Fire-resistant sheetlike molding, fire-resistant laminate for covering steel, fire-resistant structure for wall, and method for constructing fire-resistant steel and fire-resistant wall

A fire-resistant sheet molded article comprising a resin composition and showing the total endothermic value, when raising the temperature from room temperature to 600° C. at a rate of 10° C./min. by DSC, of not less than 100 J/g,

• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound, neutralized, thermally expandable graphite and an inorganic filler, the total content of said phosphorus compound and neutralized, thermally expandable graphite being 20 to 300 parts by weight and the content of said inorganic filler being 50 to 500 parts by weight, per 100 parts by weight of said thermoplastic resin, the weight ratio of said neutralized, thermally expandable graphite to said phosphorus compound (neutralized, thermally expandable graphite/phosphorus compound) being 0.01 to 9;
• or
• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound, a hydroxyl-containing hydrocarbon compound and an inorganic filler, the total content of said phosphorus compound, hydroxyl-containing hydrocarbon compound and inorganic filler being 50 to 900 parts by weight per 100 parts by weight of said thermoplastic resin, the weight ratio of said hydroxyl-containing hydrocarbon compound to said phosphorus compound (hydroxyl-containing hydrocarbon compound/phosphorus compound) being 0.4 to 5 and the weight ratio of said inorganic filler to said phosphorus compound (inorganic filler/phosphorus compound) being 0.5 to 7;
• or
• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound, neutralized, thermally expandable graphite, a hydroxyl-containing hydrocarbon compound and an inorganic filler, the total content of said phosphorus compound, neutralized, thermally expandable graphite, hydroxyl-containing hydrocarbon compound and inorganic filler being 50 to 900 parts by weight per 100 parts by weight of said thermoplastic resin, the weight ratio of said neutralized, thermally expandable graphite to said phosphorus compound (neutralized, thermally expandable graphite/phosphorus compound) being 0.01 to 9 and the weight ratio of said hydroxyl-containing hydrocarbon compound to said phosphorus compound (hydroxyl-containing hydrocarbon compound/phosphorus compound) being 0.05 to 20;
• or
• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound and a metal carbonate, the total content of said phosphorus compound and metal carbonate being 50 to 900 parts by weight per 100 parts by weight of said thermoplastic resin, the weight ratio between said metal carbonate and phosphorus compound (metal carbonate:phosphorus compound) being 6:4 to 4:6;
• or
• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound and a metal carbonate and, further comprises a hydrated inorganic compound and/or a calcium salt(calcium sulfate, gypsum or calcium diphosphate), the total content of said phosphorus compound, metal carbonate and hydrated inorganic compound and/or calcium salt(calcium sulfate, gypsum or calcium diphosphate) being 50 to 900 parts by weight per 100 parts by weight of said thermoplastic resin, the total content of said hydrated inorganic compound and/or calcium salt(calcium sulfate, gypsum or calcium diphosphate) being 1 to 70 parts per 100 parts by weight of said metal carbonate, the weight ratio of the sum of said metal carbonate and hydrated inorganic compound and/or calcium salt(calcium sulfate, gypsum or calcium diphosphate) to said phosphorus compound (the sum of metal carbonate and hydrated inorganic compound and/or calcium salt(calcium sulfate, gypsum or calcium diphosphate):phosphorus compound) being 6:4 to 4:6;
• or
• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound, neutralized, thermally expandable graphite, hydrated inorganic compound and a metal carbonate, the total content of said phosphorus compound and neutralized, thermally expandable graphite being 20 to 300 parts by weight, the content of said metal carbonate being 10 to 500 parts by weight and the content of said hydrated inorganic compound being 10 to 500 parts by weight, per 100 parts by weight of said thermoplastic resin, the weight ratio of said neutralized, thermally expandable graphite to said phosphorus compound (neutralized, thermally expandable graphite/phosphorus compound) being 0.01 to 9.

A fire-resistant sheet molded article comprising a resin composition and having an initial thickness of 0.5 to 20 mm and tackiness enough to support itself under a load of 15 to 40 N/m of width at not more than 180° C. for 30 minutes or longer,

• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound, neutralized, thermally expandable graphite and an inorganic filler, the total content of said phosphorus compound and neutralized, thermally expandable graphite being 20 to 300 parts by weight and the content of said inorganic filler being 50 to 500 parts by weight, per 100 parts by weight of said thermoplastic resin, the weight ratio of said neutralized, thermally expandable graphite to said phosphorus compound (neutralized, thermally expandable graphite/phosphorus compound) being 0.01 to 9;
• or
• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound, a hydroxyl-containing hydrocarbon compound and an inorganic filler, the total content of said phosphorus compound, hydroxyl-containing hydrocarbon compound and inorganic filler being 50 to 900 parts by weight per 100 parts by weight of said thermoplastic resin, the weight ratio of said hydroxyl-containing hydrocarbon compound to said phosphorus compound (hydroxyl-containing hydrocarbon compound/phosphorus compound) being 0.4 to 5 and the weight ratio of said inorganic filler to said phosphorus compound (inorganic filler/phosphorus compound) being 0.5 to 7;
• or
• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound, neutralized, thermally expandable graphite, a hydroxyl-containing hydrocarbon compound and an inorganic filler, the total content of said phosphorus compound, neutralized, thermally expandable graphite, hydroxyl-containing hydrocarbon compound and inorganic filler being 50 to 900 parts by weight per 100 parts by weight of said thermoplastic resin, the weight ratio of said neutralized, thermally expandable graphite to said phosphorus compound (neutralized, thermally expandable graphite/phosphorus compound) being 0.01 to 9 and the weight ratio of said hydroxyl-containing hydrocarbon compound to said phosphorus compound (hydroxyl-containing hydrocarbon compound/phosphorus compound) being 0.05 to 20;
• or
• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound and a metal carbonate, the total content of said phosphorus compound and metal carbonate being 50 to 900 parts by weight per 100 parts by weight of said thermoplastic resin, the weight ratio between said metal carbonate and phosphorus compound (metal carbonate:phosphorus compound) being 6:4 to 4:6;
• or
• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound and a metal carbonate and, further comprises a hydrated inorganic compound and/or a calcium salt(calcium sulfate, gypsum or calcium diphosphate), the total content of said phosphorus compound, metal carbonate and hydrated inorganic compound and/or calcium salt(calcium sulfate, gypsum or calcium diphosphate) being 50 to 900 parts by weight per 100 parts by weight of said thermoplastic resin, the total content of said hydrated inorganic compound and/or calcium salt(calcium sulfate, gypsum or calcium diphosphate) being 1 to 70 parts per 100 parts by weight of said metal carbonate, the weight ratio of the sum of said metal carbonate and hydrated inorganic compound and/or calcium salt(calcium sulfate, gypsum or calcium diphosphate) to said phosphorus compound (the sum of metal carbonate and hydrated inorganic compound and/or calcium salt(calcium sulfate, gypsum or calcium diphosphate):phosphorus compound) being 6:4 to 4:6;
• or
• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound, neutralized, thermally expandable graphite, hydrated inorganic compound and a metal carbonate, the total content of said phosphorus compound and neutralized, thermally expandable graphite being 20 to 300 parts by weight, the content of said metal carbonate being 10 to 500 parts by weight and the content of said hydrated inorganic compound being 10 to 500 parts by weight, per 100 parts by weight of said thermoplastic resin, the weight ratio of said neutralized, thermally expandable graphite to said phosphorus compound (neutralized, thermally expandable graphite/phosphorus compound) being 0.01 to 9.

A fire-resistant sheet molded article comprising a resin composition and having the relationship between the initial thickness t (mm)(t is 1 to 10 mm) and the temperature difference ΔT (° C.) between one side and the reverse side after heating of said one side at 500° C. for 1 hour as represented by:

• ΔT≧0.015t4−0.298t31.566t2+30.151t, and
• having said initial bulk density at 25° C. of 0.8 to 2.0 g/cm3 and the bulk density after 1 hour of heating at 500° C. of 0.05 to 0.5 g/cm3,
• wherein said resin composition has tackiness enough to support itself under a load of 15 to 40 N/m of width at not more than 180° C. for 30 minutes or longer, and
• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound, neutralized, thermally expandable graphite and an inorganic filler, the total content of said phosphorus compound and neutralized, thermally expandable graphite being 20 to 300 parts by weight and the content of said inorganic filler being 50 to 500 parts by weight, per 100 parts by weight of said thermoplastic resin, the weight ratio of said neutralized, thermally expandable graphite to said phosphorus compound (neutralized, thermally expandable graphite/phosphorus compound) being 0.01 to 9;
• or
• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound, a hydroxyl-containing hydrocarbon compound and an inorganic filler, the total content of said phosphorus compound, hydroxyl-containing hydrocarbon compound and inorganic filler being 50 to 900 parts by weight per 100 parts by weight of said thermoplastic resin, the weight ratio of said hydroxyl-containing hydrocarbon compound to said phosphorus compound (hydroxyl-containing hydrocarbon compound/phosphorus compound) being 0.4 to 5 and the weight ratio of said inorganic filler to said phosphorus compound (inorganic filler/phosphorus compound) being 0.5 to 7;
• or
• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound, neutralized, thermally expandable graphite, a hydroxyl-containing hydrocarbon compound and an inorganic filler, the total content of said phosphorus compound, neutralized, thermally expandable graphite, hydroxyl-containing hydrocarbon compound and inorganic filler being 50 to 900 parts by weight per 100 parts by weight of said thermoplastic resin, the weight ratio of said neutralized, thermally expandable graphite to said phosphorus compound (neutralized, thermally expandable graphite/phosphorus compound) being 0.01 to 9 and the weight ratio of said hydroxyl-containing hydrocarbon compound to said phosphorus compound (hydroxyl-containing hydrocarbon compound/phosphorus compound) being 0.05 to 20;
• or
• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound and a metal carbonate, the total content of said phosphorus compound and metal carbonate being 50 to 900 parts by weight per 100 parts by weight of said thermoplastic resin, the weight ratio between said metal carbonate and phosphorus compound (metal carbonate:phosphorus compound) being 6:4 to 4:6;
• or
• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound and a metal carbonate and, further comprises a hydrated inorganic compound and/or a calcium salt(calcium sulfate, gypsum or calcium diphosphate), the total content of said phosphorus compound, metal carbonate and hydrated inorganic compound and/or calcium salt(calcium sulfate, gypsum or calcium diphosphate) being 50 to 900 parts by weight per 100 parts by weight of said thermoplastic resin, the total content of said hydrated inorganic compound and/or calcium salt(calcium sulfate, gypsum or calcium diphosphate) being 1 to 70 parts per 100 parts by weight of said metal carbonate, the weight ratio of the sum of said metal carbonate and hydrated inorganic compound and/or calcium salt(calcium sulfate, gypsum or calcium diphosphate) to said phosphorus compound (the sum of metal carbonate and hydrated inorganic compound and/or calcium salt(calcium sulfate, gypsum or calcium diphosphate):phosphorus compound) being 6:4 to 4:6 or,
• wherein the resin composition comprises a thermoplastic resin, a phosphorus compound, neutralized, thermally expandable graphite, hydrated inorganic compound and a metal carbonate, the total content of said phosphorus compound and neutralized, thermally expandable graphite being 20 to 300 parts by weight, the content of said metal carbonate being 10 to 500 parts by weight and the content of said hydrated inorganic compound being 10 to 500 parts by weight, per 100 parts by weight of said thermoplastic resin, the weight ratio of said neutralized, the thermally expandable graphite to said phosphorus compound (neutralized, thermally expandable graphite/phosphorus compound) being 0.01 to 9.