending in a direction intersecting the beams being called columns.

[0112] The fire-resistant structural material 10 described above can be used in either a rigid frame structure or a braced structure, either as a column if it is the fire-resistant structural material 10 in Figure 1, or as a beam if it is the fire-resistant structural material 10 in Figure 2. Furthermore, the fire-resistant structural material 10 can also be used as a brace in a braced structure or as a structural material that forms a triangular frame in a truss structure. In steel-framed buildings, if there are multiple floors vertically, i.e., multi-story buildings with two or more floors, the columns are usually constructed to extend vertically across multiple floors. Furthermore, in steel-framed buildings, intermediate columns can be provided vertically within each floor as needed.

[0113] Steel-framed buildings, by using steel (metal) materials for columns and beams, have high load-bearing capacity, rigidity, and strength, and generally have higher resistance to earthquakes and wind pressure than wooden buildings. However, when exposed to high temperatures (around 500°C), steel (metal) loses half its strength, softens, deforms, or melts. Therefore, steel-framed buildings that use such steel (metal) in their columns and beams are highly likely to collapse in the event of a fire because the columns and beams will no longer be able to support the weight of the building.

[0114] When columns and beams using fire-resistant structural material 10 are equipped with a rigid section 15, the rigid section 15 is formed from steel pipes or the like, and therefore has load-bearing capacity, rigidity, strength, etc., that are comparable to or better than those of columns and beams in a typical steel-framed building that uses steel (metal) materials for the columns and beams. Furthermore, in columns and beams using the fire-resistant structural material 10, the heat-insulating portion 14 covers the rigid portion 15 from the outside, suppressing the transfer of high heat during a fire to the rigid portion 15 and preventing softening of the rigid portion 15. In addition, in columns and beams using the fire-resistant structural material 10, the non-combustible portion 13 placed inside the core material 12 carbonizes and hardens during a fire, reinforcing the rigid portion 15 and preventing its deformation. Therefore, in the event of a fire, a steel-framed building with columns and beams using fire-resistant structural material 10 can withstand a fire for a long period of time because the fire-resistant structural material 10 provides excellent fire resistance, preventing deformation of the columns and beams. Specifically, a steel-framed building using fire-resistant structural material 10 in its columns and beams can meet the requirement of 2-hour fire resistance under the Building Standards Act, and can also meet the requirement of 3-hour fire resistance.

[0115] (3) Walls, floors, and ceilings of buildings In wooden and / or steel-framed buildings, the walls, floors, and ceilings can be made fire-resistant by using panels made of fire-resistant material containing the same materials as the insulation section 14 described above, that is, fire-resistant material containing an inorganic fiber aggregate and a heat-resistant composition. Specifically, examples of applications of the above-mentioned panels include panels 150 (see Figure 4) that constitute load-bearing walls 61 in wooden buildings, and floorboards 622 and ceilingboards 67 (see Figure 5) that construct floor structures (rigid floors 62). In addition to these, examples of applications of the above-mentioned panels include exterior wall materials and siding materials that decorate the exterior of a building, or panels on the surface of walls that separate rooms from each other or separate rooms from corridors inside a building, as well as non-fixed walls such as movable partitions and partitions, sliding doors, and doors.

[0116] The method of attaching the above panels is not particularly limited; they may be fixed to columns or beams using nails or screws, glued to columns or beams using adhesive, or attached to columns or beams using a one-touch joint. Furthermore, the strength of the above-mentioned panels can be improved by laminating structural plywood, gypsum board, calcium silicate board, or other fire-resistant panels. In particular, when wood panels such as structural plywood are laminated, fire resistance can be improved by using wood panels that have undergone the above-mentioned flame-retardant treatment. The panels made of the above-mentioned fire-resistant material have excellent fire resistance, withstanding high temperatures during a fire and preventing cracking. This suppresses the spread of fire to other rooms or other areas when flames leak out through cracks in the wall material during a fire. Furthermore, because the panels made of the above-mentioned fire-resistant material are porous due to the presence of air bubbles derived from an inorganic fiber aggregate, they have suitable thermal insulation and soundproofing properties as building materials. Furthermore, panels made of the above-mentioned fire-resistant material can exhibit fire resistance that prevents combustion at temperatures above 1000°C. Specifically, this fire resistance that prevents combustion at temperatures above 1000°C preferably meets the requirement of 2-hour fire resistance under the Building Standards Act, and more preferably meets the requirement of 3-hour fire resistance. [Industrial applicability]

[0117] The fire-resistant structural material of the present invention is widely used in the field of construction, and is particularly suitable for use in constructing walls, floors, and structures of buildings. [Explanation of symbols]

[0118] 10; Fireproof structural material, 10A; Column, 10B; Beam, 11; outer shell material, 12; core material, 13;Noncombustible part, 111;Wood material 14; Insulation part, 21; Inorganic fiber aggregate, 22; Heat-resistant composition, 15; rigid part, 15A; first rigid part, 15B; second rigid part, 60; a wooden building; 65; a continuous column.

Claims

1. A fire-resistant structural material comprising an outer shell material formed in a long cylindrical shape using a metal material, and a core material inserted inside the outer shell material, wherein the core material is filled without any gaps inside the outer shell material, and the core material and the outer shell material together bear the load, The aforementioned core material is A non-combustible part made of wood material in which at least one combustion inhibitor from among phosphorus-based combustion inhibitors, boron-based combustion inhibitors, and halogen-based combustion inhibitors is impregnated with a silicate compound, and the silicate compound is hardened, A heat insulating part comprising an inorganic fiber aggregate and a heat-resistant composition contained within the inorganic fiber aggregate, A rigid part formed from steel pipes and / or structural steel to improve the strength and rigidity of the core material, Equipped with, The non-combustible portion is filled without any gaps inside the rigid portion. The aforementioned heat insulating portion covers the rigid portion from the outside and is disposed without any gaps between the rigid portion and the outer shell material. The material of the outer shell is fire-resistant steel. The material of the rigid part is characterized by being at least one of fire-resistant steel, nickel alloy, chromium alloy, and nickel-chromium alloy.

2. The fire-resistant structural material according to claim 1, wherein the heat insulating portion covers the entire circumference of the outer surface of the rigid portion.

3. The fire-resistant structural material according to claim 1, wherein the non-combustible portion is formed in a columnar shape from one or more of the wood materials and filled inside the rigid portion.

4. The rigid part comprises a first rigid part in the shape of a square tube and a second rigid part made of H-shaped steel, The fire-resistant structural material according to claim 1, wherein the second rigid part has concave recesses on both sides, and the non-combustible part is housed in the recesses, thereby integrating with the non-combustible part, and the integrated second rigid part and the non-combustible part are filled inside the first rigid part.

5. The fire-resistant structural material according to claim 1, wherein the inorganic fiber aggregate in the heat insulating portion comprises one or more glass fibers selected from E glass, S glass, T glass, and silica glass.

6. A building characterized by comprising columns and / or beams formed using the fire-resistant structural material described in claim 1.

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