KR100582922B1 - Flame-retardant sandwich panel using industrial waste expanded polystyrene and polyurethane composite and method of producing the same - Google Patents
Flame-retardant sandwich panel using industrial waste expanded polystyrene and polyurethane composite and method of producing the same Download PDFInfo
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- KR100582922B1 KR100582922B1 KR1020040060787A KR20040060787A KR100582922B1 KR 100582922 B1 KR100582922 B1 KR 100582922B1 KR 1020040060787 A KR1020040060787 A KR 1020040060787A KR 20040060787 A KR20040060787 A KR 20040060787A KR 100582922 B1 KR100582922 B1 KR 100582922B1
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/34—Component parts, details or accessories; Auxiliary operations
- B29C41/42—Removing articles from moulds, cores or other substrates
- B29C41/44—Articles of indefinite length
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
- B29C43/26—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length in several steps
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/92—Protection against other undesired influences or dangers
- E04B1/94—Protection against other undesired influences or dangers against fire
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Abstract
본 발명은 폐 스티로폴과 폴리우레탄을 활용하여 난연 복합 샌드위치 패널 및 그 제조방법에 관한 것이다.The present invention relates to a flame-retardant composite sandwich panel using waste styropol and polyurethane and a method of manufacturing the same.
스티로폴은 샌드위치 패널의 제조 외에도 건축용 단열재와 각종 산업용재, 포장용 패드 등 그 수를 헤아릴 수 없을 정도로 광범위하게 사용되고 있는 바, 그에 따른 폐기물의 수량 또한 엄청난 량으로 매립하게 되면 분해되지 않기 때문에 소각처리 할 수 밖에 없는 것으로 처리비용이 막대하게 소요되고, 소각 과정에서 유해 가스가 발생되어 대기를 오염시키는 또다른 환경 문제가 야기되는 등 그 처리가 매우 어려운 문제점이 있었던 것이다.In addition to the manufacture of sandwich panels, Styropol is innumerably widely used for building insulation, various industrial materials, and pads for packaging.In addition, Styropol can be incinerated because it does not decompose when landfilled in large quantities. There is a problem that the treatment is very difficult as there is only a huge cost, and the harmful gas is generated during the incineration process, causing another environmental problem that pollutes the air.
본 발명은 폐 EPS 알갱이 1~12.5 중량%, 솔루블 글래스(Soluble glass, Na2O.nSiO2.xH2O); 50~62.5 중량%, 칼슘 카보네이트(CaCO3); 12.5~24.5 중량%, 인산암모늄(NH4H2PO4); 12.5~24.5 중량%를 혼합하면 상온에서 10~60분간 건조된 난연 1급 재료 EPS 알갱이를 얻을 수 있고, 이 EPS 알갱이; 60~83.5 중량%에 폴리우레탄 바인더(Polyurethane binder)의 (A)파트인 폴리올 혼합물(Polyol mixture) 1~20 중량%를 혼합한 후 (B)파트인 디페닐 메탄 디이소시아네이트(diphenyl methane diisocyanate) 1~20 중량%를 혼합하면서 난연 EPS 알갱이 폴리우레탄 복합체(Composite)를 강판 사이에 규정된 양으로 투입하여 발포시켜 자연 건조상태로 샌드위치 패널을 연속 제조하게되는 것이다.The invention waste EPS granules 1 ~ 12.5 weight%, the glass block solution (Soluble glass, Na 2 O.nSiO 2 .xH 2 O); 50-62.5% by weight calcium carbonate (CaCO 3 ); 12.5-24.5 weight percent ammonium phosphate (NH 4 H 2 PO 4 ); By mixing 12.5-24.5 wt%, flame retardant first-class material EPS grains dried at room temperature for 10-60 minutes can be obtained, and these EPS grains; (A) Part 1 to 20% by weight of the polyol mixture (A) part of the polyurethane binder in 60 to 83.5% by weight, and (B) part diphenyl methane diisocyanate 1 While mixing ~ 20% by weight, flame-retardant EPS granules polyurethane composite (Poposite) is injected into the prescribed amount between the steel sheets and foamed to continuously produce a sandwich panel in a natural dry state.
난연, 발포폴리스티렌, 폴리우레탄, 샌드위치 패널 Flame Retardant, Foamed Polystyrene, Polyurethane, Sandwich Panel
Description
도 1은 발명의 공정을 보인 개략 사시도1 is a schematic perspective view showing a process of the invention
도 2는 본 발명의 공정도2 is a process diagram of the present invention
본 발명은 산업 폐기물로 대량 발생되는 폐 스티로폴을 재활용 하기 위하여 알갱이 상태로 분쇄한 다음 난연 처리에 의하여 난연 1급재 EPS(Expanded Polystyrene) 알갱이로 만들어 폴리우레탄(Polyurethane)의 복합체(Composite)와 혼합하여 별도의 접착 과정을 거치지 않고 강판 사이에 투입하여 발포 성형시켜서 규격 대로 절단하여 건축용 샌드위치 패널을 연속 공정으로 제조하는 방법에 관한 것이다.The present invention is pulverized in the state of granules in order to recycle the waste styropol generated as a large amount of industrial waste and then made into a flame retardant primary material EPS (Expanded Polystyrene) granules by flame retardant treatment and mixed with a composite of polyurethane (Popositur) The present invention relates to a method of manufacturing a sandwich panel for building in a continuous process by inserting between steel sheets without undergoing an adhesion process and then cutting the foam to a specification.
종래 국내에서 생산되는 스티로폴(EPS; 발포 폴리스티렌; Expanded Polystyrene)을 내장하여 제조되는 샌드위치 패널의 제조방법은 폴리스티렌 알갱이(Polystyrene beads)를 소정의 발포 배율로 예비 발포한 후 사일로(Silo)에서 건조 숙성시킨 후 성형기에서 연화할 때까지 가열 후 냉각시켜서 성형체를 만들고 1주일 동안 양생을 거쳐 열선으로 규격대로 재단을 하여 만들어진 비난연 EPS패널을 강판(아연도강판, 갈바늄강판, 불소코팅강판, 알루미늄강판, 칼라강판 등) 사이에서 접착제를 사용하여 접착 후 규격대로 컷팅(Cutting) 하여 샌드위치 패널을 만들고 있으며 이러한 비난연 EPS 샌드위치 패널은 높은 단열 효과와 탁월한 경제성, 방음성, 경량성, 기계강도, 내약품성, 인체 무해성 등이 뛰어나기 때문에 널리 사용되어 왔으나 근래에 들어 발생되는 대형화재 사고에서는 인화성과 유독가스 발생의 치명적인 문제점이 노출되어 EPS 샌드위치패널의 난연화는 매우 시급한 실정이다.Conventionally, a method for manufacturing a sandwich panel built with domestically produced Styropol (EPS; Expanded Polystyrene) is pre-foamed to form a polystyrene beads (Polystyrene beads) at a predetermined expansion ratio and then dried and aged in a silo (Silo) After heating and cooling until it is softened in the molding machine, a molded product is made and after being cured for 1 week, the non-leaded EPS panel made by cutting to the standard with a hot wire is used as a steel sheet (zinc sheet, galvanium sheet, fluorine coated sheet, aluminum sheet, Sandwich panel is made by cutting to the standard after bonding using adhesive between color steel plates, etc.The non-combustible EPS sandwich panel has high insulation effect, excellent economy, sound insulation, light weight, mechanical strength, chemical resistance, human body It has been widely used because of its excellent harmlessness, but it is a large fire that occurs recently. In the toxic exposure to this deadly problem of gas generation and flame retardant flammability of EPS sandwich panels is a very urgent situation.
또한, 스티로폴은 샌드위치 패널의 제조 외에도 건축용 단열재와 각종 산업용재, 포장용 패드 등 그 수를 헤아릴 수 없을 정도로 광범위하게 사용되고 있는 바, 그에 따른 폐기물의 수량 또한 엄청난 량으로 매립하게 되면 분해되지 않기 때문에 소각처리 할 수 밖에 없는 것으로 처리비용이 막대하게 소요되고, 소각 과정에서 유해 가스가 발생되어 대기를 오염시키는 또다른 환경 문제가 야기되는 등 그 처리가 매우 어려운 문제점이 있었던 것이다.In addition to the manufacture of sandwich panels, Styropol is innumerably widely used for building insulation, various industrial materials, and packaging pads.In addition, the amount of waste is also incinerated because it does not decompose when landfilled in large quantities. There is a problem that the treatment is very difficult, and the treatment is very difficult, such as harmful gas is generated during the incineration process, causing another environmental problem polluting the air.
난연 발포폴리스티렌에 관하여 알려진 선행하는 기술들은 난연제로 쓰이는 규산소다의 혼합 수용액을 발포폴리스티렌에 도포하여 성형한 후 4~6일 정도 방치하여 자연건조 시키거나, 복사열, 증기, 마이크로파 등을 가하여 인공적으로 가열 건조시켰으므로, 전자의 경우는 생산시간이 장기간 소요될 뿐만 아니라 작업이 번거롭고 적재 공간을 많이 차지하게 되는 문제점이 있으며, 후자의 경우는 건조를 위한 추가설비나 공정이 필요하여 난연재 발포폴리스티렌의 융착에 많은 시간이나 큰 비용이 소모되는 문제점을 갖게된다.Prior arts related to flame-retardant expanded polystyrene are applied by molding a mixed aqueous solution of sodium silicate, which is used as a flame retardant, to foamed polystyrene, and then allowed to stand for 4 to 6 days to dry naturally, or artificially heated by applying radiant heat, steam, or microwave. In the case of the former, the former is not only a long time to produce, but also a cumbersome operation and takes up a lot of loading space, the latter requires additional equipment or processes for drying, so that many of them are fused to the flame-retardant foam polystyrene You have the problem of spending time or money.
또한, 이렇게 융착된 난연제는 난연의 성능은 어느 정도 발휘할 수 있으나 발포폴리스티렌간의 결합력은 오히려 저하되어 이로 인해 소정의 규격으로 성형 가공시 지속적으로 형태를 유지하지 못하고 부서지게되고 작은 가압에도 쉽게 파손되는 결정적인 문제점이 있어 이론에 그칠 뿐 실용화되지 못하는 한계가 있었다.In addition, the fused flame retardant may exhibit a certain degree of flame retardant performance, but the bonding force between the foamed polystyrene is rather deteriorated, and thus it is not decisive to maintain the shape continuously during the molding process to a predetermined size, to be broken, and to be easily broken even at a small pressure. There was a problem that it was only a theory and could not be put to practical use.
본 발명은 산업 폐기물로 막대하게 발생되는 폐 스티로폴을 재활용하는 것과 함께 상기에서와 같이 난연 발포폴리스티렌이 갖는 결함을 동시에 해결할 수 있도록 안출한 것으로써, 먼저 각종 산업현장에서 발생되는 폐 스티로폴을 수거하여 분쇄 공정을 거친 EPS 알갱이를 난연 1급 재료로 만드는 방법은 EPS 알갱이; 1~12.5중량%, 솔루블 글래스(Soluble glass, Na2O.nSiO2.xH2O); 50~62.5 중량%, 칼슘 카보네이트(CaCO3); 12.5~24.5 중량%, 인산암모늄(NH4H2PO4); 12.5~24.5 중량%를 혼합한 후 상온에서 10~60분간 자연건조 시키게 되면 난연 1급 재료로 바뀐 난연 EPS 알갱이를 얻을 수 있게된다.The present invention is designed to solve the defects of flame retardant expanded polystyrene simultaneously with the recycling of waste styropol that is generated enormously as industrial waste, first to collect and crush the waste styropol generated in various industrial sites EPS granules can be made into flame retardant first grade materials through EPS granules; 1 ~ 12.5 weight%, the glass block solution (Soluble glass, Na 2 O.nSiO 2 .xH 2 O); 50-62.5% by weight calcium carbonate (CaCO 3 ); 12.5-24.5 weight percent ammonium phosphate (NH 4 H 2 PO 4 ); After mixing 12.5 ~ 24.5% by weight and drying for 10 ~ 60 minutes at room temperature, flame retardant EPS granules can be obtained.
이와 같이 얻어진 난연 1급재 EPS 알갱이; 60~83.5 중량%에 폴리우레탄 바인더(Polyurethane binder)의 (A)파트인 폴리올 혼합물(Polyol mixture) 1~20 중량%를 혼합한 후 (B)파트인 디페닐 메탄 디이소시아네이트(diphenyl methane diisocyanate) 1~20 중량%를 혼합하면서 난연 EPS 알갱이 폴리우레탄 혼합체를 강판 사이에 규정된 양으로 투입하여 발포시키면 별도의 접착제 처리나 건조공정 없이 자연 건조상태로 샌드위치 패널이 제조되는 것이며, 규격에 따라 재단을 하면 난연성 EPS 복합 샌드위치 패널을 얻을 수 있게되는 것이다.Flame-retardant primary-grade EPS grains thus obtained; (A) Part 1 to 20% by weight of the polyol mixture (A) part of the polyurethane binder in 60 to 83.5% by weight, and (B) part diphenyl methane diisocyanate 1 If the foamed flame retardant EPS granules polyurethane mixture is mixed between steel sheets in a prescribed amount while mixing ~ 20% by weight, the sandwich panel is manufactured in a natural dry state without any adhesive treatment or drying process. Flame-retardant EPS composite sandwich panel will be obtained.
또한, 상술한 바와 같이 연속 공정으로 생산이 가능하다.
In addition, it is possible to produce in a continuous process as described above.
이하, 첨부된 도면 및 바람직한 실시예에 따라 본 발명을 상세히 설명하면 다음과 같다.Hereinafter, the present invention will be described in detail with reference to the accompanying drawings and preferred embodiments.
도 1은 본 발명의 공정을 보인 개략 사시도이며, 도 2는 본 발명의 공정도이다.1 is a schematic perspective view showing the process of the present invention, Figure 2 is a process diagram of the present invention.
본 발명은 폐 스티로폴(EPS; 발포 폴리스티렌; Expanded Polystyrene)을 수거하여 분쇄 공정을 거친 폐 EPS 알갱이를 난연처리하여 된 난연 1급재 EPS 알갱이를 얻기위한 공정이 선행되는데, 먼저 폐 EPS 알갱이(폐 스티로폴 덩어리를 분쇄한 알갱이로서, 입자 크기에 제한이 없음.); 1~12.5중량%, 솔루블 글래스(Soluble glass, Na2O.nSiO2.xH2O); 50~62.5 중량%, 칼슘 카보네이트(CaCO3); 12.5~24.5 중량%, 인산암모늄(NH4H2PO4); 12.5~24.5 중량%를 혼합한 후 상온에서 10~60분간 자연건조시키게 되면 난연 1급 재료로 바뀐 난연 EPS 알갱이를 얻을 수 있게된다.The present invention is preceded by a process for obtaining a flame-retardant first-class EPS granules obtained by collecting waste styropol (EPS; Expanded Polystyrene) and flame-retardant waste EPS granules that have been pulverized. Pulverized grains, with no limitation on particle size.); 1 ~ 12.5 weight%, the glass block solution (Soluble glass, Na 2 O.nSiO 2 .xH 2 O); 50-62.5% by weight calcium carbonate (CaCO 3 ); 12.5-24.5 weight percent ammonium phosphate (NH 4 H 2 PO 4 ); After drying 12.5 ~ 24.5% by weight and drying for 10 ~ 60 minutes at room temperature, flame retardant EPS granules can be obtained.
이와 같이 얻어진 난연 1급재 EPS 알갱이; 60~83.5 중량%에 폴리우레탄 바인더(Polyurethane binder)의 (A)파트인 폴리올 혼합물(Polyol mixture) 1~20 중량%를 혼합한 후 (B)파트인 디페닐 메탄 디이소시아네이트(diphenyl methane diisocyanate) 1~20 중량%를 혼합하면서 난연 1급재 EPS 알갱이와 폴리우레탄 복합체(Composite)를 통상의 샌드위치 패널 성형기 상에서 롤 포밍(ROLL-FORMING) 공정을 거치면서 요철면이 형성되어 상, 하 간격을 두고 이송되어 오는 강판 사이에 규정된 양으로 투입 도포하여 발포시키면 별도의 접착제 처리나 건조공정 없이 자연 건조상태로 샌드위치 패널이 제조되는 것이며, 규격에 따라 재단을 하면 난연성 EPS 복합 샌드위치 패널을 얻을 수 있게되는 것이다.Flame-retardant primary-grade EPS grains thus obtained; (A) Part 1 to 20% by weight of the polyol mixture (A) part of the polyurethane binder in 60 to 83.5% by weight, and (B) part diphenyl methane diisocyanate 1 While mixing ~ 20% by weight, the flame-retardant first-class EPS granules and polyurethane composites are roll-formed on a conventional sandwich panel molding machine, and an uneven surface is formed and transferred at intervals of up and down. If the application is applied in a prescribed amount between the steel sheet and foamed, the sandwich panel is manufactured in a natural dry state without a separate adhesive treatment or drying process, if the cutting according to the standard will be able to obtain a flame-retardant EPS composite sandwich panel.
또한, 상술한 바와 같이 연속 공정으로 생산이 가능하다.In addition, it is possible to produce in a continuous process as described above.
이와 같은 일련의 공정에 의하여 제조되는 본 발명은 폐 스티로폴을 재생하여 샌드위치 패널로 재 생산되는 산업폐기물 재활용과 더불어 두가지 면에서 현저한 물성의 특징을 갖게되는데, The present invention manufactured by such a series of processes has remarkable physical properties in two aspects, along with the recycling of industrial waste that is regenerated into sandwich panels by recycling waste styropol.
첫째; 솔루블 글래스에 칼슘 카보네이트, 인산암모늄을 혼합함으로써 단시간(10~60분)에 자연건조가 가능케 됨으로, 건조를 위한 별도의 공정이나 장치가 생략되어 제조공정을 단순화 할 수 있게되며, 제조 원가를 현저히 절감할 수 있게된다.first; By mixing calcium carbonate and ammonium phosphate in the soluble glass, natural drying is possible in a short time (10 to 60 minutes), so that a separate process or device for drying can be omitted, simplifying the manufacturing process and significantly reducing the manufacturing cost. You can save.
둘째; 난연 발포폴리스티렌은 발포폴리스티렌 간의 결합력이 약해 어떠한 형상화를 하기 위해서는 한계성이 있기 때문에 이를 폴리우레탄 바인더로 복합체(Composite)를 만들면 난연 폴리스티렌 알갱이 간의 공간을 폴리우레탄 바인더로 충전하여 발포폴리스티렌 간의 결합력을 갖게하고 기계적 강도를 향상 시킬 수 있게되며, 경질, 연질, 반경질 등 원하는 상황에 맞는 강도와 탄성력을 선택하여 제품에서 요구되는 물성에 적합하게 만들 수 있게 되는 것이다.second; Flame-retardant expanded polystyrene has a weak binding force between foamed polystyrenes, so there is a limit to forming it. Therefore, when a composite is made of a polyurethane binder, the space between flame-retardant polystyrene grains is filled with a polyurethane binder to provide a bonding force between foamed polystyrenes and mechanical It is possible to improve the strength, and to select the strength and elasticity according to the desired situation, such as hard, soft, semi-hard, it can be made to fit the physical properties required by the product.
상기한 바와 같은 본 발명은 각종 산업현장에서 막대하게 발생되는 폐 스티로폴을 수거하여 분쇄, 난연처리, 폴리우레탄 복합체와 혼합, 발포공정을 거쳐 건축용 샌드위치 패널로 재 생산하게 되는 것으로, 화염에 노출된 상태에서도 쉽게 불에 타지 않을 뿐만 아니라 유독개스가 거의 발생되지 않는 난연 2급 이상의 성능을 가지면서도 경량, 방음, 단열 효과가 우수하여 건축용 판재로서 최적의 조건을 구비하게 되는 것이며, 제조공정에 있어서도 강제건조 공정없이 단시간에 자연건조 생산이 가능하여 생산성을 크게 향상 시키면서 생산원가를 획기적으로 절감할 수 있게되는 등의 우수한 효과가 있는 것이다.
As described above, the present invention collects waste styropol generated in various industrial sites, and re-produces the building sandwich panel through crushing, flame-retardant treatment, polyurethane composite, foaming process, and exposed to flame. Not only does it easily burn in fire, but it has the best performance as a building plate with excellent performance in light weight, soundproofing, and heat insulation while having the performance of more than second-class flame retardant which hardly causes toxic gas. It is possible to produce natural dry in a short time without a process, and it is possible to greatly reduce the production cost while greatly improving the productivity.
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