JP7699840B2 - Fire-retardant woven fabric wall base material and construction method for fire-retardant woven fabric wall - Google Patents

Description

Application of Article 30, Paragraph 2 of the Patent Act Nikkei Architectural Journal, published by Nikkei Business Publications, Inc. on November 24, 2022, page 37 contains an article entitled "Fiber walls that can reuse denim scraps."

The present invention relates to a flame-retardant woven fabric wall base material and a method for constructing a flame-retardant woven fabric wall. In particular, the present invention relates to a flame-retardant woven fabric wall base material and a method for constructing a flame-retardant woven fabric wall that uses, for example, scraps of denim woven fabric as a raw material and that can impart fire resistance such as non-combustibility or semi-non-combustibility that is higher than flame retardancy.

As an example of wallpaper made from denim, Patent Document 1 describes denim wallpaper made of denim fabric woven primarily with indigo-dyed cotton threads and lined with paper or nonwoven fabric on the reverse side.

Japanese Patent Application Publication No. 11-350397

The denim wallpaper described in Patent Document 1 does not have fire retardant properties because fire prevention performance is not taken into consideration.
Therefore, an object of the present invention is to provide a flame-retardant woven fabric wall base material and a construction method for a flame-retardant woven fabric wall that has flame retardancy and is made from raw materials such as denim woven fabric scraps.

The means for solving the problems of the present invention are as follows:

First,
35 to 75 parts by weight, preferably 45 to 65 parts by weight, more preferably 50 to 60 parts by weight of fiber scraps;
5 to 25 parts by weight, preferably 10 to 20 parts by weight, more preferably 12 to 17 parts by weight, of a thickener;
and 10 to 40 parts by weight, preferably 15 to 35 parts by weight, more preferably 20 to 30 parts by weight of a mineral-derived inorganic material.

Secondly,
35 to 75 parts by weight, preferably 45 to 65 parts by weight, more preferably 50 to 60 parts by weight of fiber scraps;
5 to 25 parts by weight, preferably 10 to 20 parts by weight, more preferably 12 to 17 parts by weight, of a thickener;
10 to 40 parts by weight, preferably 15 to 35 parts by weight, more preferably 20 to 30 parts by weight of inorganic material of mineral origin;
1.7 to 5.7 parts by weight, preferably 2.7 to 4.7 parts by weight, more preferably 3.3 to 4.2 parts by weight of a pigment;
The flame retardant woven wall substrate is characterized in that the ratio of the black component to the blue component of the pigment is 1:2 to 1:4, preferably 1:2.5 to 1:3.5, and more preferably 1:2.7 to 1:3.3.

Third,
35 to 75 parts by weight, preferably 45 to 65 parts by weight, more preferably 50 to 60 parts by weight of fiber scraps;
5 to 25 parts by weight, preferably 10 to 20 parts by weight, more preferably 12 to 17 parts by weight, of a thickener;
10 to 40 parts by weight, preferably 15 to 35 parts by weight, more preferably 20 to 30 parts by weight of inorganic material of mineral origin;
1.7 to 5.7 parts by weight, preferably 2.7 to 4.7 parts by weight, more preferably 3.3 to 4.2 parts by weight of a pigment;
The thickener is a mixture of a high-viscosity thickener having a viscosity of 600 to 800 (mPa·s 1%, 25°C) and a low-viscosity thickener having a viscosity of 10 to 200 (mPa·s 1%, 25°C), and the ratio of the high-viscosity thickener to the low-viscosity thickener is 1:0.55-0.80, preferably 1:0.60-0.75, and more preferably 1:0.65-0.70.

Fourth,
35 to 75 parts by weight, preferably 45 to 65 parts by weight, more preferably 50 to 60 parts by weight of fiber scraps;
5 to 25 parts by weight, preferably 10 to 20 parts by weight, more preferably 12 to 17 parts by weight, of a thickener;
10 to 40 parts by weight, preferably 15 to 35 parts by weight, more preferably 20 to 30 parts by weight of inorganic material of mineral origin;
1.7 to 5.7 parts by weight, preferably 2.7 to 4.7 parts by weight, more preferably 3.3 to 4.2 parts by weight of a pigment;
the thickener is a mixture of a high-viscosity thickener having a viscosity of 600 to 800 (mPa·s 1%, 25°C) and a low-viscosity thickener having a viscosity of 10 to 200 (mPa·s 1%, 25°C), the ratio of the high-viscosity thickener to the low-viscosity thickener being 1:0.55-0.80, preferably 1:0.60-0.75, more preferably 1:0.65-0.70;
The flame retardant woven wall substrate is characterized in that the ratio of the black component to the blue component of the pigment is 1:2 to 1:4, preferably 1:2.5 to 1:3.5, and more preferably 1:2.7 to 1:3.3.

Fifth,
The flame-retardant woven fabric wall substrate according to any one of claims 1 to 4, further comprising 0.1 to 0.5 parts by weight, preferably 0.2 to 0.4 parts by weight, of a mildew-proofing material.

Sixth,
A method for constructing a fire-retardant woven fabric wall using the fire-retardant woven fabric wall base material according to any one of claims 1 to 5,
After preparing the surface of the target wall with a base treatment agent containing powdered resin,
The method for constructing a fire-retardant woven fabric wall using a fire-retardant woven fabric wall base material comprises adding water to the fire-retardant woven fabric wall base material, kneading the mixture, and applying the mixture.

Here, the textile scraps are fibers used for clothing that have been cut into small pieces.
For example, denim scraps cut into pieces having a length of 4 to 12 mm, preferably 6 to 10 mm, and more preferably 7 to 9 mm can be used.

By using black and blue as pigments, with the ratio of black components to blue components in the range of 1:2 to 1:4, preferably 1:2.5 to 1:3.5, and more preferably 1:2.7 to 1:3.3, even if there is some variation in the shade of the raw denim fiber, particularly when denim is used as the fiber scraps, it is possible to reduce the difference, and to achieve a finished color that has a nearly uniform shade of color and the uneven color characteristic of denim without significantly compromising the original color and texture of the denim fiber.

The thickener functions as a "glue" and can be carboxymethylcellulose, which is an anionic water-soluble polymer obtained from natural cellulose as a raw material.
As the thickener, a mixture of a high-viscosity thickener with a viscosity of 600 to 800 (mPa·s 1%, 25°C) and a low-viscosity thickener with a viscosity of 10 to 200 (mPa·s 1%, 25°C) is used in a ratio of the high-viscosity thickener to the low-viscosity thickener in the range of 1:0.55 to 0.80, preferably 1:0.60 to 0.75, and more preferably 1:0.65 to 0.70, whereby it is possible to improve only the water retention without increasing the viscosity, resulting in good workability and a relatively soft film after drying, and in particular when denim is used as the fiber scrap, it is possible to achieve a finished surface that does not impair the texture of the denim fiber.
Here, application is possible even when only a high-viscosity thickener with a viscosity of 600 to 800 (mPa·s 1%, 25°C) is used; however, it is necessary to mix in an amount sufficient to impart water retention to the extent that the mixing water does not drip. This results in a significantly increased viscosity after mixing, which makes the product less easy to work with and also makes the finished surface after drying quite hard.

As the mineral-derived inorganic material, mica having a mesh size of 100 to 300 mesh, preferably 150 to 250 mesh, and more preferably 180 to 220 mesh can be used.
Here, particularly when denim is used as the fiber scraps, the use of mica makes it possible to obtain a specific gravity as close as possible to that of denim fiber without impairing the texture of denim fiber.
Specifically, it has been confirmed that, particularly when denim is used as the fiber scrap, mica having a mesh size of 100 to 300, preferably 150 to 250, and more preferably 180 to 220, is suitable as a mineral-derived inorganic material that is light, fine, and has an inconspicuous color.

Antifungal materials that contain organic nitrogen and available sulfur as active ingredients can be used.

The present invention can achieve the following effects:

It is a mixture of fiber scraps, thickeners, and mineral-derived inorganic materials in a specific ratio, making it effective as a base material for flame-retardant wall materials.

In particular, when denim is used as the fiber scraps, by using black and blue pigments in specific ranges, even if there is some variation in the shade of the raw denim fiber, the difference can be reduced, and the original color and texture of the denim fiber is not significantly damaged, and it is possible to achieve a finished color with almost uniform color shade and the color unevenness that is characteristic of denim.
In addition, by using a specific range of mica, the texture of the denim fiber can be maintained.
In addition, by using a mixture of a high viscosity thickener and a low viscosity thickener in a specific ratio range as the thickener, it is possible to achieve a finish with good workability, a relatively soft film after drying, and a texture that does not impair the denim fiber texture.

FIG. 2 is an illustration of a fire-retardant woven fabric wall substrate according to Example 1 of the present invention.

Hereinafter, an embodiment of the present invention will be described.
It should be noted that the description given here is merely one embodiment of the present invention, and the present invention is not limited to this embodiment.

As shown in the explanatory diagram of Figure 1, the flame-retardant woven fabric wall base material of this Example 1 is composed of fiber scraps 1, thickener 2, mineral-derived inorganic material 3, mold inhibitor 4, and pigment 5.

The fiber scraps 1 are denim fibers obtained by cutting denim fabric scraps into pieces of about 8 mm.
As the thickener 2, a mixture of Nippon Paper Group's CMC Sunrose (registered trademark) with raw material part numbers SN-60C and SLD-F1 is used.
As the mineral-derived inorganic material 3, mica of 200 mesh is used.
As the antifungal material 4, Biocide (registered trademark) manufactured by Taisho Technos Co., Ltd., raw material part number R-ZPT is used.
The pigment 5 used is a mixture of blue and black.

The mix is 120.00 kg (55.2%) denim fiber, 19.60 kg (9.0%) SN-60C, 13.23 kg (6.1%) SLD-F1, 56.00 kg (25.7%) mica, 0.70 kg (0.3%) R-ZPT, 6.00 kg (2.8%) blue pigment, and 2.00 kg (0.9%) black pigment.

Next, we will explain how to construct a fire-retardant woven fabric wall using the above-mentioned fire-retardant woven fabric wall base material.

For smooth walls such as plasterboard, Shinko Co., Ltd.'s Kote Guard (product name), a one-material type containing powdered resin, is applied as a base treatment.
When applying Trowel Guard, the standard amount of water to be mixed is 4 to 4.5 liters per bag (5.5 kg) of Trowel Guard. However, gradually add less water than the standard amount while mixing thoroughly, then add the remaining water to adjust the mixture until it is easy to apply.
After mixing, leave it for about 30 minutes before painting, and the base preparation is complete.

By carrying out the above-mentioned base preparation using the trowel guard, the workability of the flame-retardant woven fabric wall base material of this embodiment is extremely good even when the base material is applied to a smooth wall such as a plasterboard.
In other words, if the product is applied to a smooth wall such as plasterboard without first preparing the base with a trowel guard, the denim fibers will slip because there is no base to catch on, resulting in transparency on the applied surface and uneven fiber distribution, making application extremely difficult.

5 liters of water is added to 700 g of the blended flame-retardant woven fabric wall base material, kneaded, and applied with a trowel to a wall surface that has been primed, completing the application process.
Wall surfaces installed with this flame-retardant woven fabric wall base material are flame-retardant while retaining the feel of denim, and have obtained flame-retardant certification RM-9364, non-combustible certification NM-8575, and semi-non-combustible certification QM-9815.

The wall surface made of denim scraps and coated with the flame-retardant woven fabric wall base material of this embodiment can be easily repaired even if it gets scratched or has a hole, because it becomes soft by spraying water on it.
Furthermore, when it is time to remove it, it can be easily removed by spraying water on it.
Furthermore, the removed flame-retardant woven fabric wall base material can be reused by adding water and kneading it, and can function as a recyclable plastering material.

1. Fiber scraps 2. Thickeners 3. Mineral-derived inorganic materials 4. Mildew-proofing materials 5. Pigments

Claims (3)

35 to 75 parts by weight of denim fibers cut into 7 to 9 mm pieces ;
5 to 25 parts by weight of a thickener;
10 to 40 parts by weight of mineral-derived inorganic material;
and 1.7 to 5.7 parts by weight of a pigment,
the thickener is a mixture of a high-viscosity thickener having a viscosity of 600 to 800 (mPa·s 1%, 25°C) and a low-viscosity thickener having a viscosity of 10 to 200 (mPa·s 1%, 25°C), the ratio of the high-viscosity thickener to the low-viscosity thickener being 1:0.55 to 0.80;
The flame retardant woven wall substrate is characterized in that the ratio of the black component to the blue component of the pigment is 1:2 to 1:4. The flame-retardant woven fabric wall substrate according to claim 1, characterized in that the mineral-derived inorganic material is 180-220 mesh mica. A method for constructing a fire-retardant woven fabric wall using the fire-retardant woven fabric wall base material according to claim 1 or 2 ,
After preparing the surface of the target wall with a base treatment agent containing powdered resin,
The method for constructing a fire-retardant woven fabric wall using a fire-retardant woven fabric wall base material comprises adding water to the fire-retardant woven fabric wall base material, kneading the mixture, and applying the mixture.