JPH01114430A - fire resistant resin foam - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

Detailed Description of the Invention (Field of Industrial Application) The present invention relates to a fire-resistant resin foam, and more specifically, to a fire-resistant resin foam that has excellent fire resistance, waterproof property, surface smoothness, adhesion, etc. The purpose is to provide improved productivity, workability, and construction efficiency.

(Prior art) Foamed polystyrene,
Resin foams such as foamed polyethylene, foamed polypropylene, and foamed polyurethane are widely used.

Although these resin foams have the above-mentioned excellent properties, they have the disadvantage of being inferior in fire resistance, hardness, strength, water resistance, chemical resistance, and the like.

As a method to solve these drawbacks, a method has been used in which a mortar layer made of Portland cement or the like is formed on the surface of the resin foam. In addition, when forming the mortar layer, in order to improve the strength of the mortar layer to be formed,
A method of incorporating alkali-resistant glass fibers into the mortar layer has also been carried out.

(Problems to be Solved by the Invention) Although the fire resistance of the resin foam can be improved by forming a mortar layer on the surface of the resin foam, this method has the following drawbacks.

(1) Even if reinforcing fibers are used, the strength is still insufficient.

(2) Waterproofness is insufficient, allowing moisture to penetrate into the interior. Especially in winter and in cold regions, the freezing and thawing of water causes cracks and cracks in the hardened layer.

(3) The adhesion between the mortar layer and the resin foam is insufficient, requiring costly and complicated treatments such as using adhesives, forming uneven shapes on the surface of the resin foam, and pasting mesh. is required.

(4) There are major problems in productivity, workability, and construction efficiency.

In other words, in both on-site production and on-site construction,
There is a disadvantage that it takes a long time for the mortar to harden and cure, and other processing or processes cannot be performed during that time.

Particularly during on-site construction in winter or in cold regions, there is the problem of freezing and thawing before the mortar is sufficiently hardened, which is a major cause of numerous cracks and fissures in the mortar layer and the occurrence of defective parts.

Therefore, there is a need for the development of a fire-resistant resin foam that overcomes the drawbacks of the prior art as described above.

(Means for Solving the Problems) The needs of the prior art described above are met by the present invention as described below.

That is, the present invention provides a fire-resistant resin foam in which a hardened layer made of a cement composition is provided on the surface of a synthetic resin foam. This is a fire-resistant resin foam, characterized in that it is cured by adding one or more of 2 g or more selected from salts and ammonium salts.

(Function) When forming a mortar layer on the surface of the resin foam, by adding a specific combination of salts to the hydraulic cement material, the composition can be given significantly superior workability and workability. To provide a fire-resistant resin foam which can provide improved curability and adhesion, and can significantly improve the hardness, strength, waterproofness, etc. of the obtained cured layer, and which solves the drawbacks of the prior art. I can do it.

(Preferred Embodiments) Next, the present invention will be described in more detail by citing preferred embodiments.

1 to 3 are diagrams schematically showing cross sections of the fire-resistant resin foam of the present invention.

The example shown in the first figure is an example in which a hardened layer 2 is provided on one side of a resin foam 1. For example, a hydraulic cement composition as described below is applied by brushing the surface of the resin foam 1 having an arbitrary shape. The cured layer 2 is obtained by applying and curing the coating by troweling, spraying, etc.

The example shown in the second figure is an example in which the hardened layer 2 is formed on both sides of the resin foam 1, and it can be formed by the same method as shown in the first figure. It may be cured and then cut into the required size for manufacturing.

The example shown in FIG. 3 is an example in which the cured layer 2 is formed on the entire surface of the resin foam 1, and can be formed in the same manner as the examples shown in FIG. 1 and FIG. 2.

Examples of the resin foam used in the present invention include:
It may be any conventionally known resin foam such as foamed polystyrene, foamed polyethylene, foamed polypropylene, foamed polyurethane, etc., and is not particularly limited. In addition, the shape thereof is generally a plate-like body with a size of 100 to several tens of cflI, but is not particularly limited to other shapes such as a columnar body or a block body.

Furthermore, the foaming ratio is not particularly limited, and the surface shape may be, for example, one with a skin layer, one with bubbles exposed on the surface even when sliced, and one with unevenness, grooves, etc. formed on the surface. It's okay.

-F The hardened layer formed on the surface of the resin foam mainly characterizes the present invention, and is formed from a hydraulic cement composition composed of a hydraulic cement material and specific additives. The thickness of the cured layer to be formed may be arbitrary, and although not particularly limited, it is generally about 0.5 to 20 cm thick.

The hydraulic cement materials used in the present invention include, for example, Portland cement, granulated blast furnace slag cement,
It is a hydraulic cement material for use in various mortars and concretes, such as alumina cement, etc., and is not particularly limited.

The additive used in the present invention and mainly characterized by the present invention has calcium chloride as a main component, and one or two selected from iron salts, potassium salts, and ammonium salts.
It consists of salt or more as an auxiliary ingredient.

According to detailed research by the present inventors, by adding such a specific combination of salts to the conventionally known hydraulic cement material, the workability and workability of the composition are significantly improved. It has been found that the adhesiveness, waterproofness, strength, etc. of the cured layer formed on the surface of the foam are significantly improved.

As the iron salt as an auxiliary component, for example, conventionally known iron salts such as WL iron and iron chloride can be used, and as the potassium salt, for example, conventionally known potassium salts such as potassium carbonate and potassium chloride can be used. Furthermore, as the ammonium salt, any conventionally known ammonium salt such as ammonium chloride, ammonium sulfate, etc. can be used. These auxiliary components may be used alone or as a mixture of two or more, and the preferred range is a total amount of about 0.3 to 30 parts by weight of the auxiliary components per 100 parts by weight of calcium chloride.

If the auxiliary component consists of two salts, iron salts, e.g.
It is desirable that the proportion of ferric acid, etc., be maximized, and the proportion of ammonium salts, such as ammonium chloride, as auxiliary components be minimized. As mentioned above, the intended purpose is usually achieved by containing these auxiliary components in a total amount of about 0.3 to 30% of 7 fl of calcium chloride weight. After many experiments, we found that a more preferable composition is 100 parts by weight of calcium chloride, an iron salt such as 2 to 15 parts by weight of ferrous sulfate, and a potassium salt such as 1 to 9 parts by weight of potassium carbonate.
As the ammonium salt, for example, ammonium chloride can be used alone or in any combination of two types in the range of 0.3 to 5 parts by weight, and the most preferable composition is based on 100 parts by weight of calcium chloride. , as an iron salt, for example, 3.7 to 4.6 parts by weight of ferrous sulfate,
As a potassium salt, for example, potassium carbonate 1.9 to 2.5
The results showed that the ammonium salt was in the range of, for example, 1.1 to 1.4 parts by weight of ammonium chloride.

The above additives are used in the hydraulic cement material too.
, 1) It is preferably added in a proportion of about 1 to 50 parts by weight per g part.

The hydraulic cement composition used in the present invention has the above-mentioned components as essential components, and any aggregates and additives conventionally used in this type of composition can be similarly used in the present invention. .

Examples of the above-mentioned aggregate include known aggregates such as sand and gravel, and are not particularly limited. These aggregates are preferably used in a proportion of about 30 to 90% by weight based on 100 parts by weight of the composition.

The above-mentioned components and their usage ratios may be the same as any conventionally known similar compositions, and other known additives such as colorants and reinforcing fibers may also be optionally included. .

The properties of the hydraulic cement composition used in the present invention are not particularly limited, and for example, it may be a powder composition in which each component is mixed in powder form. In the case of such a powdered composition, an appropriate amount of water can be added to the composition before use to give the composition desired fluidity.

Further, the hydraulic cement composition used in the present invention may be in a state in which water is added and mixed as described above, or a fluid composition is prepared by adding water to the hydraulic cement material and mixing. The additive may be added as a powder or an aqueous solution and mixed on the spot at the time of use, and is not particularly limited.

In the above embodiment, when additives are added later, each component is preferably added to water and dissolved, and used in the form of an aqueous solution, since the additives can be uniformly distributed throughout the composition.

The fire-resistant resin foam of the present invention is obtained by forming a hardened layer made of the cement composition on the surface of the resin foam, and can be produced, for example, as follows.

(1) A method of applying and curing the hydraulic cement composition on the surface of a factory-produced resin foam by brushing, troweling, spraying, etc.

A method of soaking in a fluid hydraulic cement composition.

A method in which a hydraulic cement composition is poured into a certain mold, and before it hardens, a resin foam is layered on the surface of the composition, and both are hardened integrally.

On the other hand, there is a method in which a resin foam is placed in a mold in advance, and a hydraulic cement composition is poured onto the foam and hardened.

(2) On-site construction Brush painting on the outside or inside of wall materials, etc. at construction sites, etc.
A method of applying and curing a hydraulic cement composition by troweling, spraying, etc.

(effect) According to the present invention as described above, the following effects are achieved.

(1) The hydraulic cement composition used in the present invention has extremely excellent workability and workability.

That is, in order to impart troweling properties and sprayability to conventional homogeneous hydraulic cement compositions, it was necessary to add a considerable amount of water to impart sufficient fluidity. For this reason, after application, liquid drips, making it difficult to achieve uniform application.Furthermore, several days of curing time and longer curing time are required after application.

In order to prevent stiffness, the hydraulic cement composition used in the present invention has extremely excellent thixotropy (thixotropy, the property of maintaining sufficient fluidity while an external force is applied, but solidifying immediately when the external force is removed). ), it can maintain sufficient fluidity as long as it is stirred when applied to the surface of the resin foam, and after applying it to the surface of the resin foam, for example, after applying with a trowel or spraying, the resin Since it solidifies immediately on the foam surface, no sagging occurs. Furthermore, when force is applied to the coated surface using a trowel or the like, the coating recovers its fluidity and becomes easily flattened, and when the force of the trowel is removed, it immediately hardens and retains its shape.

In addition, the coating film cures very quickly, achieving sufficient hardness within a few hours, eliminating the need for long curing times and allowing the next processing step to be started immediately, reducing overall productivity and work. The characteristics, workability, etc. have been significantly improved.

(2) The hardened layer that is formed has significantly improved hardness and strength compared to conventional hardened layers of the same type, has high density, and exhibits extremely high waterproofness. Furthermore, since these hardened layers have sufficient strength and hardness in a short period of time, problems caused by freezing and thawing do not occur even in winter or in cold regions.

(3) It has excellent adhesion to resin foams and can form a cured layer that does not peel off easily. In contrast, conventional similar compositions have insufficient adhesion to resin foams, and are almost impossible to use unless an adhesive is used or a special shape is formed on the surface of the foam. However, since the hydraulic cement composition used in the present invention has sufficient adhesion to these resin foams, no special adhesion treatment is required.

(4) Surface properties were gently improved. That is, while conventional hardened layers made of similar compositions inevitably had surface roughness due to aggregates such as sand, the composition used in the present invention significantly improved the surface smoothness of the hardened layers. It can provide smooth and glossy surface properties similar to those of ceramics or tiles.

(5) Any sharp shape can be given to the surface. That is, the composition used in the present invention has coating No. 1)
After or immediately after molding, the fluidity is easily restored when external force is applied, and it solidifies immediately when the external force is removed.
By embossing the surface of the cured layer when forming it, sharp shapes and patterns can be easily imparted.

(Example) Next, the present invention will be described in more detail with reference to Examples. In the text, parts or percentages are based on dosage unless otherwise specified.

Example 1 Calcium chloride 95 parts Ferrous sulfate 4 parts Ammonium chloride
Dissolve 1.5 parts of the above ingredients in tap water and add 1.
It was made into a 0% solution.

Portland cement 4,000 parts (1) Sand
Water was added little by little to 2,500 parts and mixed.

While mixing this mixture with a mixer, parts of the mixed aqueous solution i and ooo were added and further mixed sufficiently to obtain a viscosity suitable for spraying. This mixture retains sufficient fluidity as long as it continues to be stirred, but when a portion of it was taken out and poured into a mold, when I pressed my finger against it after about 5 minutes, it dented and the shape of my fingertip remained the same. It solidified to the extent that it remained. When I continued to apply force to this thing, it regained its original fluidity. When this fluid is poured into the mold again and left for 30 minutes, it hardens sufficiently without leaving a finger print even when pressed with a finger. Liquidity did not recover.

Next, when the above composition was sprayed to a thickness of about 5 mm on the surface of an extruded polystyrene board of size 10100 x 150 and thickness of 5 cIo in an upright state using a spray gun, no liquid dripping occurred. I didn't. After about 5 minutes, smooth the surface with a trowel and
When left for 0 minutes, the coating became sufficiently hard and
Even if an impact was applied from the back side of the board after leaving it for 4 hours, no peeling of the coating film occurred.

Comparative Example 1 Same as Example 1 except that a mixed salt aqueous solution was used.
When the same procedure was applied, the coating film was soft after 30 minutes of application.
When pressed with a finger, a finger print was formed, and when an impact was applied from the back side of the board after leaving it for 24 hours, most of the layers peeled off and fell.

Comparative Example 2 When a 10% aqueous solution of calcium chloride was used in place of the mixed salt solution in Example 1, and the other conditions were the same as in Example 1, the curing time of the coating film was slightly improved, but the adhesion was poor. That was enough.

Example 2 The same results as in Example 1 were obtained even when a salt mixture having the following composition was used in place of the salt mixture in Example 1.

Composition↓ Calcium chloride 850 parts Ferrous sulfate 40 parts Potassium carbonate
20 parts Calcium chloride 850 parts Potassium carbonate 20 parts Ammonium chloride
10 parts paper) Calcium chloride 500 parts Ammonium chloride 10 parts

[Brief explanation of the drawing]

1 to 3 are diagrams schematically showing cross sections of the fire-resistant resin foam of the present invention. 1: Resin foam 2: Hardened layer

Claims (5)

[Claims] (1) A fire-resistant resin foam comprising a hardened layer made of a cement composition on the surface of a synthetic resin foam, wherein the hardened layer contains calcium chloride, iron salt, potassium salt, and ammonium in a hydraulic cement material. A fire-resistant resin foam, characterized in that it is cured by adding one or more salts selected from the group consisting of salts. (2) The fire-resistant resin foam according to claim (1), wherein the synthetic resin foam is a plate made of expanded polystyrene, expanded polyolefin, or expanded polyurethane. (3) The fire-resistant resin foam according to claim (1), which has a hardened layer on one side of the synthetic resin foam. (4) The fire-resistant resin foam according to claim (1), which has a hardened layer on both sides of the synthetic resin foam. (5) The fire-resistant resin foam according to claim (1), which has a hardened layer on the entire surface of the synthetic resin foam.