KR20180128815A - Method for fabricating of noncombustible styrofoam panel - Google Patents

Abstract

The present invention relates to a method of manufacturing a semi-noncombustible styrofoam panel with a perforated film structure. An objective of the present invention is to provide a method of manufacturing a semi-noncombustible styrofoam panel with a perforated film structure which can evenly emit heat and can minimize harmful gases by allowing a heat flow to be smoothly flown during combustion. According to the present invention, the method comprises: a first step of preparing styrofoam beads and mixing 40 to 50 wt% of pure water, 20 to 30 wt% of acrylic resin, 5 to 10 wt% of a ceramic powder, 5 to 10 wt% of expanded graphite, 3 to 5 wt% of aluminum hydroxide, and 3 to 5 wt% of zinc borate with respect to weight of the styrofoam beads to prepare a first mixture; a second step of injecting the first mixture together with the styrofoam beads into a mixer at the ratio of 1:2 to 1:3 with respect to the weight of the styrofoam beads, and mixing the first mixture with the styrofoam beads to coat the styrofoam beads with the first mixture to obtain coated styrofoam beads; a third step of drying the coated styrofoam beads; a fourth step of injecting the coated styrofoam beads passing through the third step into a molding machine to manufacture a base panel by molding the coated styrofoam beads while applying steam to the coated styrofoam beads; and a fifth step of perforating a film having heat resistance and incombustibility to obtain a perforated film and performing a film coating process of coating the perforated film on one surface, both surfaces or the entire surface of the base panel manufactured through the fourth step.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a method for fabricating a non-combustible styrofoam panel having a perforated film structure,

The present invention relates to a method of manufacturing a semi-combustible styrofoam panel having a perforated film structure, and more particularly, to a method of manufacturing a semi-inflammable styrofoam panel having a perforated film structure that is excellent in heat insulation and economical, .

In the current society, there is an increasing demand for excellent thermal insulation materials that are economical and flame retardant because they have excellent thermal energy saving and heat insulation in various fields related to building, shipbuilding and energy transportation.

In general, heat insulating materials are classified into organic insulating materials, inorganic insulating materials and composite insulating materials. Glass insulating materials such as glass fiber and phenol foam, organic insulating materials such as urethane foam and styrofoam are widely used as insulating materials.

Glass wool, which is a typical insulation material for inorganic insulation materials, has the advantage of having strong flame retardancy which is not burned because it is a glass material that does not burn itself, but it is expensive and has high moisture permeability which is one of the important factors of insulation materials. It absorbs moisture about 20 times more than the weight of the raw material and has a disadvantage in that the heat insulating property remarkably lowers. However, since there is no suitable material to substitute for a prefabricated building that constructs a wall or a roof by a sandwich panel, it is mainly constructed at the time of construction of a prefabricated building.

The phenol product is a thermosetting material made by condensing phenol and formaldehyde. Since the material itself has strong heat resistance, it is good in flame retardancy, but it is expensive and has high moisture permeability like glass wool. Therefore, after a certain period of time, There is a disadvantage that the heat insulating performance is deteriorated by absorbing moisture. Also, since it has a strong acidity, when it is made into a sandwich panel, there is a disadvantage that it slowly corrodes the steel plate by acting with moisture permeated with time.

The heat insulation performance of urethane foam, which is an organic insulation material, depends on which gas is filled in itself, and hcfc-141b is used as the gas to be injected into the foam. This gas causes global warming, , There is a risk that a fire may occur even in a small fire. As time passes, there is a disadvantage in that the shrinkage phenomenon occurs due to the nature of the material, and the thermal conductivity is increased by about 20%. The shrinkage causes a gap due to the shrinkage to generate a gap, and moisture permeating the gap is impermeable to the material ), The structure may be damaged.

Styrofoam is an organic insulation material composed of 98% air and 2% polystyrene resin. It is not only very vulnerable to fire because it is an organic material, but it also produces a toxic gas such as mono-oxidizing gas and liquid- But still occupies more than 70% of the insulation market because it is cheap and easy to install.

In the case of these types of styrofoam insulation materials, as the fire fighting law and the construction method have been strengthened, the products used for the buildings are permitted to be only the materials having the performance of flame retardancy or semi-fireproofing. .

Accordingly, there is a demand for a heat insulating material having a flame retardancy and a nonflammable property, a high heat insulating property, and a safe insulation while having advantages of low cost and easy construction.

Korean Registered Patent No. 10-1313409 (2013.09.24)

Accordingly, it is an object of the present invention to provide a method of manufacturing a styrofoam panel having a perforated film structure capable of overcoming the above-described problems.

It is another object of the present invention to provide a method of manufacturing a styrofoam panel having a perforated film structure capable of uniformly discharging heat to facilitate heat flow (heat flow) during combustion and minimizing noxious gas.

Another object of the present invention is to provide a method of manufacturing a styrofoam panel having a perforated film structure which is excellent in heat insulation and economical, and has flame retardancy and incombustibility.

Another object of the present invention is to provide a method of manufacturing a styrofoam panel having a waterproof function-enhanced perforated film structure.

According to another embodiment of the present invention, there is provided a method of manufacturing a styrofoam panel, comprising: preparing styrofoam beads; preparing a styrofoam bead by mixing 40 to 50 wt% The first mixture is prepared by mixing 20 to 30% by weight of ceramic powder, 5 to 10% by weight of ceramic powder, 5 to 10% by weight of expanded graphite, 3 to 5% by weight of aluminum hydroxide and 3-5% Wow; A second step of mixing the first mixture with the styrofoam beads in a mixing ratio of 1: 2 to 1: 3 based on the weight of the styrofoam beads, and coating the mixture of styrofoam beads with the first mixture; ; A third step of drying the coated styrofoam beads; A fourth step of putting the coated styrofoam beads having passed through the third step into a molding machine and shaping them while applying steam to manufacture a base panel; And a fifth step of performing a coating process on one surface, both surfaces, or the entire surface of the base panel by drilling a heat-resistant and non-flammable coating material on the base panel manufactured through the fourth step.

The coating material used in the coating step may be at least one selected from the group consisting of aluminum foil, ceramic-containing paper, mineral fiber, glass fiber, nonwoven fabric, inorganic nonwoven fabric and glass paper.

The fifth step may include a drilling step of forming at least one hole having a diameter of 0.01 mm to 20.0 mm in the coating material; A coating step of coating or adhering at least one selected material selected from the group consisting of liquid ceramic, inorganic binder and inorganic powder on one side or both sides of the coating material or the base panel; And a coating step of forming a coating surrounding one surface, both surfaces, or the entire surface of the base panel using the coating material.

In the fifth step, at least two coating materials having different materials are adhered to each other to form a multi-coating material; A perforation step of forming at least one hole having a diameter of 0.01 mm to 20.0 mm in the multi-coating material; A coating step of coating or adhering at least one selected material selected from the group consisting of liquid ceramic, inorganic binder and inorganic powder on one side or both sides of the multi-coating material or the base panel; And a coating step of forming a coating surrounding one surface, both surfaces, or the entire surface of the base panel using the multi-coating material.

According to the present invention, there is an advantage that it can be used as an interior and exterior material of a building which is required to have high heat insulation, strong flame retardancy and nonflammability. In addition, by coating a styrofoam bead using a mixture made of an inorganic material without using a chemical component such as a halogen type or a bromine type, it is possible to minimize the emission of harmful gas as well as the prevention of flame propagation in a fire. And it is made as an environmentally friendly, semi-fireproof flame retardant product, and it has the advantage of maximizing the insulation efficiency by strengthening the waterproof function of the existing insulation. In addition, due to the structure of the styrofoam panel, the air layer accounts for 98% of the bead material, so that the strength and the bending strength are weak. However, it is possible to compensate for this by performing the coating process. Depending on the material and thickness of the coating material, Or nonflammable styrofoam panels can be manufactured. Especially, it is possible to manufacture according to various demands of interior and exterior materials of buildings. Further, by forming holes in the film, the heat flow (heat flow) during combustion can be facilitated and heat can be discharged uniformly, thereby preventing the heat from being aggregated in any part of the panel and significantly reducing the generation of noxious gas have.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a flowchart illustrating a manufacturing process of a semi-inflammable styrofoam panel according to an embodiment of the present invention,
FIG. 2 is a cross-sectional view of the styrofoam panel produced by FIG. 1,
Fig. 3 shows a pore structure of the coating.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings without intending to intend to provide a thorough understanding of the present invention to a person having ordinary skill in the art to which the present invention belongs.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a flowchart illustrating a manufacturing process of a styrofoam panel having semi-fireproof performance according to an embodiment of the present invention; FIG.

As shown in FIG. 1, in order to manufacture a styrofoam panel according to an embodiment of the present invention, styrofoam beads are prepared in a mixer (S110). The styrofoam beads can be applied to one kind of white or two kinds of white beads, and the beads foamed to a degree of 90 to 100 times of the raw materials are used to increase flame retardancy. When the amount of foaming drainage is low, the density of the styrofoam beads is increased and the heat insulation is improved. However, since the amount of burning in a fire is increased, the flame is increased and smoke is generated in a large amount. Use foamed beads.

Next, a first mixture is prepared (S112).

Wherein the first mixture comprises 40 to 50% by weight of pure water, 20 to 30% by weight of acrylic resin, 5 to 10% by weight of ceramic powder, 5 to 10% by weight of expanded graphite, 3 to 5% By weight, and 3 to 5% by weight of zinc borate.

Acrylic resin is selected because it is superior in water resistance and adhesive force than other organic resin. Ceramic powder is fine particles of 1 nm or more, so that the inorganic powders coated on the styrofoam beads to be adhered are large enough to be fixed evenly without fine gaps, . The ceramic powder may be composed of silica and alumina.

Expansion graphite is mainly used in a size of 80 mesh and a expansion ratio of 150 to 250 (preferably 200). The expanded graphite is flame retardant or nonflammable to initiate the reaction first at a temperature of 300 ° C. when the flame strikes the styrofoam panel according to the present invention and to first block the flame to 200 times the size of the magnetic particles. The expanded graphite has a good flame retardant effect. However, when the amount of the expanded graphite exceeds the predetermined amount due to its large particle size, it may interfere with adhesion and molding of the beads in the molding step described later. Should be used.

Aluminum hydroxide is added to increase the adhesion of various mixtures and to enhance the waterproofing performance. When added too little, there is no waterproof performance. When it exceeds 5.0 wt%, it is limited to 3 to 5 wt% do.

Zinc borate is a flame retardant that minimizes the generation of smoke during combustion and reduces the amount of harmful gases to a minimum. If too little is added, there is no abrasive performance, and when it exceeds 5.0% by weight, only a certain amount should be used to weaken the adhesive property and the water resistance.

The first mixture is mixed with the styrofoam beads in a mixer at a ratio of 1: 2 to 1: 3 based on the weight of the styrofoam beads (S114). When the mixture is thoroughly mixed in the mixer for 5 to 15 minutes (preferably about 10 minutes), the first mixture is stuck to the styrofoam bead to be flame retarded (S114).

Thereafter, the flame-coated styrofoam beads are dried in a fluidized bed dryer at a temperature of 50 to 70 DEG C for 3 to 4 minutes (S116). Here, the drying temperature and the drying time can be controlled according to the input magnification of the first mixture with respect to the styrofoam beads. The higher the loading rate, the higher the drying temperature and the longer the drying time.

The flame retarded coated styrofoam beads that have undergone the drying step can be subjected to a step of cooling the applied heat at the time of drying. Then, the aging process for 30 minutes to 4 hours may be performed as needed.

Thereafter, the heat treatment and the molding process may be performed (S118).

The flame-coated styrofoam beads having been subjected to the drying step are placed in a molding machine, and steam having a temperature of 95 to 110 ° C is injected at a pressure of 2.0 to 3.0 kg / cm 2 (preferably at a pressure of 2.5 kg / cm 2) And then subjected to a heat treatment to form a base panel.

Here, the steam temperature, pressure, and spraying time must be changed according to the type of styrofoam beads and the input ratio of the first mixture. If the temperature, pressure, and spraying time do not match, the heat insulating property of the heat insulating material deteriorates and the water-

The base panel produced by the above process may have flame retardant performance, but many mixtures must be uniformly adhered during the stirring and coating process, and some styrofoam beads may not be coated properly. In this case, since there is a possibility that the flame retardant performance is lowered, a coating process can be further carried out for enhancing the flame retardancy and the incombustibility.

In the coating process, a coating process for one surface, both surfaces, or the entire surface of the base panel is performed using a coating material having heat resistance and nonflammability on the base panel (S120).

The coating material used in the coating step may be at least one selected from the group consisting of aluminum foil, ceramic-containing paper, mineral fiber, glass fiber, nonwoven fabric, inorganic nonwoven fabric and glass paper, May be 0.01 mm to 5.0 mm, and may have various thicknesses depending on the type of the coating material.

In the coating process, the base panel is cut according to the size as necessary, and a coating is formed on the entire upper and lower surfaces of the cut base panel, the upper and lower surfaces, and the upper and lower surfaces, both sides and sides. In the above-described coating step, the coating material and the coating thickness may vary depending on the application.

The coating process may be carried out through a perforation step, a coating step, and a coating step.

The perforating step forms at least one hole having a diameter of 0.01 mm to 20.0 mm in the coating material. In the drilling step, heat dissipation becomes difficult due to the coating material when the base panel is burned. As a result, there is a problem that the panel is twisted or deformed and the harmful gas is also trapped in the inside of the panel. Therefore, it is possible to improve the heat flow so that the heat can be evenly discharged, And the generation of harmful gas can be remarkably reduced.

That is, the perforating step is to form at least one hole in the coating material for suppressing the noxious gas or the like by allowing the heat release to be evenly performed when burning and facilitating the discharge of the noxious gas.

3 (a), 3 (b), 3 (c), and 3 (d) show a hole formed in the coating material 120, And may be formed in various shapes such as a star shape, a square shape, a triangle shape, a circular shape, and the like, and may be variously changed as needed.

The coating step is a step of coating or adhering at least one material selected from a liquid ceramic, an inorganic binder and an inorganic powder on one side or both sides of the coating material and reducing the size of the flame and increasing the water resistance Coating the coating material.

The coating step may be performed on the base material, or may be performed on the base material.

The coating step is a step of forming a coating by using the coating material in the coating step so that the coating material is adhered so as to surround one surface, both surfaces, or the entire surface of the base panel.

2 is a cross-sectional view of the styrofoam panel produced by FIG.

As shown in FIG. 2, when the coating process is performed, the base panel 110 has a structure coated with a coating material 120 having apertures 125 of various sizes and numbers, The semi-inflammable styrofoam panel 100 having a film structure is completed.

The coating may be performed using one coating material, but it may be performed using at least two coating materials having different materials. In this case, at least two coating materials having different materials are adhered to each other to form a multi-coating material, at least one hole having a diameter of 0.01 mm to 20.0 mm is formed in the multi-coating material, Or after the coating step of coating or adhering at least one selected material selected from the group consisting of liquid ceramic, inorganic binder and inorganic powder on one or both sides of the base panel, the multi-coating material is applied to one surface, , Or a whole-surrounding coating process may be performed to produce a semi-combustible styrofoam panel having a perforated film structure. In this case, the firmness of the coating film and the improvement of the flame retardant performance can be expected.

The flame retardant styrofoam panel having a perforated film structure manufactured by the above-mentioned process has an advantage that it can be used as an interior and exterior material of a building requiring high heat insulation and strong flame retardancy. In addition, by coating a styrofoam bead using a mixture made of an inorganic material without using a chemical component such as a halogen type or a bromine type, it is possible to minimize the emission of harmful gas as well as the prevention of flame propagation in a fire. And it is made as an environmentally friendly, semi-fireproof flame retardant product, and it has the advantage of maximizing the insulation efficiency by strengthening the waterproof function of the existing insulation. In addition, due to the structure of the styrofoam panel, the air layer accounts for 98% of the bead material, so that the strength and the bending strength are weak. However, it is possible to compensate for this by performing the coating process. Depending on the material and thickness of the coating material, Or nonflammable styrofoam panels can be manufactured. Especially, it is possible to manufacture according to various demands of interior and exterior materials of buildings. In addition, by forming holes in the film, it is possible to smooth the heat flow during combustion, uniformly distribute heat, and significantly reduce the generation of noxious gas.

The foregoing description of the embodiments is merely illustrative of the present invention with reference to the drawings for a more thorough understanding of the present invention, and thus should not be construed as limiting the present invention. It will be apparent to those skilled in the art that various changes and modifications may be made without departing from the basic principles of the present invention.

Claims (4)

A method for producing a styrofoam panel comprising:
A styrofoam bead is prepared and is prepared by mixing 40 to 50 wt% of pure water, 20 to 30 wt% of acrylic resin, 5 to 10 wt% of ceramic powder, 5 to 10 wt% of expanded graphite, 3 to 5 wt% of aluminum hydroxide %, And zinc borate in an amount of 3 to 5% by weight to prepare a first mixture;
A second step of mixing the first mixture with the styrofoam beads in a mixing ratio of 1: 2 to 1: 3 based on the weight of the styrofoam beads, and coating the mixture of styrofoam beads with the first mixture; ;
A third step of drying the coated styrofoam beads;
A fourth step of putting the coated styrofoam beads having passed through the third step into a molding machine and shaping them while applying steam to manufacture a base panel;
And a fifth step of performing a coating process on one surface, both surfaces, or the entire surface of the base panel by drilling a heat-resistant and non-flammable coating material on the base panel manufactured through the fourth step. A method of manufacturing a panel. The method according to claim 1,
The coating material used in the coating step is at least one selected from the group consisting of aluminum foil, ceramic-containing paper, mineral fiber, glass fiber, nonwoven fabric, nonwoven fabric containing inorganic material, and glass paper. A method of manufacturing a panel. The method as claimed in claim 1,
A perforation step of forming at least one hole having a diameter of 0.01 mm to 20.0 mm in the coating material;
A coating step of coating or adhering at least one selected material selected from the group consisting of liquid ceramic, inorganic binder and inorganic powder on one side or both sides of the coating material or the base panel;
And a coating step of forming a coating surrounding one surface, both surfaces, or the entire surface of the base panel using the coating material. The method as claimed in claim 1,
Attaching at least two coating materials having different materials to each other to form a multi-coating material;
A perforation step of forming at least one hole having a diameter of 0.01 mm to 20.0 mm in the multi-coating material;
A coating step of coating or adhering at least one selected material selected from the group consisting of liquid ceramic, inorganic binder and inorganic powder on one side or both sides of the multi-coating material or the base panel;
And a coating step of forming a coating surrounding one surface, both surfaces, or the entire surface of the base panel using the multi-coating material.

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