JP2016117810A - Incombustible coating composition and incombustible plate and fire resistant structure using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To achieve enhancement of workability and reduction of dry load by generating a uniform incombustible plate on a coating layer 5 on an incombustible plate A having a coating layer on a surface of a substrate for building 1 to provide sufficient performance regarding gas barrier property or incombustibility and reducing the number of coating.SOLUTION: A coating layer 5 consisting of incombustible composition is formed on a surface of a substrate for building 1 via a sealer layer 3. The incombustible composition contains a fine powder of purified bentonite having high purity with the percentage content of montmorillonite of 85 wt.% or more and a soap free emulsion resin. The coating layer 5 is formed with the amount of montmorillonite of 3.3 g/mor more.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a noncombustible coating composition, a noncombustible plate material using the composition as a coating layer, and a fireproof structure.

  Conventionally, halogen flame retardants have been widely used as flame retardants for flame retardant coating compositions, but there are problems with dioxins and chlorofluorocarbons generated from these halogen flame retardants, which may be preferable for environmental protection. Absent.

  In addition, inorganic flame retardants such as aluminum hydroxide are also used. However, aluminum hydroxide has problems such as deterioration of physical properties and water resistance of the coating material and the substrate coated with the coating material.

  In addition, flame retardants containing swellable inorganic compounds as essential components for the application to architectural inorganic boards to form a flame retardant layer have been studied, but with other components such as water-soluble polymers. There exists a problem that a viscosity becomes too high by an effect | action and coating property falls.

  Therefore, the present applicant previously described, as shown in Patent Document 1, a flame retardant containing a scale-like swellable inorganic compound such as bentonite, a water-swellable substance, and a soap-free emulsion adhesive. Proposal coating compositions are proposed.

  According to the flame retardant coating composition of the cited document 1, since the scale-like swellable inorganic compound and the soap-free emulsion adhesive are contained, the physical properties of the object to be coated (for example, a building substrate) In addition, the flame retardancy can be exhibited without causing a decrease in water resistance and the like, and also in consideration of the environment. In addition, since the water-swellable substance is added to the coating composition, the adhesion as the flame-retardant coating composition is improved, and the flame retardancy and heat insulation are stabilized. In addition, even when a flame retardant coating composition is applied to the surface of an object to be coated and a coating layer is formed by drying and curing, small cracks are less likely to occur, which is preferable not only in appearance but also as a coating. The effect of stabilizing gas barrier properties and flame retardancy can be obtained.

JP 2011-68853 A

  By the way, since the flame retardant coating composition of the above-mentioned Patent Document 1 is a crude bentonite obtained by pulverizing bentonite by wet, a large amount of impurities (other than montmorillonite) are contained in the bentonite. Thus, a uniform incombustible film is not formed on the coating layer.

  Therefore, in order to obtain sufficient performance with respect to gas barrier properties and nonflammability, it is necessary to increase the amount of bentonite in the coating layer by increasing the coating amount of the coating composition on the substrate.

  However, as the amount of bentonite applied increases, the number of coatings increases and not only the workability deteriorates, but also the drying time after application increases and the drying load increases. There is room for.

  An object of the present invention is to improve the composition of the coating composition to produce a uniform incombustible film as a coating layer so that even a thin coating layer can provide sufficient performance with respect to gas barrier properties and incombustibility. The purpose is to reduce the number of times of painting to improve workability and reduce the drying load.

  In order to achieve the above object, in the present invention, as bentonite contained in the coating composition, crude bentonite is dispersed in water, and is made up of purified bentonite fine powder obtained by purification and drying by centrifugation. . As an index of high-purity purified bentonite, attention was paid to the purity (montmorillonite content) of bentonite, and the purified bentonite was composed of a fine powder with a purity higher than a predetermined level.

  Specifically, the incombustible coating composition according to the first invention is characterized by containing a high-purity refined bentonite powder having a purity of a predetermined value or more and a soap-free emulsion resin. . Here, the purity of the high-purity purified bentonite equal to or higher than a predetermined value means that the content of montmorillonite, which is the main component, is 80% by weight or more.

  In the first invention, since the soap-free emulsion resin is contained in the incombustible coating composition, the coating strength can be increased. And since the bentonite contained in the incombustible coating composition is a refined high-purity fine powder, a uniform incombustible film is formed on the coating layer of the incombustible coating composition by the refined high-purity bentonite powder. The gas barrier property and nonflammability can be improved. Therefore, the application amount of the non-combustible coating composition is extremely reduced and a minimum application amount is required, the number of coatings is reduced, and the coating layer can be formed in a short drying time.

  According to a second aspect of the present invention, in the first aspect, the high-purity purified bentonite fine powder is formed by drying a high-purity purified bentonite solid content obtained by purifying a crude liquid in which the crude bentonite is dispersed in water by centrifugation. It is characterized by being.

  In the second aspect of the invention, the separated and purified bentonite solid content obtained by purification from an aqueous dispersion of crude bentonite by centrifugation is dried to form a purified bentonite fine powder. In this way, it is possible to easily and surely obtain the fine powder of the high purity purified bentonite.

  A third invention is characterized in that, in the first or second invention, the high-purity purified bentonite fine powder has a montmorillonite content of 85% by weight or more.

In the third aspect of the invention, since the montmorillonite content of bentonite is 85% by weight or more, the bentonite fine powder is surely of high purity, and a uniform non-combustible film is reliably formed on the coating layer by the non-combustible coating composition. Gas barrier properties and non-flammability can be stably and reliably improved.For example, when a coating layer is formed from a non-combustible coating composition, the non-flammability performance can be improved in a heat generation test using a cone calorimeter. Depending on the material conditions, a stable incombustibility of 7.2 MJ / m ² or less can be obtained with a total calorific value of 20 minutes.

  The incombustible plate material according to the fourth invention is characterized in that a coating layer made of the incombustible coating composition according to any one of the first to third inventions is formed on one side or both sides of a building base material. And

  In addition, “non-combustible plate material” is not a non-combustible material that meets the standards of the Building Standards Act, but includes flame retardants, semi-incombustible materials, and non-combustible materials that meet the standards of the Building Standards Act. Is used to mean.

  In this 4th invention, since the coating layer which consists of the said nonflammable coating composition was formed in the incombustible board | plate material on the one or both surfaces of the base material for construction, a nonflammable board material with high incombustibility is obtained. It is done. Moreover, since the number of coatings of the noncombustible coating composition applied to one or both sides of the building base material is small and the drying time is short, the manufacturing process of the noncombustible plate can be simplified and the manufacturing cost can be reduced.

A fifth invention is characterized in that, in the fourth invention, the coating layer of the incombustible plate material is formed so that the amount of montmorillonite is 3.3 g / m ² or more.

In this fifth invention, since the amount of montmorillonite in the coating layer of the non-combustible plate material is 3.3 g / m ² or more, the gas barrier property and non-combustibility can be stably and reliably improved. For example, the non-combustible plate material In the exothermic test using a cone calorimeter, a stable incombustible performance of 7.2 MJ / m ² or less can be achieved with a total calorific value of 20 minutes depending on the conditions of the substrate.

  A sixth invention is the fourth or fifth invention, wherein a sealer layer is provided on one or both sides of the building base material, and an incombustible coating layer made of an incombustible coating composition is formed on the sealer layer. It is characterized by being.

  In this 6th invention, since the nonflammable coating film layer which consists of a nonflammable coating composition is formed in the single side | surface or both surfaces of the building base material through the sealer layer, the single side | surface or both surfaces of the building base material are formed by the sealer layer. Smooth surface. By forming a coating film layer on this smooth surface, the coating film layer can be made into a uniform and beautiful non-combustible coating film layer, and the nonflammability by the coating film layer can be obtained stably. Further, the sealer layer can prevent the incombustible coating composition from penetrating into the building base material as in the case of directly applying the incombustible coating composition to one or both sides of the building base material. Therefore, both the smoothing of the application surface of the incombustible coating composition and the formation of a uniform coating layer by preventing soaking can be achieved by the sealer layer.

  According to a seventh invention, in any one of the fourth to sixth inventions, a resin coat layer is formed on the incombustible coating film layer.

  In the seventh invention, since the resin coat layer is formed on the incombustible coating layer, the water resistance of the incombustible coating layer can be further improved. Moreover, if the resin coat layer is formed with a coating amount that does not impair the incombustibility of the incombustible coating layer, both incombustibility and water resistance can be achieved.

  According to an eighth invention, in any one of the fourth to seventh inventions, the building base material is flame-retardant, semi-incombustible or non-combustible as defined in the Building Standard Law. .

  In the eighth invention, the architectural base material can be made more difficult to burn by the coating layer made of the non-combustible coating composition formed on one side or both sides of the architectural base material. In the case of a base material, its flame retardancy, in the case of a quasi-incombustible construction base material, its quasi-incombustibility, and in the case of a non-flammable construction base material, its non-flammability is further ensured. It does not maintain stable and can be increased.

A ninth aspect of the invention is any one of the fourth to eighth aspects of the invention, in which the non-combustible coating layer is destroyed when the building base material is heated under the condition of 50 kW / m ² in terms of radiant heat. It is characterized by not being deformed until.

In this ninth invention, even if the building base material is heated under the condition of radiant heat of 50 kW / m ² and, for example, shrinks and deforms, the incombustible coating layer formed on one or both sides thereof is destroyed. Does not deform. For this reason, even if a base material for building is deformed, the incombustible coating layer itself is not destroyed, and the incombustibility can be maintained by the incombustible coating layer, and the incombustibility of the incombustible plate material is stabilized. It can be reliably maintained.

  The fireproof structure according to the tenth invention is characterized in that any one of the noncombustible plate materials of the fourth to ninth inventions is used.

  In the tenth aspect of the invention, it is possible to obtain a fireproof structure in which the difficulty of burning is stably and reliably maintained. At this time, the term “fireproof structure” is not a fireproof structure according to the standard that satisfies the standards of the Building Standard Act, but includes a fireproof structure, a semi-fireproof structure, and a fireproof structure according to the standard of the Building Standard Law. Used to mean “difficult structure”.

  As described above, according to the present invention, the incombustible coating composition contains a refined fine powder of purified high-purity bentonite and a soap-free emulsion resin. A uniform non-combustible film can be formed on the coating layer of the non-combustible coating composition with the bentonite fine powder, and gas barrier properties and non-combustible properties can be improved. In addition, the application amount of the incombustible coating composition is extremely reduced, and a minimum application amount is required. Thus, the number of coatings is reduced, and the incombustible coating layer can be formed in a short drying time.

  According to the second invention, the high-purity purified bentonite fine powder is formed by drying a separated and purified bentonite solid content obtained by purifying a crude liquid in which crude bentonite is dispersed in water by centrifugation. Purified bentonite fine powder can be obtained easily and reliably.

According to the third invention, the high-purity purified bentonite powder has a montmorillonite content of 85% by weight or more, so that a uniform incombustible film can be reliably formed on the coating layer by the incombustible coating composition. Thus, the gas barrier property and nonflammability can be stably and reliably improved. For example, the nonflammability performance can be improved by a heat generation test using a cone calorimeter. Stable incombustible performance of ² MJ / m ² or less can be obtained.

  According to 4th invention, the nonflammable board | plate material is a nonflammable board | plate material with high nonflammability by assuming that the coating-film layer which consists of a nonflammable coating composition is formed in the single side | surface or both surfaces of the base material for construction. As a result, the manufacturing process is simplified and the manufacturing cost can be reduced.

According to the fifth invention, the coating layer of the non-combustible plate material is formed so that the amount of montmorillonite is 3.3 g / m ² or more. Depending on the conditions of the substrate, it is possible to obtain a stable incombustible performance of a total calorific value of 7.2 MJ / m ² or less for 20 minutes.

  According to the sixth invention, a sealer layer is provided on one or both sides of a building base material, and a non-combustible coating layer made of a non-combustible coating composition is formed on the sealer layer. Both the smoothing of the coated surface and the formation of a uniform coating layer by preventing penetration into the substrate can be achieved.

  According to the seventh invention, the water resistance of the coating layer can be further improved by forming the resin coating layer on the non-combustible coating layer.

  According to the eighth invention, the architectural base material is a flame retardant, quasi-incombustible or non-combustible material as defined in the Building Standard Law, so that the architectural base material is made of a non-combustible coating composition. Can make it even more difficult to burn.

According to the ninth invention, the building base material is not deformed to such an extent that the non-combustible coating layer is destroyed when heated under the condition of radiant heat of 50 kW / m ^2. Even if the material is heated and contracted, for example, the noncombustible coating layer can maintain the noncombustibility, and the noncombustibility of the noncombustible plate material can be stably maintained.

  According to the fire resistant structure of the tenth invention, by using the non-combustible plate material, it is possible to obtain a fire resistant structure in which the difficulty of burning is stably and reliably maintained.

FIG. 1 is a schematic cross-sectional view of a noncombustible plate material according to an embodiment of the present invention. FIG. 2 is a diagram showing the composition of a noncombustible coating composition that forms a coating layer in a bentonite purity test. FIG. 3 is a graph showing the relationship with the total calorific value for 20 minutes when the purity of bentonite is changed. FIG. 4 is a diagram showing the relationship with the total calorific value for 20 minutes when the purity of bentonite is changed. FIG. 5 is a diagram showing the composition of a non-combustible coating composition that forms a coating layer in a test for the amount of montmorillonite in the coating layer. FIG. 6 is a diagram showing the relationship with the total calorific value for 20 minutes when the amount of montmorillonite in the coating layer is changed. FIG. 7 is a diagram showing the relationship with the total calorific value for 20 minutes when the amount of montmorillonite in the coating layer is changed. FIG. 8 is a diagram showing a total calorific value for 20 minutes when a coating layer made of a non-combustible coating composition is formed on a semi-incombustible calcium plate having a thickness of 9 mm. FIG. 9 is a diagram showing a total calorific value for 20 minutes when a coating layer of a non-combustible coating composition is formed on a non-combustible calcium plate having a thickness of 6 mm.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The following description of the embodiments is merely illustrative in nature and is not intended to limit the present invention, its application, or its use at all.

  FIG. 1 shows a non-combustible plate A in which a non-combustible coating composition according to an embodiment of the present invention is used, and this non-combustible plate A is used as a non-combustible building material such as a wall material of a building. It is what makes. The non-combustible plate material A includes, for example, a rectangular plate-like building base material 1, and a sealer layer 3 is formed on one surface of the building base material 1 by an undercoating material, and a coating film is formed on the sealer layer 3. The layer 5 is formed of a top coat, and a resin coat layer 7 is formed on the coating layer 5. In addition, this coating film layer 5 has a noncombustible coating composition.

  In this embodiment, the incombustible plate A is not a standard incombustible material that satisfies the standards of the Building Standard Act, but includes a flame retardant material, a semi-incombustible material, or a non-combustible material in accordance with the standard of the Building Standard Law. It is used to mean “not easy to burn”. In addition, “fireproof structure” is not a standard fireproof structure that meets the standards of the Building Standards Act, but it includes fireproof structures, semi-fireproof structures, and fireproof structures according to the standards of the Building Standards Law. The term “structure” is used.

(Base material for construction)
The building base material 1 is made of a flame-retardant, semi-incombustible or non-flammable plate material as stipulated in the Building Standards Act. For example, inorganic materials such as a volcanic glassy multilayer board, a calcite board, and a gypsum board Or a metal plate, a resin plate, etc. can be selected suitably. And although these materials originally have the characteristics which are hard to burn (flame retardance and nonflammability), the coating layer 5 which has a nonflammable coating composition is formed in the surface (it becomes nonflammable board material A). Thus, in addition to the original characteristics, the degree of flame retardance is further increased by the synergistic effect of the coating layer 5.

In particular, when the building base material 1 is heated under a predetermined heating condition, for example, a radiant heat amount of 50 kW / m ² and undergoes deformation such as contraction or expansion, the degree of deformation is reduced to the surface coating film. It is desirable that the layer 5 is not broken. If such deformation occurs, the coating layer 5 is broken, and the nonflammable function and effect of the coating layer 5 are reduced. As such a construction substrate 1, for example, a volcanic glassy multilayer board (JIS A 5440) (trade name “Dailite” of Daiken Kogyo Co., Ltd.) having a thickness of 6 mm to 12 mm, a thickness of 9 mm A quasi-incombustible calcium plate (trade name “Anshin” manufactured by Nichiha Co., Ltd.) or a non-combustible calcium plate having a thickness of 6 mm (trade name “HI-LACK” manufactured by A & A Materials Co., Ltd.) is preferably used.

(Sealer layer)
The sealer layer 3 is formed by applying an undercoat paint to the surface of the building substrate 1. This sealer layer 3 combines the smoothing of the surface of the building base material 1 and the prevention of non-uniform soaking of the non-combustible coating composition to be the coating layer 5 into the building base material 1. The surface of the building substrate 1 is made smooth by the sealer layer 3 so that the coating film layer 5 thereon can be formed into a uniform and beautiful non-combustible coating film layer. I am doing so.

  In addition, formation of the sealer layer 3 is not essential, and may be appropriately performed as necessary. If the smoothing process for making the surface of the building base material 1 smooth can be performed, it can be adopted. Moreover, if the surface of the building base 1 is originally a smooth surface, the coating layer 5 can be formed by directly applying the non-combustible coating composition on the surface without forming the sealer layer 3. However, considering that the surface of the building base 1 can be smoothed, the non-uniform infiltration of the non-combustible coating composition, and the adhesion between the non-burning coating composition layer and the building base 1 can be combined, It is desirable to form the sealer layer 3.

  The type of the sealer layer 3 is not particularly specified, and various synthetic resins such as an acrylic resin, a urethane resin, an epoxy resin, a vinyl chloride resin, and a silicone resin, and a mixture thereof are used. Moreover, various inorganic pigments, auxiliaries and the like can be added to the sealer layer 3 as necessary.

The coating amount of the sealer layer 3 is preferably 10 to 100 g / m ^2, for example. Moreover, the application | coating method of the sealer layer 3 is not specifically specified, Well-known methods, such as a roll coater, a flow coater, and a spray, may be used. The drying and solidification method can be performed by a known method such as a hot air dryer.

(Coating layer)
The coating layer 5 has a noncombustible coating composition. This incombustible coating composition contains fine powder of high-purity purified bentonite having a purity (montmorillonite content) of a predetermined value or more and a soap-free emulsion resin.

  The purity of the high purity purified bentonite fine powder is such that the montmorillonite content is 80% by weight or more, preferably 85% by weight or more, and most preferably 95% by weight or more.

  In order to specify the purity of this bentonite, for example, a colorimetric determination method of methylene blue in accordance with JBAS-107-91, that is, a sample is added to a sodium pyrophosphate solution and a methylene blue solution, and the solution is dropped on a filter paper. Use a method of observing whether there is a limit. Then, the purity is determined by dividing the amount of methylene blue adsorbed by bentonite whose purity is unknown by the amount of methylene blue adsorbed with a montmorillonite content of 100% by weight. For example, when the methylene blue adsorption amount of bentonite whose purity is unknown is 136 mmol / 100 g, the methylene blue adsorption amount of montmorillonite content 100 wt% is defined as 140 mmol / 100 g, and the purity of bentonite is (136/140) × 100 = Calculated as 97% by weight.

  When producing such a fine powder of purified bentonite, a crude bentonite obtained by pulverizing ore is added to water to swell and disperse it into a crude liquid, and this crude liquid is centrifuged in multiple stages (for example, three stages). Separation treatment is performed to obtain a purified solution (impurities settle), and the purified solution is dried to obtain a high-purity purified bentonite powder. This makes it possible to easily and reliably obtain a fine powder of purified bentonite.

  The particle size of the bentonite fine powder is desirably 45 μm or less when wet (100% passing when 325 mesh is wet). Further, the swelling power of bentonite is desirably 45 ml / 2 g or more, for example.

The concentration of the high-purity purified bentonite fine powder in the incombustible coating composition is set to, for example, 3% by weight or more so that it can be uniformly applied, and the coating layer 5 has, for example, 3.3 g of montmorillonite. / M ² or more.

  The soap-free emulsion resin is an emulsion resin in which a surfactant used during emulsion polymerization is a reactive surfactant. Thereby, coating-film intensity | strength and water resistance can be raised.

  As the soap-free emulsion resin, for example, acrylic resins, urethane resins, epoxy resins, vinyl chloride resins, various synthetic resins such as silicone resins, and mixtures thereof are used. In particular, an acrylic resin is preferable because it has an excellent balance of film forming property, hardness, gas permeability, and filler dispersion stability.

  The concentration of the emulsion resin is desirably 3 to 30% by weight in terms of solid content. If it is less than 3% by weight, the adhesion to the building substrate 1 becomes insufficient, and sufficient strength cannot be obtained for the coating film. If it exceeds 30% by weight, the resin in the coating layer 5 This is because the amount of components increases and the resin (coating layer 5) itself tends to burn.

  When preparing an incombustible coating composition, for example, bentonite fine powder may be added to water and stirred with a stirrer, etc., and emulsion resin may be added while stirring, or bentonite may be added after adding resin to water. You may make it disperse | distribute.

  As other additives, auxiliary agents such as an antifoaming agent, a dispersing agent, a wetting agent, and an antifungal agent may be added, and a pigment may be added depending on applications.

The coating amount of the top coat for forming the coating layer 5 may be such that the montmorillonite is 3.3 g / m ² or more, for example, depending on the bentonite content in the paint and the montmorillonite content in the bentonite. What is necessary is just to design suitably so that it can apply | coat uniformly and is easy to dry. Further, the method for applying the top coating is not particularly specified, and a known method such as a flow coater, a roll coater, or a spray can be employed, and a drying and solidifying method can be performed by a known method such as a hot air dryer.

(Resin coat layer)
The resin coat layer 7 is formed by applying a resin liquid to the coating film layer 5 of the building substrate 1 and is provided to further improve the water resistance of the coating film layer 5.

  The formation of the resin coat layer 7 is not essential, and may be appropriately performed as necessary. If the water resistance of the incombustible coating layer 5 is originally sufficient, it is not necessary to form the resin coat layer 7. However, considering that the nonflammability and water resistance of the nonflammable coating layer can be achieved together, it is preferable to form the resin coat layer 7.

  The type of the resin coat layer 7 is not particularly specified, and various synthetic resins such as acrylic resin, urethane resin, epoxy resin, vinyl chloride resin, silicone resin, and mixtures thereof are used. In addition, various inorganic pigments, auxiliaries and the like can be added to the resin coat layer 7 as necessary.

The coating amount of the resin coating layer 7 must be a degree that does not impair the noncombustible noncombustible coating layer 5, for example 10 to 100 g / m ² is preferred. Moreover, the coating method of the resin coat layer 7 is not particularly specified, and a known method such as a roll coater, a flow coater, or a spray may be used. The drying and solidification method can be performed by a known method such as a hot air dryer.

(Method for producing non-combustible plate material)
When the non-combustible plate A is produced by forming the sealer layer 3, the coating layer 5 and the resin coat layer 7 on the surface of the building substrate 1, for example, a sealer coating process, a first drying solidification process, a non-combustible paint coating process The second dry solidification step, the resin coat coating step, and the third dry solidification step are performed in this order. In the sealer coating process, the sealer layer 3 is formed on the surface of the building base material 1 by performing sealer coating using, for example, a roll coater. The coating amount of the sealer layer 3 is preferably 10 to 100 g / m ² , for example.

  In the next first drying and solidifying step, drying is appropriately performed with a dryer or the like.

In the subsequent non-combustible paint coating step, the coating layer 5 is formed by applying a top coat with a non-combustible paint composition on the surface of the building substrate 1 after drying using, for example, a flow coater. The coating amount of the top coating is, for example, 10 to 200 g / m ² in terms of solid content. The application method is not particularly specified.

  Drying is performed in the next second drying and solidifying step, and the solvent is volatilized to form a film.

In the subsequent resin coat coating step, the resin coat layer 7 is formed by performing resin coat coating, for example, by spraying or the like on the surface of the building substrate 1 after drying. The coating amount of the resin coat layer 7 is preferably 10 to 100 g / m ² , for example, as long as the incombustibility is not impaired.

  Drying is performed in the final third drying and solidifying step, and the solvent is volatilized to form a film.

  Therefore, in the said embodiment, the nonflammable board | plate material A has the coating layer 5 which consists of a nonflammable coating composition formed in the surface of the base material 1 for construction through the sealer layer 3, This coating film The incombustible coating composition of layer 5 is a composition containing a fine powder of high purity bentonite having a montmorillonite content of, for example, 80% by weight or more and a soap-free emulsion resin. The powder forms a thin and uniform incombustible film with few impurities on the coating layer 5, and can improve the gas barrier property and the incombustibility of the coating layer 5. Since the gas barrier property and nonflammability of the coating film layer 5 are increased in this way, the amount of the nonflammable coating composition applied to the building base material 1 is extremely reduced, and a minimum amount of coating can be achieved. The number of coatings is reduced, and the coating layer 5 can be formed in a short drying time to reduce the drying load.

In particular, the fine powder of the high-purity purified bentonite has a montmorillonite content of 85% by weight or more, more preferably 95% by weight or more, thereby ensuring a uniform non-combustible film on the coating layer 5 of the non-combustible coating composition. The gas barrier property and nonflammability can be stably and reliably improved. For example, in a 20 minute heat generation test using a cone calorimeter of the nonflammable plate A, the total calorific value is 7.2 MJ / m ² or less. Incombustible performance can be obtained. This 20 minute total calorific value of 7.2 MJ / m ² or less is the total calorific value that is the performance required by the Building Standards Act as a flame retardant material, semi-incombustible material and non-combustible material in the exothermic test. It is a numerical value lower than 8.0 MJ / m ² or less, and in the embodiment of the present invention, this numerical value is set as a reference for performance that is more difficult to burn.

  That is, the incombustibility of the incombustible plate A in which the coating layer 5 made of the incombustible coating composition having such a gas barrier property and high incombustibility is formed on the surface of the building substrate 1 is increased. Since the number of coatings of the noncombustible coating composition applied to the material 1 is small and the drying time is short, the manufacturing process of the noncombustible plate A can be simplified and the manufacturing cost can be reduced.

The coating layer 5 of the non-combustible plate A is formed so that the amount of montmorillonite is 3.3 g / m ² or more. A stable incombustible performance of 7.2 MJ / m ² or less can be obtained.

  Moreover, the sealer layer 3 is formed on the surface of the building base material 1 in the noncombustible plate A, and the surface of the building base material 1 becomes a smooth surface by the sealer layer 3, and the coating layer 5 is formed on the smooth surface. Therefore, the coating layer 5 can be made into a uniform and beautiful non-combustible coating layer, and the non-flammability by the coating layer 5 can be obtained stably. Moreover, compared with the case where a nonflammable coating composition is applied directly on the surface of the building base material 1, the sealer layer 3 can prevent the nonflammable coating composition from penetrating into the building base material 1. Therefore, both the smoothing of the application surface of the incombustible coating composition and the formation of a uniform coating layer by preventing soaking can be achieved by the sealer layer 3.

  Moreover, the resin coat layer 7 is formed on the coating layer 5 of the base material 1 for building in the incombustible plate material A, and the water resistance of the coating layer 5 is further improved by providing this resin coating layer 7. Can do. Since the resin coat layer 7 is applied to such an extent that the incombustibility is not impaired, both the incombustibility and water resistance of the coating layer 5 can be achieved.

  The architectural base material 1 is flame retardant, semi-incombustible or non-combustible, and the architectural base material 1 is formed by a coating layer 5 made of a non-combustible coating composition formed on the surface thereof. In addition, it can be made difficult to burn. Therefore, in the case of the flame-retardant building base material 1, the flame-retardant property, in the case of the quasi-incombustible building base material 1, the quasi-incombustibility, and further the non-flammable building base material 1. In this case, the non-flammability can be maintained or increased more reliably and stably.

And since the said base material 1 for construction is a thing which does not deform | transform to such an extent that the coating-film layer 5 is destroyed when it heats on the conditions of 50 kW / m < ² > in terms of radiant heat, suppose that it is 50 kW / m in terms of radiant heat. ^Even if the building base material 1 is heated and contracted, for example, under the condition ² , it will not be deformed to the extent that the coating layer 5 formed on the surface is destroyed, and the building base material 1 is deformed. However, the coating film layer 5 itself is not destroyed, and the coating film layer 5 can maintain nonflammability. Therefore, the incombustibility of the incombustible plate A can be more stably and reliably maintained.

  And when the noncombustible board | plate material A obtained in this way is used as a wall material, for example, and a fireproof structure is constructed, the fireproof structure is fireproof in which the difficulty of burning was stably maintained reliably. It becomes a structure. At this time, the term “fireproof structure” is not a fireproof structure according to the standard that satisfies the standards of the Building Standard Act, but includes a fireproof structure, a semi-fireproof structure, and a fireproof structure according to the standard of the Building Standard Law. Used to mean “difficult structure”.

(Other embodiments)
In the said embodiment, although the nonflammable board | plate material A in which the coating-film layer 5 which consists of a nonflammable coating composition is formed in the surface (one side) of the building base material 1 is demonstrated, the back surface of the building base material 1 You may form the coating layer 5 which consists of the same nonflammable coating composition on (one side). Further, the non-combustible plate material A may be formed by forming a coating layer 5 made of the same non-combustible coating composition on the back surface (both front and back surfaces) in addition to the surface of the building substrate 1. The nonflammability of A can be further improved.

  Next, a specific example will be described.

(1) Test on bentonite purity The relationship between bentonite purity (montmorillonite content) and nonflammability was tested. Bentonite fine powder was put into water and stirred with a stirrer, and an acrylic resin was added while stirring to prepare a noncombustible coating composition. The composition is shown in FIG. The acrylic resin has a solid content concentration.

  At that time, as shown in FIG. 3, a plurality of bentonites with different purities (montmorillonite content) were prepared. This bentonite has a different purity because the mixing ratio of Kunipia F having a montmorillonite content of 98.5% by weight or more and Kunigel V1 (all trade names of Kunimine Industries Co., Ltd.) of 46 to 49% by weight is different. The purity was determined by the colorimetric determination method of methylene blue.

For the 6mm prototype according to the quasi-incombustible composition of volcanic glassy multilayer board (JIS A 5440), which is sanded and smoothed as the base material for construction, the primer coating composition is applied to the surface. 80 g / ^{m 2} coating to form a sealer layer, suitably dried after application amount 100 g / ^{m 2} approximately as montmorillonite of bentonite incombustible coating composition onto the sealer layer is 4.0 g / ^{m 2} Was applied to form a non-combustible coating layer, and dried appropriately to evaporate the solvent to form a film.

The sample of the noncombustible plate material thus obtained was subjected to a heat generation test using a cone calorimeter, and the total heat generation amount for 20 minutes was measured. The results are shown in FIGS. According to these figures, the total calorific value for 20 minutes in the exothermic test is 8.0 MJ / m ^2, which is the performance requirement content required by the Building Standard Act as a flame retardant material, semi-incombustible material and non-combustible material. It was confirmed that the content of montmorillonite in bentonite is required to be 85% by weight or more in order to obtain stable nonflammability, for example, lower than 7.2 MJ / m ² or less.

(2) Test on amount of montmorillonite in coating layer Next, the relationship between the amount of montmorillonite in the coating layer and nonflammability was tested. In the same manner as in the above test, bentonite fine powder was put into water and stirred with a stirrer, and an acrylic resin was added while stirring to prepare a noncombustible coating composition. At that time, as for bentonite, a montmorillonite content rate of 98.5% by weight or more Kunipia F (trade name of Kunimine Kogyo Co., Ltd.) is used, and a plurality of types with different concentrations of 2 to 4% by weight are prepared. did. The composition is shown in FIG. The acrylic resin has a solid content concentration.

For the 6mm prototype according to the quasi-incombustible composition of volcanic glassy multilayer board (JIS A 5440), which is sanded and smoothed as the base material for construction, the primer coating composition is applied to the surface. After applying 80 g / m ² to form a sealer layer and drying appropriately, the nonflammable coating composition is applied onto the sealer layer so that the amount of montmorillonite of bentonite is 2.4 to 4.4 g / m ^2. An incombustible coating layer was formed by coating at about / m ² , and dried as appropriate to evaporate the solvent to form a film.

As shown in FIG. 6, montmorillonite amount even if the coating amount of the coating layer is a ² to a certain extent of 100 g / ^m it is different from the 2.4~4.4g / ^{m 2,} the topcoat incombustible coating composition This is due to the difference in the concentration of bentonite, and the amount of montmorillonite in the coating layer increases as the concentration of bentonite increases.

In addition, only a sealer layer is formed on the surface of a 6 mm prototype according to the semi-incombustible composition of volcanic glassy multilayer board (JIS A 5440), which has been sanded to make a smooth surface. A sample in which a coating layer was not formed was also prepared. The amount of montmorillonite in this sample is 0 g / m ² .

The sample of the noncombustible plate material thus obtained was subjected to a heat generation test using a cone calorimeter, and the total heat generation amount was measured. The results are shown in FIGS. According to these figures, the amount of montmorillonite in the coating layer needs to be 3.3 g / m ² or more in order to obtain a stable nonflammability with a total calorific value of 7.2 MJ / m ² or less, for example. It was confirmed that.

(3) Formation of a coating layer on other building base materials In addition to the 6 mm prototype according to the quasi-incombustible composition of the volcanic glassy multilayer board (JIS A 5440) as described above, a thickness of 9 mm Two types of quasi-incombustible calcium plates (Nichiha Corporation's product name “Anshin”) and 6 mm thick non-combustible calcium plates (A & A Materials Co., Ltd. product name “Hi-Lac”) are prepared. They were tested for nonflammability by the coating layer.

  In the same manner as in the above test, bentonite fine powder was put into water and stirred with a stirrer, and an acrylic resin was added while stirring to prepare a noncombustible coating composition. At that time, as for bentonite, a montmorillonite content rate of 98.5% by weight or more Kunipia F (trade name of Kunimine Kogyo Co., Ltd.) is used, and a plurality of types with different concentrations of 2 to 4% by weight are prepared. (See FIG. 5). The acrylic resin has a solid content concentration.

As an architectural base material, 80 g / m of the primer coating composition is applied to the surface of the above-mentioned 9 mm-thick quasi-incombustible calcium plate and 6 mm-thick non-combustible calcium plate which are sanded and smoothed. ^{2. After} applying a sealer layer and drying appropriately, the incombustible coating composition was applied on the sealer layer at a coating amount of about 100 g / m ² so that the montmorillonite amount of bentonite was 3.7 g / m ^2. A non-combustible coating layer was formed and dried as appropriate to evaporate the solvent to form a film.

Also, a sample in which only the sealer layer is formed on the surface of the above-mentioned two types of semi-incombustible calcium plate and the non-combustible calcium plate that are sanded and smooth, and the coating layer is not formed on the non-combustible coating composition. Also made. The amount of montmorillonite in this sample is 0 g / m ² .

  The sample of the noncombustible plate material thus obtained was subjected to a heat generation test using a cone calorimeter, and the total heat generation amount was measured. FIG. 8 shows the results for the 9 mm thick semi-incombustible calcium plate, and FIG. 9 shows the results for the 6 mm thick non-combustible calcium plate. According to these figures, in any of the semi-incombustible and non-combustible calcium plates, the non-combustible coating layer is formed by the non-combustible coating composition on the surface, and there is no non-combustible coating layer. In comparison, the total calorific value for 20 minutes in the exothermic test is lowered, indicating that the gas barrier property and incombustibility of the incombustible plate material having the incombustible coating layer by the incombustible coating composition can be improved.

  In the present invention, the coating amount of the incombustible coating composition for generating a uniform incombustible film in the coating layer and improving the gas barrier property and incombustibility is extremely small, and the number of coatings and the drying time can be shortened. Very useful.

A Non-combustible plate 1 Base material for building 3 Sealer layer 5 Coating layer 7 Resin coating layer

Claims (10)

  A non-combustible coating composition characterized by containing a high-purity purified bentonite powder having a purity of a predetermined value or more and a soap-free emulsion resin. In claim 1,
The fine powder of high-purity purified bentonite is a nonflammable coating composition formed by drying a purified bentonite solid content obtained by purifying a crude liquid in which crude bentonite is dispersed in water by centrifugation. In claim 1 or 2,
A non-combustible coating composition characterized in that the fine powder of high-purity purified bentonite has a montmorillonite content of 85% by weight or more.   An incombustible plate material, wherein a coating layer made of the incombustible coating composition according to any one of claims 1 to 3 is formed on one side or both sides of a building base material. In claim 4,
The non-combustible plate material, wherein the coating layer is formed so that the amount of montmorillonite is 3.3 g / m ² or more. In claim 4 or 5,
A sealer layer is provided on one or both sides of the building substrate,
A nonflammable plate material, wherein a nonflammable coating layer made of a nonflammable coating composition is formed on the sealer layer. In any one of Claims 4-6,
A non-combustible plate material, wherein a resin coat layer is formed on a non-combustible coating layer. In any one of Claims 4-7,
The non-combustible plate material, wherein the building base material is flame retardant, semi-incombustible or non-combustible as defined in the Building Standard Law. In any one of Claims 4-8,
The non-combustible plate material, wherein the building base material is not deformed to such an extent that the non-combustible coating layer is destroyed when heated under the condition of radiant heat of 50 kW / m ² .   A fire-resistant structure using the non-combustible plate material according to any one of claims 4 to 9.

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