JP6979978B2 - Section structure and its construction method - Google Patents

Description

The present invention relates to a section structure formed in a building structure in which a flat deck is used, and a construction method thereof.

Conventionally, a flat deck may be used to construct a floor or roof structure of a building structure such as reinforced concrete or steel-framed reinforced concrete. As disclosed in Patent Document 1, for example, the flat deck generally extends along the longitudinal direction, and a plurality of reinforcing ribs having cavities inside are formed on the lower surface, and the upper surface is formed flat. .. Flat decks are used in floor or roof structures, for example, as formwork for placing concrete on top surfaces.

Further, in a building structure, a fireproof section may be formed by a face material such as gypsum board. In the fire protection section, in order to prevent the flame from spreading in the event of a fire, in order to ensure sound insulation and heat insulation in the section other than the fire protection section, it is necessary to prevent a gap from being formed between the floor structure and the roof structure. ..
For example, when a flat deck is provided on the floor structure and a partition material for forming a partition such as a fireproof partition is abutted on the lower surface thereof, a gap is created between the floor structure and the partition material due to the cavity inside the reinforcing rib. Therefore, it is necessary to remove the ribs by cutting the flat deck or the like at the portion where the partition materials are abutted. The work of removing the ribs will be performed on-site, for example, after placing concrete. However, if the work of removing the ribs is performed at the construction site, the workability is deteriorated.

Japanese Unexamined Patent Publication No. 2017-110453

Therefore, the present invention provides a section structure in which a flat deck is provided in a floor structure, a roof structure, or the like, and the cavity inside the reinforcing ribs does not create a gap and has good fire resistance, sound insulation, and heat insulation. The purpose is to enable construction with high workability.

The gist of the present invention is as follows.
[1] A flat deck having a plurality of reinforcing ribs protruding from one surface and having a cavity inside, a partition material abutted against the one surface of the flat deck, and the reinforcing ribs being filled inside. A compartmentalized structure with a urethane foam containing a flame retardant.
[2] The compartmental structure according to the above [1], wherein the flame retardant contains red phosphorus.
[3] The flame retardant is at least one selected from the group consisting of a phosphoric acid ester, a phosphate-containing flame retardant, a bromine-containing flame retardant, a boron-containing flame retardant, an antimony-containing flame retardant, and a metal hydroxide. The section structure according to the above [2] including.
[4] In any one of the above [1] to [3], wherein the partition material is any one of gypsum board, extruded cement board, lightweight aerated concrete, precast concrete board, and glass fiber reinforced concrete board. Described compartmentalized structure.
[5] The end surface of the partition material protrudes into one surface of the flat deck so that a plurality of notches are provided on the end surface of the partition material and each reinforcing rib is arranged inside each of the notches. The section structure according to any one of the above [1] to [4] to be combined.
[6] The section structure according to the above [5], wherein the gap between the reinforcing rib and the notch is closed by the gap filling material.
[7] The section structure according to the above [6], wherein the gap filling material is selected from rock wool and glass wool.
[8] A flat deck projecting from one surface, having a plurality of reinforcing ribs having cavities inside, and having urethane foam containing a flame retardant filled inside the reinforcing ribs is used as a building structure. The process of laying and
A method for constructing a section structure including a step of abutting a section member on one surface of the flat deck provided with the reinforcing rib.

According to the present invention, in a building structure in which a flat deck is provided in a floor structure, a roof structure, or the like, a section having good fire resistance, sound insulation, heat insulation, etc. is provided without creating a gap due to a cavity inside the reinforcing rib. , Can be constructed with high workability.

It is a perspective view which shows the partition structure which concerns on one Embodiment of this invention. It is sectional drawing which shows the structure of the butt part of the flat deck and the section material in the section structure which concerns on one Embodiment of this invention.

FIGS. 1 and 2 show a partition structure 10 according to an embodiment of the present invention. Hereinafter, the section structure will be described in detail with reference to the drawings. As shown in FIGS. 1 and 2, the partition structure 10 includes a flat deck 11, a partition material 20, and urethane foam 30.

In the flat deck 11, the upper surface 11U has a flat surface or a flat portion having minute irregularities formed on the flat surface, and a plurality of reinforcing ribs 12 are projected from the lower surface 11D of the flat portion. Each reinforcing rib 12 is a ridge having a cavity inside, and is arranged so as to extend along the longitudinal direction, and both end portions 12A and 12B in the longitudinal direction may be crushed and closed. The flat deck 11 can be obtained by, for example, rolling or press forming a metal plate such as a steel plate or other materials. The cross-sectional shape of the reinforcing rib 12 of the flat deck 11 is triangular in FIG. 2, but is not particularly limited, and may be another shape such as a quadrangle as long as a cavity is formed inside.

The flat deck 11 is laid on a building structure or the like and is used to form a floor structure, a roof structure or the like. The flat deck 11 constitutes a floor structure, a roof structure, and the like, for example, by placing both ends thereof in the longitudinal direction on the support members 14 and 14 such as beams and erection between the support members 14 and 14. The flat deck 11 is used, for example, as a formwork material, and when used as a formwork material, concrete (not shown) is cast on the upper surface 11U.

The partition material 20 is a member for forming a partition, and in the present embodiment, it is composed of gypsum boards 21 and 21. Further, a wall 25 is provided in the building structure, and the gypsum boards 21 and 21 constitute the wall 25. The wall 25 is provided with a support frame 26 installed on the building structure. The support frame 26 is, for example, a frame-shaped member composed of a horizontal rail extending in the horizontal direction and a vertical rail extending in the vertical direction, and gypsum boards 21 and 21 are screwed on both sides of the support frame 26. Is fixed by.

As shown in FIG. 2, the gypsum board 21 is provided with a plurality of notches 22 on the upper end surface 21U, and the upper end surface 21U has an upper end surface 21U so that each reinforcing rib 12 is arranged inside each of the notches 22. It is abutted against the lower surface 11D constituting one surface of the flat deck 11.

The cavity inside the reinforcing rib 12 of the flat deck 11 is filled with urethane foam 30 containing a flame retardant. The urethane foam 30 can be made nonflammable by containing a flame retardant. More specifically, the urethane foam 30 has a total calorific value of 8 MJ / m ² or less ^{after 20 minutes when heated at a radiant heat intensity of 50 kW / m 2 in} accordance with the ISO-5660 test method. Is preferably used.
The urethane foam 30 may be formed by injecting a liquid urethane resin composition described later from an injection port 13 provided on the side surface of the reinforcing rib 12, for example, and curing and foaming the urethane foam 30 inside the reinforcing rib 12.

Further, a gap 23 is provided between the reinforcing rib 12 of the flat deck 11 and the notch 22, and the gap 23 is closed by the gap filling material 27. As the gap filling material 27, known gap filling materials such as rock wool and glass wool can be used.

Hereinafter, the construction method of the section structure according to the present embodiment will be described. First, in the present embodiment, a flat deck 11 having a urethane foam 30 inside is prepared. Specifically, for example, a flat deck 11 is manufactured by a known method, an injection port 13 is formed in the reinforcing rib 12 of the flat deck 11, and a liquid urethane resin composition is applied to the inside of the reinforcing rib 12 from the injection port 13. The urethane resin composition may be internally foamed and cured by injecting it into the cavity of.

The flat deck 11 in which the urethane foam 30 is filled inside the reinforcing rib 12 is laid in the building structure. For example, as shown in FIG. 1, the flat deck 11 may be laid across the support members 14 and 14 such as beams.

After that, the partition member 20 is arranged so as to abut against one surface of the flat deck 11. Specifically, the gypsum boards 21 and 21 are arranged so that their upper end surfaces 21U and 21U abut against the lower surface 11D of the flat deck 11. Then, in that state, the gypsum boards 21 and 21 may be attached to the support frame 26 installed inside the building structure with screws or the like. In this case, the gypsum board 21 is arranged so that the reinforcing rib 12 is inserted into the notch 22 provided in the gypsum board 21. After that, the gap 23 between the gypsum boards 21 and 21 (partition material 20) and the reinforcing rib 12 is filled with the gap filling material 27, and the partition structure 10 as shown in FIG. 1 is obtained.

As described above, in the present embodiment, the cavity inside the reinforcing rib 12 is filled with the urethane foam 30 containing the flame retardant, so that the cavity formed inside the reinforcing rib 12 creates a gap in the compartment. It is possible to form a section having good fire resistance, sound insulation, heat insulation and the like. Further, if the urethane foam 30 is pre-filled in the cavity inside the reinforcing rib 12, it is not necessary to perform work such as injecting the urethane resin composition at the construction site, so that the workability is improved.
Further, as described above, by making the urethane foam 30 buried in the gap nonflammable, the fire resistance, heat insulating property and the like are further improved. Further, the gap 23 formed between the reinforcing rib 12 and the partition material 20 can also be filled with the gap filling material 27 to improve the fire protection performance.

Further, although the reinforcing rib 12 is often provided with a narrow gap inside, the urethane foam 30 is reinforced by injecting a liquid urethane resin composition into the inside of the reinforcing rib 12 to form the urethane foam 30. It becomes possible to follow even a narrow gap inside the rib 12. Further, the urethane foam 30 has self-adhesiveness, and by adhering to the inner surface of the reinforcing rib 12, the gap filling property becomes good.
In addition, since the urethane foam 30 has good moisture resistance, it does not shrink even under high humidity and has excellent fire protection performance. Further, since the urethane foam 30 is foamed and cured in a short time such as within 5 minutes after the urethane resin composition is produced, it can be formed inside the flat deck 11 in a short time.

The section structure 10 is not limited to the above structure and can be changed in various ways. For example, the gap 23 formed between the partition material 20 and the reinforcing rib 12 does not have to be closed by the gap filling material 27. Even if the partition material 20 is not blocked by the gap filling material 27, the notch 22 of the partition material 20 is made to match the shape of the reinforcing rib 12 as much as possible to reduce the size of the gap 23, so that the partition material 20 and the reinforcing rib 12 are formed. It is possible to suppress deterioration of fire protection, heat insulation, and sound insulation performance due to the gap 23 formed between them.

Further, the partition material 20 is not limited to the plaster board 21, and various materials can be used, such as extruded cement board, lightweight aerated concrete (ALC) board, precast concrete (PC) board, and glass fiber reinforced concrete (GRC). ) It may be another face material such as a plate. Further, depending on the type of the partition material, the support frame body 26 may be omitted as appropriate, or another support body may be used instead.

Further, the partition member 20 does not have to be provided with a notch on the end surface (upper end surface 21U in FIG. 2) that abuts against the flat deck 11. In such a case, the end face of the partition member 20 is abutted against the reinforcing rib 12 (the lower surface 12D of the rib 12 in FIG. 2) and cannot be abutted against the flat portion, and is between the section member 21 and the flat deck 11. Although the gap becomes large, even in such a case, by closing the gap with the gap filling material 27, it is possible to secure a certain level of fire protection, heat insulation, and sound insulation performance. Further, the reinforcing rib 13 may be provided on the upper surface of the flat deck 12, the lower surface may be flat, and the partition member 20 may be abutted against the upper surface of the flat deck 11.

[Urethane foam]
Next, the urethane foam filled in the cavity of the reinforcing rib will be described in more detail. The urethane foam used in the present invention is formed by curing and foaming a urethane resin composition. The urethane resin contained in the urethane foam is a reaction product obtained by mixing and reacting a polyisocyanate compound and a polyol compound. The urethane resin composition is liquid at room temperature (23 ° C.) immediately after being prepared by mixing various components so that it can be easily injected into the reinforcing rib 12 and can be filled inside the reinforcing rib 12 without gaps.

Examples of the polyisocyanate compound used for urethane foam include aromatic polyisocyanates, alicyclic polyisocyanates, and aliphatic polyisocyanates.
Examples of the aromatic polyisocyanate include phenylenediocyanate, tolylene diisocyanate, xylylene diisocyanate, diphenylmethane diisocyanate, dimethyldiphenylmethane diisocyanate, triphenylmethane triisocyanate, naphthalene diisocyanate, and polymethylene polyphenyl polyisocyanate.

Examples of the alicyclic polyisocyanate include cyclohexylene diisocyanate, methylcyclohexylene diisocyanate, isophorone diisocyanate, dicyclohexylmethane diisocyanate, dimethyldicyclohexylmethane diisocyanate and the like.
Examples of the aliphatic polyisocyanate include methylene diisocyanate, ethylene diisocyanate, propylene diisocyanate, tetramethylene diisocyanate, hexamethylene diisocyanate and the like.
The polyisocyanate compound may be used alone or in combination of two or more.
The polyisocyanate compound is preferably diphenylmethane diisocyanate (MDI) because it is easy to use and easily available.

Examples of the polyol compound include polylactone polyols, polycarbonate polyols, aromatic polyols, alicyclic polyols, aliphatic polyols, polyester polyols, polymer polyols, and polyether polyols.
Examples of the polylactone polyol include polypropiolactone glycol, polycaprolactone glycol, polyvalerolactone glycol and the like.
Examples of the polycarbonate polyol include a polyol obtained by dealcoholization of a hydroxyl group-containing compound such as ethylene glycol, propylene glycol, butanediol, pentanediol, hexanediol, octanediol, and nonanediol with diethylene carbonate, dipropylene carbonate, and the like. Etc.

Examples of the aromatic polyol include bisphenol A, bisphenol F, phenol novolac, cresol novolak and the like.
Examples of the alicyclic polyol include cyclohexanediol, methylcyclohexanediol, isophoronediol, dicyclohexylmethanediol, and dimethyldicyclohexylmethanediol.
Examples of the aliphatic polyol include ethylene glycol, propylene glycol, butanediol, pentanediol, and hexanediol.

Examples of the polyester polyol include a polymer obtained by dehydration condensation of a polybasic acid and a polyhydric alcohol, and a polymer obtained by ring-opening polymerization of a lactone such as ε-caprolactone and α-methyl-ε-caprolactone. Examples thereof include a condensate of hydroxycarboxylic acid and the above-mentioned polyhydric alcohol and the like.
Specific examples of the polybasic acid include adipic acid, azelaic acid, sebacic acid, terephthalic acid, isophthalic acid, and succinic acid. Specific examples of the polyhydric alcohol include bisphenol A, ethylene glycol, 1,2-propylene glycol, 1,4-butanediol, diethylene glycol, 1,6-hexaneglycol, neopentyl glycol and the like. ..
Specific examples of the hydroxycarboxylic acid include castor oil and reaction products of castor oil and ethylene glycol.

The polymer polyol is, for example, a polymer obtained by graft-polymerizing an ethylenically unsaturated compound such as acrylonitrile, styrene, methyl acrylate, and methacrylate with the above-mentioned aromatic polyol, alicyclic polyol, aliphatic polyol, polyester polyol, or the like. , Polybutadiene polyols, modified polyols of polyhydric alcohols, hydrogenated additives thereof and the like.
Examples of the modified polyol of the polyhydric alcohol include those modified by reacting the polyhydric alcohol as a raw material with an alkylene oxide.
Examples of the polyhydric alcohol used for the modified polyol include trihydric alcohols such as glycerin and trimethylolpropane, pentaerythritol, sorbitol, mannitol, sorbitan, diglycerin, dipentaerythritol and the like, sucrose, glucose, mannose, fructose, etc. Tetra-octavalent alcohols such as methyl glucoside and derivatives thereof, phenol, fluorocrucin, cresol, pyrogallol, catechol, hydroquinone, bisphenol A, bisphenol F, bisphenol S, 1-hydroxynaphthalene, 1,3,6,8-tetrahydroxy Polyphenolic butadiene polyols such as naphthalene, anthrol, 1,4,5,8-tetrahydroxyanthracene, 1-hydroxypyrene, castor oil polyols, hydroxyalkyl (meth) acrylate polymers or copolymers, and polyvinyl alcohols. Examples thereof include functional (for example, 2 to 100 functional groups) polyols and condensates (novolak) of phenol and formaldehyde.

The method for modifying the polyhydric alcohol is not particularly limited, but a method for adding an alkylene oxide (hereinafter abbreviated as AO) is preferably used.
Examples of AO include AO having 2 to 6 carbon atoms, for example, ethylene oxide (hereinafter abbreviated as EO), 1,2-propylene oxide (hereinafter abbreviated as PO), 1,3-propireoxide, 1,2-. Examples thereof include butylene oxide and 1,4-butylene oxide.
Among these, PO, EO and 1,2-butylene oxide are preferable, and PO and EO are more preferable, from the viewpoint of properties and reactivity.
When two or more types of AO are used (for example, PO and EO), the addition method may be block addition, random addition, or a combination thereof.

As the polyether polyol, for example, at least one kind of alkylene oxide such as ethylene oxide, propylene oxide and tetrahydrofuran is ring-opened polymerized in the presence of at least one kind such as a low molecular weight active hydrogen compound having two or more active hydrogens. Examples thereof include the obtained polymer.
Examples of the low molecular weight active hydrogen compound having two or more active hydrogens used in the polyether polyol include diols such as bisphenol A, ethylene glycol, propylene glycol, butylene glycol, 1,6-hexanediol, glycerin, and trimethylol. Examples thereof include triols such as propane, amines such as ethylenediamine and butylene diamine.

As the polyol used in the urethane foam, it is preferable to use a polyester polyol or a polyether polyol because the effect of reducing the total calorific value at the time of combustion is large, and the polyester polyol is more preferable. Among them, it is preferable to use a polyester polyol having a molecular weight of 200 to 800, and it is further preferable to use a polyester polyol having a molecular weight of 300 to 500.

The isocyanate index of the urethane resin is preferably in the range of 120 to 1000, more preferably in the range of 200 to 800, and even more preferably in the range of 300 to 600. When the isocyanate index is 120 or more, the isocyanate group becomes excessive from the hydroxyl group, it becomes easy to be quantified, and it becomes easy to impart nonflammability. Further, when it is 1000 or less, the balance between nonflammability and manufacturing cost becomes good.

The isocyanate index can be calculated by the following method.
Isocyanate index = equivalent number of polyisocyanate ÷ (equivalent number of polyol + equivalent number of water) × 100
Here, each equivalent number can be calculated as follows.
Equivalent number of polyisocyanate = amount of polyisocyanate used (g) x NCO content (mass%) / molecular weight of NCO (mol) x 100
Equivalent number of polyol = OHV × amount of polyol used (g) ÷ molecular weight of KOH (mmol)
OHV is the hydroxyl value (mgKOH / g) of the polyol.
Equivalent number of water = molecular weight of water (g) / molecular weight of water (mol) x number of OH groups of water In each of the above formulas, the molecular weight of NCO is 42 (mol) and the molecular weight of KOH is 56100 (mmol). The molecular weight of water is 18 (mol), and the number of OH groups in water is 2.

[Flame retardants]
The flame retardant contained in the urethane foam preferably contains red phosphorus, and in addition to red phosphorus, a phosphate ester, a phosphate-containing flame retardant, a bromine-containing flame retardant, a boron-containing flame retardant, an antimon-containing flame retardant and It is more preferable to contain at least one selected from metal hydroxides. By containing these flame retardants, urethane foam can easily impart nonflammability.
It is more preferable that the flame retardant used in the urethane foam contains red phosphorus and a phosphoric acid ester from the viewpoint of nonflammability, handleability and the like. The flame retardant is composed of red phosphorus, a phosphoric acid ester, and at least one selected from a phosphate-containing flame retardant, a bromine-containing flame retardant, a boron-containing flame retardant, an antimony-containing flame retardant, and a metal hydroxide. Is also preferable.

(Red phosphorus)
The red phosphorus used in the present invention is not limited, and a commercially available product can be appropriately selected and used. Red phosphorus does not need to be blended with red phosphorus alone, and may be surface-treated as appropriate.
The blending amount of red phosphorus in the urethane foam is preferably in the range of 3.0 to 18 parts by mass, and more preferably 4.0 to 12 parts by mass with respect to 100 parts by mass of the urethane resin. By setting the blending amount of red phosphorus to 3.0 parts by mass or more, the self-extinguishing property of the urethane foam is maintained, and it becomes easy to impart nonflammability to the urethane foam. Further, when the content is 18 parts by mass or less, the foaming of the urethane resin composition is not hindered. As described above, the urethane resin is a reaction product of the polyisocyanate compound and the polyol compound, and 100 parts by mass of the urethane resin means a total of 100 parts by mass of the polyisocyanate compound and the polyol compound in the urethane resin composition. do.

(Phosphate ester)
The phosphoric acid ester is not particularly limited, but it is preferable to use a monophosphate ester, a condensed phosphoric acid ester, or the like. The monophosphate ester is a compound having one phosphorus atom in the molecule.
The monophosphate ester is not particularly limited, but for example, trimethyl phosphate, triethyl phosphate, tributyl phosphate, tri (2-ethylhexyl) phosphate, tributoxyethyl phosphate, triphenyl phosphate, tricresyl phosphate, trixylenyl phosphate, etc. Tris (isopropylphenyl) phosphate, tris (phenylphenyl) phosphate, trinaphthyl phosphate, cresyldiphenyl phosphate, xylenyldiphenyl phosphate, diphenyl (2-ethylhexyl) phosphate, di (isopropylphenyl) phenyl phosphate, monoisodecyl phosphate, 2-Acryloyloxyethyl acid phosphate, 2-methacryloyloxyethyl acid phosphate, diphenyl-2-acryloyloxyethyl phosphate, diphenyl-2-methacryloyloxyethyl phosphate, melamine phosphate, dimelamine phosphate, melamine pyrophosphate, tris (β-chloro) Propyl) phosphate and the like can be mentioned.

The condensed phosphoric acid ester is not particularly limited, but for example, trialkylpolyphosphate, resorcinolpolyphenyl phosphate, resorcinolpoly (di-2,6-kisilyl) phosphate (manufactured by Daihachi Chemical Industry Co., Ltd., trade name PX-200). ), Hydroquinonepoly (2,6-xylyl) phosphate and condensed phosphoric acid esters such as condensates thereof.
Examples of commercially available condensed phosphate esters include resorcinol polyphenyl phosphate (trade name CR-733S), bisphenol A polycresyl phosphate (trade name CR-741), aromatic condensed phosphate ester (trade name CR747), and resorcinol. Examples thereof include polyphenyl phosphate (manufactured by ADEKA, trade name Adecastab PFR), bisphenol A polycresyl phosphate (trade names FP-600, FP-700) and the like.

Among the above, it is preferable to use a monophosphate ester because it has a high effect of reducing the viscosity in the composition before curing and the effect of reducing the initial calorific value, and tris (β-chloropropyl) phosphate should be used. Is more preferable. The phosphoric acid ester may be used alone or in combination of two or more.

The blending amount of the phosphoric acid ester is preferably in the range of 1.5 to 52 parts by mass, more preferably in the range of 1.5 to 20 parts by mass with respect to 100 parts by mass of the urethane resin. It is more preferably in the range of 0 to 15 parts by mass, and most preferably in the range of 2.0 to 10 parts by mass.
When the amount of the phosphoric acid ester is 1.5 parts by mass or more, it is possible to prevent the dense residue formed from the urethane foam from cracking in the event of a fire, and when the amount is 52 parts by mass or less, the foaming of the urethane resin composition is not hindered. .. Further, by setting it within the above range, it becomes easy to impart nonflammability.

(Phosphate-containing flame retardant)
The phosphate-containing flame retardant is composed of, for example, a salt of the various phosphoric acids and at least one metal or compound selected from the metals of Group IA to IVB of the Periodic Table, ammonia, aliphatic amines and aromatic amines. Phosphate can be mentioned.
The phosphoric acid is not particularly limited, and examples thereof include various phosphoric acids such as monophosphoric acid, pyrophosphoric acid, and polyphosphoric acid.
Examples of the metals of Group IA to Group IVB of the Periodic Table include lithium, sodium, calcium, barium, iron (II), iron (III), and aluminum. Examples of the aliphatic amine include methylamine, ethylamine, diethylamine, triethylamine, ethylenediamine, piperazine and the like. Further, examples of the aromatic amine include pyridine, triazine, melamine, ammonium and the like.
The above-mentioned phosphate-containing flame retardant may be subjected to a known water resistance improving treatment such as a silane coupling agent treatment or a coating with a melamine resin.

Specific examples of the phosphate-containing flame retardant include monophosphate, pyrophosphate, polyphosphate and the like.
The monophosphate is not particularly limited, but for example, ammonium salts such as ammonium phosphate, ammonium dihydrogen phosphate, diammonium hydrogen phosphate, monosodium phosphate, disodium phosphate, trisodium phosphate, and phosphite. Sodium salts such as monosodium, disodium phosphite, sodium hypophosphite, monopotassium phosphate, dipotassium phosphate, tripotassium phosphate, monopotassium phosphite, dipotassium phosphite, hypophosphite Potassium salts such as potassium, monolithium phosphate, dilithium phosphate, trilithium phosphate, monolithium phosphate, dilithium phosphate, lithium salts such as lithium hypophosphite, barium dihydrogen phosphate, phosphorus Barium salts such as barium hydrogen phosphate, tribarium phosphate, barium hypophosphite, magnesium monohydrogen phosphate, magnesium hydrogen phosphate, trimagnesium phosphate, magnesium salts such as magnesium hypophosphite, calcium dihydrogen phosphate , Calcium hydrogen phosphate, tricalcium phosphate, calcium salts such as calcium hypophosphite, zinc salts such as zinc phosphate, zinc phosphite, zinc hypophosphite and the like.

The polyphosphate is not particularly limited, and examples thereof include ammonium polyphosphate, piperazine polyphosphate, melamine polyphosphate, ammonium polyphosphate amide, and aluminum polyphosphate.
Among these, monophosphate is preferably used, and ammonium dihydrogen phosphate is more preferable, because the self-extinguishing property of the phosphate-containing flame retardant is improved.
The phosphate-containing flame retardant may be used alone or in combination of two or more.

The blending amount of the phosphate-containing flame retardant is preferably in the range of 1.5 to 52 parts by mass, and more preferably in the range of 1.5 to 20 parts by mass with respect to 100 parts by mass of the urethane resin. , 2.0 to 15 parts by mass, more preferably 2.0 to 10 parts by mass.
When the blending amount of the phosphate-containing flame retardant is 1.5 parts by mass or more, the self-extinguishing property of the urethane foam is maintained, and the fire resistance is easily imparted. Further, when it is 52 parts by mass or less, foaming of the urethane resin composition is not hindered.

(Brominated flame retardant)
The bromine-containing flame retardant is not particularly limited as long as it is a compound containing bromine in its molecular structure, and examples thereof include aromatic brominated compounds.
Specific examples of the aromatic brominated compound include hexabromobenzene, pentabromotoluene, hexabromobiphenyl, decabromobiphenyl, hexabromocyclodecane, decabromodiphenyl ether, octabromodiphenyl ether, hexabromodiphenyl ether, and bis (pentabromo). Examples thereof include monomeric organic bromine compounds such as phenoxy) ethane, ethylene-bis (tetrabromophthalimide), and tetrabromobisphenol A.
Further, a polycarbonate oligomer produced from brominated bisphenol A as a raw material, a brominated polycarbonate such as a copolymer of a polycarbonate oligomer and bisphenol A, a diepoxy compound produced by the reaction of brominated bisphenol A with epichlorohydrin, and a brominated phenol. Brominated epoxy compounds such as monoepoxy compounds obtained by the reaction of varieties with epichlorohydrin, poly (brominated benzyl acrylate), brominated polyphenylene ether, brominated bisphenol A, condensates of cyanur chloride and brominated phenol, brominated ( Examples thereof include brominated polystyrenes such as polystyrene), poly (bromineed styrene) and crosslinked brominated polystyrene, and halogenated bromine compound polymers such as crosslinked or non-bridged brominated poly (-methylstyrene).
From the viewpoint of controlling the calorific value at the initial stage of combustion, brominated polystyrene, hexabromobenzene and the like are preferable, and hexabromobenzene is more preferable.
The bromine-containing flame retardant may be used alone or in combination of two or more.

The blending amount of the bromine-containing flame retardant used in the present invention is preferably in the range of 1.5 to 52 parts by mass, and preferably in the range of 1.5 to 20 parts by mass with respect to 100 parts by mass of the urethane resin. Is more preferable, and it is more preferably in the range of 2.0 to 15 parts by mass, and most preferably in the range of 2.0 to 10 parts by mass.
When the blending amount of the bromine-containing flame retardant is 0.1 parts by mass or more, the self-extinguishing property of the urethane foam is maintained, and the fire resistance is easily imparted. Further, when it is 52 parts by mass or less, foaming of the urethane resin composition is not hindered.

(Boron-containing flame retardant)
Examples of the boron-containing flame retardant include borax, boron oxide, boric acid, borate and the like.
Examples of the boron oxide include diboron trioxide, boron trioxide, diboron dioxide, tetraboron trioxide, tetraboron pentoxide and the like.
Examples of the borate include alkali metals, alkaline earth metals, elements of Groups 4, 12, and 13 of the Periodic Table, and ammonium borates.
Specifically, an alkali metal borate salt such as lithium borate, sodium borate, potassium borate, and cesium borate, an alkaline earth metal salt borate such as magnesium borate, calcium borate, and barium borate, boro Examples thereof include zirconium acid, zinc borate, aluminum borate, and ammonium borate.
The boron-containing flame retardant is preferably borate, more preferably zinc borate.
The boron-containing flame retardant may be used alone or in combination of two or more.

The blending amount of the boron-containing flame retardant is preferably in the range of 1.5 to 52 parts by mass, more preferably in the range of 1.5 to 20 parts by mass, with respect to 100 parts by mass of the urethane resin. It is more preferably in the range of 0 to 15 parts by mass, and most preferably in the range of 2.0 to 10 parts by mass.
When the amount of the boron-containing flame retardant is 1.5 parts by mass or more, the self-extinguishing property of the urethane foam is maintained, and the fire resistance is easily imparted. Further, when it is 52 parts by mass or less, foaming of the urethane resin composition is not hindered.

(Antimony-containing flame retardant)
Examples of the antimony-containing flame retardant used in the present invention include antimony oxide, antimony acid salt, pyroantimony acid salt and the like.
Examples of antimony oxide include antimony trioxide and antimony pentoxide. Examples of the antimonate include sodium antimonate, potassium antimonate and the like. Examples of the pyroantimonate include sodium pyroantimonate, potassium pyroantimonate and the like.
The antimony-containing flame retardant is preferably antimony oxide.
The antimony-containing flame retardant may be used alone or in combination of two or more.

The blending amount of the antimony-containing flame retardant is preferably in the range of 1.5 to 52 parts by mass, more preferably in the range of 1.5 to 20 parts by mass, with respect to 100 parts by mass of the urethane resin. It is more preferably in the range of 0 to 15 parts by mass, and most preferably in the range of 2.0 to 10 parts by mass. When the blending amount of the antimony-containing flame retardant is 1.5 parts by mass or more, the self-extinguishing property of the urethane foam is maintained, and the fire resistance is easily imparted. Further, when it is 52 parts by mass or less, foaming of the urethane resin composition is not hindered.

(Metal hydroxide)
Examples of the metal hydroxide include magnesium hydroxide, calcium hydroxide, aluminum hydroxide, iron hydroxide, nickel hydroxide, zirconium hydroxide, titanium hydroxide, zinc hydroxide, copper hydroxide, vanadium hydroxide, and water. Examples include tin oxide. The metal hydroxide may be used alone or in combination of two or more.

The blending amount of the metal hydroxide is preferably in the range of 1.5 to 52 parts by mass, more preferably in the range of 1.5 to 20 parts by mass, with respect to 100 parts by mass of the urethane resin. It is more preferably in the range of 0 to 15 parts by mass, and most preferably in the range of 2.0 to 10 parts by mass. When the blending amount of the metal hydroxide is 1.5 parts by mass or more, the self-extinguishing property of the urethane foam is maintained, and the fire resistance is easily imparted. Further, when it is 52 parts by mass or less, foaming of the urethane resin composition is not hindered.

Preferred combinations of the flame retardants include, for example, any of the following (a) to (n), and among these, a combination containing at least red phosphorus and a phosphoric acid ester is preferable.
(A) Red phosphorus and phosphate ester
(B) Flame retardant containing red phosphorus and phosphate
(C) Flame retardant containing red phosphorus and bromine
(D) Flame retardant containing red phosphorus and boron
(E) Flame retardant containing red phosphorus and antimony
(F) Red phosphorus and metal hydroxides
(G) Flame retardant containing red phosphorus, phosphate ester and phosphate
(H) Flame retardant containing red phosphorus, phosphoric acid ester and bromine
(I) Flame retardant containing red phosphorus, phosphoric acid ester and boron
(J) Red phosphorus, phosphate-containing flame retardant and bromine-containing flame retardant
(K) Red phosphorus, phosphate-containing flame retardant and boron-containing flame retardant
(L) Red phosphorus, bromine-containing flame retardant and boron-containing flame retardant
(M) Red phosphorus, phosphate ester, phosphate-containing flame retardant and bromine-containing flame retardant
(N) Red phosphorus, phosphate ester, phosphate-containing flame retardant, bromine-containing flame retardant and boron-containing flame retardant

The total amount of the flame retardant to be blended is preferably in the range of 4.5 to 70 parts by mass, more preferably in the range of 4.5 to 40 parts by mass with respect to 100 parts by mass of the urethane resin. It is more preferably in the range of 5 to 30 parts by mass, and most preferably in the range of 4.5 to 20 parts by mass.
When the blending amount of the flame retardant is 4.5 parts by mass or more, it becomes easy to impart nonflammability to the urethane foam. In addition, it is possible to prevent the dense residue formed from the urethane foam from cracking in the event of a fire. When it is 70 parts by mass or less, the foaming of the urethane resin composition is not hindered by the flame retardant.

As described above, the urethane foam of the present invention is formed by curing and foaming the urethane resin composition. The urethane resin composition contains the above-mentioned polyol compound, isocyanate compound and flame retardant, and generally further contains a catalyst, a foaming agent, and a foam stabilizer.

(catalyst)
The urethane resin composition may contain, for example, a resinification catalyst, a trimerization catalyst, or both of them as a catalyst, but it is preferable to contain both of them. The resinification catalyst is a catalyst that promotes the reaction between the polyol compound and the polyisocyanate.

Examples of the resinification catalyst include triethylamine, N-methylmorpholine bis (2-dimethylaminoethyl) ether, N, N, N', N ", N" -pentamethyldiethylenetriamine, N, N, N'-trimethylamino. Contains nitrogen atoms such as ethyl-ethanolamine, bis (2-dimethylaminoethyl) ether, N-methyl, N'-dimethylaminoethyl piperazine, and imidazole compounds in which the secondary amine functional group in the imidazole ring is replaced with a cyanoethyl group. Examples include catalysts.
The blending amount of the resinification catalyst is preferably in the range of 0.02 to 5 parts by mass, more preferably in the range of 0.04 to 3 parts by mass, and 0. It is more preferably in the range of 04 to 2 parts by mass, and most preferably in the range of 0.06 to 1 part by mass.
When the amount is 0.02 parts by mass or more, the formation of urethane bonds is promoted and the curability becomes good. Further, when the content is 5 parts by mass or less, an appropriate foaming rate can be maintained and it is easy to handle.

The trimerization catalyst is a catalyst that promotes the formation of an isocyanurate ring by reacting an isocyanate group contained in a polyisocyanate compound to trimerize it. By using a trimerization catalyst, it becomes easy to improve nonflammability.
As the trimerization catalyst, nitrogen-containing aromatic compounds such as tris (dimethylaminomethyl) phenol, 2,4-bis (dimethylaminomethyl) phenol, and 2,4,6-tris (dialkylaminoalkyl) hexahydro-S-triazine. , Carboxylic acid alkali metal salts such as potassium acetate, potassium 2-ethylhexanoate, potassium octylate, tertiary ammonium salts such as trimethylammonium salt, triethylammonium salt, triphenylammonium salt, tetramethylammonium salt, tetraethylammonium, tetra A quaternary ammonium salt such as a phenylammonium salt can be used.

The blending amount of the trimerization catalyst is preferably in the range of 0.6 to 10 parts by mass, more preferably in the range of 0.6 to 8 parts by mass, and 0. It is more preferably in the range of 6 to 6 parts by mass, and most preferably in the range of 0.6 to 3.0 parts by mass.
When it is 0.6 parts by mass or more, there is no problem that the triglyceride of isocyanate is hindered, and when it is 10 parts by mass or less, an appropriate foaming rate can be maintained and it is easy to handle.

(Effervescent agent)
The foaming agent contained in the urethane resin composition promotes the foaming of the urethane resin. Specific examples of the foaming agent include, for example, low boiling hydrocarbons such as water, propane, butane, pentane, hexane, heptane, cyclopropane, cyclobutane, cyclopentane, cyclohexane, cycloheptane, dichloroethane, propyl chloride, isopropyl chloride, and the like. Chlorinated aliphatic hydrocarbon compounds such as butyl chloride, isobutyl chloride, pentyl chloride and isopentyl chloride, fluorine compounds such as trichloromonofluoromethane and trichlorotrifluoroethane, and hydro such as _{CHF 3} , CH ₂ F ₂ and CH _{3 F.} Fluorocarbon, dichloromonofluoroethane, (eg, HCFC141b (1,1-dichloro-1-fluoroethane), HCFC22 (chlorodifluoromethane), HCFC142b (1-chloro-1,1-difluoroethane)), HFC-245fa (1). , 1,1,3,3-pentafluoropropane), hydrochlorofluorocarbon compounds such as HFC-365mfc (1,1,1,3,3-pentafluorobutane), ether compounds such as diisopropyl ether, or compounds thereof. Examples thereof include organic physical foaming agents such as a mixture of the above, inorganic physical foaming agents such as nitrogen gas, oxygen gas, argon gas, and carbon dioxide gas.

The blending amount of the foaming agent used in the urethane resin composition is preferably in the range of 0.1 to 30 parts by mass with respect to 100 parts by mass of the urethane resin. The foaming agent is more preferably in the range of 0.1 to 18 parts by mass and further preferably in the range of 0.5 to 18 parts by mass with respect to 100 parts by mass of the urethane resin. Most preferably, it is in the range of parts by mass.
When the content of the foaming agent is 0.1 part by mass or more, foaming is promoted and the density of the obtained urethane foam can be reduced. When it is 30 parts by mass or less, it is possible to prevent the foam from breaking and the foam from being formed.

(Defoamer)
The defoaming agent contained in the urethane resin composition improves the foamability of the urethane resin composition.
Examples of the defoaming agent include a polyoxyalkylene-based defoaming agent such as polyoxyalkylene alkyl ether and a surfactant such as a silicone-based defoaming agent such as organopolysiloxane.
The blending amount of the foam stabilizer with respect to the urethane resin is preferably in the range of 0.1 to 10 parts by mass with respect to 100 parts by mass of the urethane resin, for example.
The resinification catalyst, the quantification catalyst, the foaming agent and the defoaming agent may be used alone or in combination of two or more.

The urethane resin composition may further contain an inorganic filler. The inorganic filler is not particularly limited, but for example, silica, diatomaceous earth, alumina, titanium oxide, calcium oxide, magnesium oxide, iron oxide, tin oxide, antimony oxide, ferrites, basic magnesium carbonate, calcium carbonate, magnesium carbonate. , Zinc carbonate, barium carbonate, dosonite, hydrotalcite, calcium sulfate, barium sulfate, gypsum fiber, potassium salts such as calcium silicate, talc, clay, mica, montmorillonite, bentonite, active white clay, sebiolite, imogolite, sericite, Glass fiber, glass beads, silica balun, aluminum nitride, boron nitride, silicon nitride, carbon black, graphite, carbon fiber, carbon balun, charcoal powder, various metal powders, potassium titanate, magnesium sulfate, lead zirconate titanate, aluminum borate , Molybdenum sulfide, silicon carbide, stainless steel fiber, various magnetic powders, slag fiber, fly ash, silica-alumina fiber, alumina fiber, silica fiber, zirconia fiber and the like.
The inorganic filler may be used alone or in combination of two or more.

Further, the urethane resin composition is a phenol-based, amine-based, sulfur-based or other antioxidant, heat stabilizer, metal damage inhibitor, antistatic agent, and stable, as required, as long as the object of the present invention is not impaired. Additives such as agents, cross-linking agents, lubricants, softeners, pigments and tackifier resins, and tackifiers such as polybutene and petroleum resins can be included.

The density of the urethane foam is not particularly limited, but is preferably in the range of ^{0.030 to 0.130 g / cm 3.} By setting the density to 0.130 g / cm ³ or less, the urethane foam becomes lightweight, and it becomes easy to lay a flat deck filled with urethane foam inside. Further, when it is 0.030 g / cm ³ or more, it becomes easy to develop the desired nonflammability. From these viewpoints, the density of urethane foam, more preferably in the range of 0.040~0.100g / cm ^3, more preferably in a range of 0.040~0.080g / cm ^3, 0. Most preferably, it is in the range of 050 to 0.060 g / cm ^3.

Since the urethane resin composition reacts and cures, it is preferable to divide the urethane resin composition into two liquids before molding the urethane foam. Specifically, it may be divided into a polyol liquid containing a polyol compound and an isocyanate liquid containing a polyisocyanate compound. At this time, the components other than the polyol compound and the polyisocyanate compound may be appropriately added to the polyol solution or the isocyanate solution, but are preferably added to the polyol solution. This is because the polyol compound has low reactivity, and even if it is mixed with a component other than the polyol compound and the polyisocyanate compound, a side reaction is unlikely to occur.

The urethane resin composition can be made into urethane foam by injecting it into the reinforcing rib and curing and foaming it inside the reinforcing rib. The method of injecting the urethane resin composition into the reinforcing rib is not particularly limited, but the polyol liquid and the isocyanate liquid are mixed before being poured into the reinforcing rib to obtain a mixture, and the mixture is put into the reinforcing rib. The polyol solution and the isocyanate solution may be injected separately into the reinforcing ribs and mixed inside the reinforcing ribs.
Specifically, although not particularly limited, the isocyanate liquid and the polyol liquid are separately housed in two containers, mixed with a caulking gun or the like, and the mixture is discharged from the caulking gun to the inside of the reinforcing rib. It is good to inject into.
When each component is mixed, the urethane resin composition starts a reaction, its viscosity increases with the passage of time, curing and foaming proceed, and it loses its fluidity to become a polyurethane foam. The urethane resin composition is usually cured and foamed by being left at around room temperature (for example, about 10 to 40 ° C.), but may be heated or the like if necessary.

Hereinafter, the present invention will be described in more detail with reference to Examples, but the present invention is not limited to these Examples.

[Fire resistance]
The fire resistance of urethane foam was evaluated by the following method. Urethane foam was cut into 10 cm in length, 10 cm in width and 5 cm in thickness to prepare a sample for a cone calorimeter test. Using the cone calorimeter test sample, measure the total calorific value after 20 minutes by the cone calorimeter test when heated for 20 minutes at ^{a radiant heat intensity of 50 kW / m 2} in accordance with the ISO-5660 test method. And evaluated the fire resistance.
[Curability]
The curability when forming urethane foam from the urethane resin composition was evaluated according to the following evaluation criteria.
A: Within 5 minutes after the urethane resin composition was prepared, curing and foaming proceeded sufficiently, and urethane foam could be formed.
B: Even after 5 minutes had passed since the urethane resin composition was prepared, curing and foaming did not proceed sufficiently, and urethane foam could not be formed.

The components used in Examples and Comparative Examples were as follows.
Polyol compound: p-Polyester phthalate polyol (manufactured by Kawasaki Kasei Chemicals, product name: Maximol RFK-505, hydroxyl value = 250 mgKOH / g)
Flame Retardant 1: Red Phosphorus (manufactured by Phosphorus Chemical Industry Co., Ltd., product name: Nova Excel 140)
Flame Retardant 2: Tris (β-chloropropyl) phosphate (manufactured by Daihachi Chemical Co., Ltd., product name: TMCPP)
Resinification catalyst: N, N, N', N ", N" -pentamethyldiethylenetriamine (manufactured by Tosoh Corporation, product name: TOYOCAT-DT)
Triquantization catalyst 1: 2-potassium ethylhexanoate (manufactured by Tokyo Chemical Industry Co., Ltd., product code: P0048)
Trimerization catalyst 2: Trimerization catalyst (manufactured by Tosoh Corporation, product name: TOYOCAT-TR20)
Foaming Agent 1: Water Foaming Agent 2 (HFC): HFC-365mfc (1,1,1,3,3-pentafluorobutane, manufactured by Central Glass Co., Ltd.) and HFC-245fa (1,1,1,3,3-). Pentafluoropropane (manufactured by Nippon Solvay), mixing ratio: HFC-365mfc / HFC-245fa = 7/3 (mass ratio)
Defoaming agent: Polyoxyalkylene-based defoaming agent (manufactured by Toray Dow Corning, product name: SH-193)
Polyisocyanate compound: MDI (manufactured by Nippon Urethane Industry Co., Ltd., product name: Millionate MR-200)

[Example 1]
According to the formulation shown in Table 1, a resinification catalyst, a quantification catalyst, a foaming agent, and a foam stabilizer were added to the polyol compound and stirred to obtain a mixture. The mixture and the flame retardant were weighed in a 1000 mL polypropylene beaker and stirred by hand at 25 ° C. for 1 minute to obtain a polyol solution. An isocyanate liquid consisting of a polyisocyanate compound was added to the polyol liquid, and the mixture was stirred with a hand mixer for about 10 seconds to obtain a urethane resin composition. The obtained urethane resin composition lost its fluidity with the passage of time and became urethane foam. The obtained urethane foam was evaluated for fire resistance and curability.

[Comparative Example 1]
A urethane foam was produced in the same manner as in Example 1 except that a flame retardant was not added, and the fire resistance and curability were evaluated.

As is clear from the results of Example 1, the urethane foam containing the flame retardant had a lower total calorific value and was nonflammable as compared with the comparative example containing no flame retardant. Therefore, by filling the inside of the reinforcing rib with the urethane foam of Example 1, it is possible to obtain a partition structure having good fire resistance, heat insulation, and sound insulation. Further, since the urethane foam of Example 1 has good curability, it can be produced in a short time after injecting the urethane resin composition into the reinforcing ribs.

10 Section structure 11 Flat deck 11D Bottom surface (one side)
11U top surface (the other surface)
12 Reinforcing ribs 13 Injection port 14 Support material 20 Section material 21 Gypsum board 21U Top surface 22 Notch 23 Gap 25 Wall 26 Support frame 27 Gap filling material 30 Urethane foam

Claims (8)

A flat deck having a plurality of reinforcing ribs protruding from one surface and having a cavity inside, a partition material abutted against the one surface of the flat deck, and a flame retardant filled inside the reinforcing ribs. e Bei a urethane foam containing the flame retardant containing red phosphorus, partition structure. According to claim 1, when the urethane foam is ^{heated at a radiant heat intensity of 50 kW / m 2 in} accordance with the ISO-5660 test method, the total calorific value after 20 minutes is 8 MJ / m ² or less. Described compartment structure. Claimed that the flame retardant further comprises at least one selected from the group consisting of a phosphate ester, a phosphate-containing flame retardant, a bromine-containing flame retardant, a boron-containing flame retardant, an antimony-containing flame retardant and a metal hydroxide. The partition structure according to 1 or 2. The section structure according to any one of claims 1 to 3, wherein the section material is any one of gypsum board, extruded cement board, lightweight aerated concrete, precast concrete board, and glass fiber reinforced concrete board. A claim in which the end face of the partition material is abutted against one surface of the flat deck so that a plurality of notches are provided on the end surface of the partition material and each reinforcing rib is arranged inside each of the notches. Item 6. The section structure according to any one of Items 1 to 4. The partition structure according to claim 5, wherein the gap between the reinforcing rib and the notch is closed by the gap filling material. The section structure according to claim 6, wherein the gap filling material is selected from rock wool and glass wool. A process of laying a flat deck projecting on one surface, having a plurality of reinforcing ribs having cavities inside, and filling the inside of the reinforcing ribs with urethane foam containing a flame retardant, in a building structure. When,
A method for constructing a compartment structure, comprising a step of abutting a partition material on one surface of the flat deck provided with the reinforcing ribs , wherein the flame retardant contains red phosphorus.

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