KR100625914B1 - Formaldehyde-free coating composition for roofing panel made by mineral wool and the roofing panel coated thereby - Google Patents

Abstract

The present invention relates to a coating composition for rockwool ceiling plates that do not contain formaldehyde and to rockwool ceiling plates coated with the composition. More specifically, the unsaturated ethylene monocarboxylic acid monomer alone or the monomer and unsaturated ethylene monomer A coating composition for rockwool top plates comprising a water-soluble acrylic resin polymer obtained by solution polymerization in an aqueous phase by a radical reaction by a water-soluble radical polymerization initiator and containing no formaldehyde having a pH of 2 to 6, and a rockwool top plate coated with the composition will be.

Since the water-soluble acrylic resin according to the present invention is water-soluble, it does not contain an organic volatile solvent and does not cause environmental pollution by evaporation of the solvent during coating, and there is no formaldehyde emission, and sagging of the ceiling plate when coating on rock wool ceiling It can be said that the coating agent can improve the phenomenon.

Formaldehyde, Rockwool, Ceiling, Coating, Carboxylic Acid, Acrylic Resin, Sag

Description

Formaldehyde-free coating composition for roofing panel made by mineral wool and the roofing panel coated hence}

The present invention relates to a coating composition for rockwool ceiling plates that do not contain formaldehyde and to rockwool ceiling plates coated therewith, and more particularly, to unsaturated ethylene monocarboxylic acid monomers alone or the monomer and unsaturated ethylene monomers. The present invention relates to a coating composition for rockwool top plate comprising a water-soluble acrylic resin obtained by solution polymerization in an aqueous phase by radical reaction by and containing no formaldehyde having a pH of 2 to 6, and a rockwool top plate coated with the same.

Rock wool sound-absorbing ceiling plate was formed in the form of a plate of mineral wool as a main raw material to process a variety of patterns and irregularities and then painted the surface, originally invented in the United States. The original rock wool sound-absorbing ceiling is a wood-board ceiling, which is a surface-treated product of wood. After that, the fireproofing for public buildings was required, replacing the rock wool sound-absorbing ceiling. Compared to the conventional gypsum cement board, it is only 1/3, but has high strength, can be manufactured with a large plate, develops various construction systems, creates a unique space, and absorbs and blocks noise. This has an excellent advantage. The rock wool ceiling plate has been improved by various efforts in many aspects, such as improvement of the original composition, improvement of the pattern, diversification of the pattern (Pattern), improvement of processing precision, improvement of the sag resistance properties.

Conventionally, rock wool, which is a mineral fiber, is composed of 10 to 100 solids composed of fillers such as bentonite, organic binders such as starch, phenol resins, and pulp, and binder aids such as emulsion wax, alumina sulfate, and polyacrylamide. A slurry has been prepared by dispersing it in about twice as much water as water, and using this method to produce a plate-like rockwool ceiling plate by a wet evaporation method. However, when used for a long time after construction, sagging occurs due to deformation of the starch due to humidity and the load of the product itself, and the appearance may look bad. In some cases, the environmental conditions at the time of construction of the ceiling plate on the building Deficit phenomena in poor (hot and humid) conditions can cause dissatisfaction from end users. As a result, numerous efforts have been made, such as the development of many suitable methods and changes in the formulation of the disc to resist sagging due to moisture absorption.

For example, first, it is possible to use a lightweight filler such as perlite and a fibrous raw material such as paper in the formulation by lowering the density and reducing the load of the ceiling plate product itself, but it has a disadvantage of inferior flame retardancy. Second, it is possible to expect a sag resistance effect by hardening the product itself rather than the load of the product by increasing the density very high, but the end product is heavy, the manufacturing cost increases. Third, in order to reinforce the weak wet strength according to the perlite formulation, the pulp is used by beating treatment, which makes the fiber bundle soft and dense, so that there is a method of tightly intertwining the tissue in the rock wool sound-absorbing ceiling plate, thereby improving the sag property. Fourth, a method of coating the compound on the surface of the ceiling plate to complement the deflection has emerged.

In the related art, melamine-formaldehyde resin has been typically used as a coating agent for supplementing deflection properties in rock wool ceiling plates, which is described in US Patent No. 5,714,200 as follows. In order to prevent the ceiling plate from sagging, at least two different coating surfaces, such as one coating on the surface and one coating on the back, are required for the ceiling plate, and the modulus of elasticity of both coating surfaces must be at least 400,000 psi to have the rigidity of the board. In addition, it is mentioned that the backside coating should have a higher coefficient of moisture expansion than the surface coating. Suitable front coatings for surfaces with an elastic modulus of 400,000 psi are acrylic, urethane, epoxy, etc. having a Tg of 40 ° C. or higher at low filler / binder ratios (below 7/1), and suitable back coating materials have high hydrophilic modulus. It has the function of carbon group or hydrogen group. For example, melamine formaldehyde coatings are typical. The coatings presented have a high modulus of elasticity and a coefficient of moisture expansion, with a filler / binder ratio of less than 7/1 of melamine formaldehyde and a maximum filler / binder ratio in order to obtain a minimum modulus of elasticity. It is said to be necessary. U.S. Patent Nos. 5,753,871 and 3,655,431 specify that rock wool, including rock starch, has significant resistance to sagging due to melamine-formaldehyde resins, especially at high temperature and high humidity conditions.

However, such melamine-formaldehyde resins have the disadvantage of discharging significant amounts of unreacted formaldehyde and its low molecular weight products in vapor form during the manufacture of the ceiling material. They are very costly to prevent environmental pollution due to release to the atmosphere from the ceiling plate production line and can also be harmful to the human body due to the release of formaldehyde remaining in the final ceiling product manufacture. Although modern people spend more than 80% of the time living in the interior of artificial buildings, formaldehyde can not be removed or diluted and gradually accumulates in the room. Until now, the importance of the indoor air environment has been underestimated.

Odors from formaldehyde are generally felt at 1 ppm, but some people detect them at concentrations of 0.05 ppm. In December 1980, the National Institutes of Health and Human Services (NIOSH) and OSHA recommended that formaldehyde should be treated as a carcinogen in labor hygiene. In general, when the concentration of formaldehyde is less than 1ppm, symptoms such as irritation of the eyes, nose and throat, and less than 5ppm causes severe asthma attacks in asthma patients. In addition, symptoms below 20ppm complain of coughing, lung pressure, heaviness in the head, and heart rhythm, etc.At high concentrations below 100ppm, symptoms of accumulation of pulmonary fluid, pulmonary inflammation, and death in severe cases are caused. Can be.

Accordingly, in order to solve the above problems, the present invention has developed a water-soluble acrylic resin that does not contain formaldehyde as a coating agent capable of improving the deflection of rock wool sound absorption ceiling plates without generating formaldehyde. It is finished.

Accordingly, an object of the present invention is to spray the air spray, airless spray well during the coating operation to have good productivity and non-toxicity, in particular, it does not contain a volatile organic solvent in water solubility due to solvent pollution during coating It is to provide a coating composition for rockwool top plate that does not contain formaldehyde and does not cause formaldehyde that can serve as a more stable coating agent than melamine-formaldehyde resin.

Another object of the present invention is to provide a method of using the coating composition for rockwool top plate that does not contain the formaldehyde.

Still another object of the present invention is to provide a rockwool ceiling plate coated with a coating composition for rockwool ceiling plates that do not contain the formaldehyde.

To achieve the above object, the coating composition of the present invention which does not contain the formaldehyde-containing coating material for an unsaturated ethylene monocarboxylic acid monomer alone or a radical reaction of the monomer and the unsaturated ethylene monomer with a water-soluble radical polymerization initiator in an aqueous phase It comprises a water-soluble acrylic resin polymer obtained by solution polymerization and consists of pH 2-6.

Method of using the composition for achieving the other object of the present invention consists of applying the coating composition for rockwool ceiling plate within the range of 0.005 ~ 5kg per rock wool ceiling plate.

The rock wool ceiling plate for achieving another object of the present invention is coated with the coating composition.

Looking at the present invention in more detail as follows.

In general, rock wool sound-absorbing ceiling plate can be produced by the wet felt method of perlite having a closed hole structure. The wet felt method is a widely used method for preparing a ceiling plate in which rock wool, perlite, binder, pulp, filler, etc. are diluted in water and molded into felt. Rock wool sound-absorbing ceiling plate coating process is described in more detail, such as rock wool, organic starch, attapulgite, polyacrylamide, organic fibrous waste paper, wax emulsion, liquid coagulant, and broken product recycled powder broke. After blending and molding to a water content of%, the coating is sprayed on the molding, and then dried at about 100 ° C. for 90 minutes.

According to the present invention, the coating agent includes a water-soluble acrylic resin polymer obtained by solution polymerization of an unsaturated ethylenic monocarboxylic acid monomer alone or the monomer and an unsaturated ethylenic monomer in an aqueous phase by radical reaction with a water-soluble radical polymerization initiator. When the rock wool ceiling plate is coated with the coating agent, the acrylic resin polymer attached to the rock wool fibers dissolves SiO ₂ , CaO, Al ₂ O _3, etc., which are the main components of the rock wool, and undergoes a curing step described below. It is possible to improve the deflection phenomenon of the rockwool ceiling plate generated at the time.

Referring to the curing behavior of the acrylic resin polymer used in the coating agent in the present invention in detail as follows. The coating step takes place at 50 to 60% of the water content, including rock wool, before passing through the drying furnace. When coating with the coating agent of the present invention, an acid-base reaction occurs with water as a medium between the acrylic acid component of the water-soluble acrylic resin polymer and SiO ₂ which is the main component of rock wool, so that SiO ₂ is dissolved and Ca ²⁺ , Al in the rock wool component. Ions such as ³⁺ are released to the outside. Curing proceeds through the following two steps.

Firstly, Si (OH) ₄ produced by dissolution of SiO ₂ is gelled by condensation polymerization reaction due to dehydration as it passes through a drying furnace and curing occurs. That is, the dispersibility of the acrylic polymer according to the present invention minute (COO ^-) is presented and a Si (OH) ₄ is dissolved in the SiO ₂ component of the rock wool, these Si (OH) ₄ are combined with each other polycondensation reaction. Secondly, curing occurs as a crosslinked structure is formed between the eluted metal ion and the carboxyl group of the water-soluble acrylic resin polymer, thereby increasing the strength and hardness of the rockwool ceiling plate.

In addition, when a metal ion-containing material such as ZnO is used in the coating composition as the acrylic resin polymer, the Zn ²⁺ ion reacts with two carboxyl groups (-COO-) to chelate to form a crosslinked gel state. The strength and hardness of the ceiling plate may vary depending on the ZnO / acrylic ratio, ZnO reactivity, particle size, additives, and the molecular weight and concentration of the acrylic resin polymer.

As such, the rock wool components and the water-soluble acrylic resin polymer react to increase the bonding strength of the surface of the ceiling plate, thereby preventing sagging of the ceiling plate.

When the acrylic resin polymer used in the present invention is described in detail, the acid value of the water-soluble acrylic resin polymer is 300 to 850 KOH / mg, preferably 500 to 700 KOH / mg. If the acid value is lower than 300, the degree of reaction of the rock wool component with the inorganic components (SiO ₂ , CaO, Al ₂ O ₃ ) is low, and as a result, there is a possibility that the resistance to sag is insignificant. Since it is unreacted and exists on the ceiling plate, the moisture resistance of the product may be lowered, which may cause sagging at high temperature and high humidity.

In the preparation of the water-soluble acrylic resin polymer useful in the present invention, the monomer component includes an unsaturated ethylenic monocarboxylic acid monomer as an essential component, and may be used as a copolymer through copolymerization with other unsaturated ethylenic monomers.

Examples of the unsaturated ethylenic-monocarboxylic acid monomers include acrylic acid, methacrylic acid, vinylbenzene acid, isopentyl benzene acid, crotonic acid, acryloxypropionic acid, methacrylicoxy-propionic acid, acryloxyacetic acid, methacrylicoxyacetic acid and monomethyl. One or more selected from the group consisting of maleate, monomethyl itaconate, monomethyl fumarate, and the like, the amount of which is preferably 50 to 100% by weight based on solids based on the total monomers used in the acrylic resin polymerization. Do.

In addition, the unsaturated ethylene monomer copolymerized with the unsaturated ethylene-monocarboxylic acid monomer is styrene, vinyl toluene, ethylene, vinyl acetate, vinyl chloride, vinylidene chloride, acrylonitrile, acrylamide, methacrylamide, methyl meth Acrylate, methyl acrylate, ethyl acrylate, ethyl methacrylate, butyl acrylate, butyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, benzyl acrylate, benzyl methacrylate, One or more selected from the group consisting of lauryl acrylate, lauryl methacrylate, palmity acrylate, palmity methacrylate, stearyl acrylate, and stearyl methacrylate. When used, the amount used is based on the total monomers used in the polymerization of the acrylic resin. 0.1 to 50% by weight are preferred to the solid content.

According to the present invention, the monomer can be copolymerized by using a radical reaction in an ionized water in the presence of a polymerization initiator, wherein the polymerization initiator is ammonium persulfate, potassium persulfate, potassium persulfate, sodium persulfate, cyclohexyl hydride. Consisting of loperoxide, cumene hydroperoxide, n-octyl hydroperoxide, t-butyl hydroperoxide, sec-butyl hydroperoxide, and 1-phenyl-2-methylpropyl 1-hydroperoxide Water-soluble initiators capable of radical polymerization selected from one or more of the groups can be used. Selection of the polymerization initiator is appropriately selected according to the reaction temperature, and an appropriate amount is used because the amount of the polymerization initiator may affect the molecular weight.

Since the solution used in the present invention uses water, not an organic solvent, and the reaction temperature of solution polymerization is related to molecular weight, it may be selected according to the molecular weight and may vary depending on the monomer and initiator, but the reaction is usually performed at 80 to 90 ° C. do. In addition, since the change in molecular weight occurs due to the control of the heat of reaction, the polymerization time is generally in the range of about 30 minutes to 8 hours, preferably 3 to 4 hours, depending on the amount of the reactants.

The water-soluble acrylic resin polymer of the present invention has a weight average molecular weight in the range of 10,000 to 500,000, preferably a weight average molecular weight of 50,000 to 250,000. If the molecular weight is less than 10,000 oligomer, there is a possibility that the mechanical properties, that is, the sag resistance when using as a coating agent in the ceiling plate is inadequate, and the resin viscosity becomes very high when it exceeds 500,000, it is difficult to control during the manufacturing process of rockwool ceiling plate There is this.

When using an unsaturated ethylenic-monocarboxylic acid monomer as in the present invention, any inorganic base or organic base may be used as a neutralizing agent to neutralize the acid component in order to prevent corrosion of the equipment. Examples of neutralizing agents include inorganic bases such as sodium hydroxide, potassium hydroxide, and / or lithium hydroxide, sodium carbonate, and / or amines such as monoethanolamine, diethanolamine, diethyl Aminoethanol, ammonia, trimethylamine, triethylamine, tripropylamine, dimethylethanolamine and / or morpholine.

In the present invention, when the neutralizing agent is used, the amount of the neutralizing agent is preferably 0.1 to 100 parts by weight based on 100 parts by weight of the acrylic resin polymer solids. This may affect the sag resistance deterioration.

In addition, a metal ion-containing material may be added in the preparation of the coating agent including the water-soluble acrylic resin polymer to obtain a sag resistance improvement effect of the ceiling plate. The metal ion-containing material is an oxide, hydroxide, sulfur oxide, chloride or the like containing calcium ions, aluminum ions or zinc ions, and one or more thereof are selected and used. Representative examples of the metal ion-containing material include Al ₂ (SO ₄ ) ₃ , CaCl ₂ , ZnO, CaSO ₄ , Al (OH) ₃ , and the like, when the metal ion-containing material is used, the amount of the metal resin-containing solid is 0.1-100 weight part is preferable with respect to 100 weight part.

The pH of the coating agent of this invention is 2-6, Preferably it is pH 3-5. If the pH is lower than 2, excess acid is not reacted with the inorganic material, so it exists in the ceiling plate, which may lower the moisture resistance of the product and cause sagging at high temperature and high humidity.If it is higher than 6, the inorganic component of rock wool component (SiO ₂ , The degree of reaction with CaO and Al ₂ O ₃ ) is low, and as a result, there is a possibility that the resistance to sag is insignificant.

In preparing the coating agent according to the present invention, in addition to the water-soluble acrylic resin polymer, neutralizing agent, and metal ion-containing material, a thickener, extender pigment, and antifoaming agent may be included. In addition, other additives commonly used as preservatives, dispersants, non-tackifiers, stabilizers, Cryoprotectants, wetting penetrants and the like. When it contains the above additives, the content is 0.5 to 5 parts by weight of a thickener based on 100 parts by weight of the acrylic resin polymer solids. 50 to 500 parts by weight of extender pigment, 0.1 to 5 parts by weight of antifoaming agent, and 0.1 to 1 part by weight of other additives are preferable. If the content of thickener is less than 0.5 parts by weight, there is a problem of sedimentation of the sieving pigment. If the content of the thickening agent is more than 5 parts by weight, it is difficult to control workability during application. It is feared that the flame retardancy may decrease, and if it exceeds 500 parts by weight, the wettability of the resin to the pigment may be inferior. In addition, if the content of the antifoaming agent is less than 0.1 parts by weight, there is a problem that the bubble suppressing ability is lowered, if the content of more than 5 parts by weight there is a problem that the cost of the coating increases. In the present invention, the thickener may be acrylic, urethane, bentonite, fused silica, cellulose or the like, and the extender pigment may be used alone or in combination with silica, talc, calcium carbonate, clay, etc., and the pigment volume concentration is 90%. It can be used within the range below. As the antifoaming agent, a fluorine modified siloxane type, an organic modified siloxane type, a mineral oil, or the like can be used.

According to the present invention, the coating agent is preferably applied to the front, back or both sides of the rockwool ceiling plate within the range of 0.005 to 5 kg, preferably 0.05 to 0.5 kg per square. If the coating amount is less than 0.005kg / pyeong, there is a possibility that the deflection resistance ability is insufficient, if it exceeds 5kg / pyeong there is a problem of manufacturing cost rise and the ceiling plate may be bent and productivity may be poor. Spraying method of coating solution may be Air Spray, Airless Spray method, spraying before passing through drying furnace, spraying after spraying before passing through drying furnace, Various methods such as spraying after passing through a drying furnace can be used.

The sagging property of the rockwool ceiling plate coated with the coating agent of the present invention preferably has a sag value of 2.2 mm or less when left at 50 ° C. and 95% RH for 24 hours, and at 17 ° C. at 50 ° C. and 95% RH. The sag value is preferably 2.5 mm or less after 4 times of standing for 7 hours at 23 ° C. and 50% relative humidity.

Hereinafter, the present invention will be described in more detail with reference to Preparation Examples and Examples, but the following Examples are illustrative only and are not intended to limit the present invention. The following shows an example of preparing the acrylic resin polymer synthesis and coating agent.

Preparation Example 1

Preparation of Water Soluble Acrylic Resin Polymer

2659.24 g of ionized water was added to a 5-liter four-necked flask equipped with a thermometer, and the temperature was raised to 85 ° C. When the temperature is maintained at 85 ° C., nitrogen is injected for 5 minutes, the reaction part is placed in a nitrogen atmosphere, and nitrogen is removed. Dissolve 14.5 g of potassium persulfate in 149.0 g of ionized water, insert it into the reactor, and age for 30 minutes. 647.1 g of methacrylic acid is added dropwise for 120 minutes and then maintained for 1 hour. The reactor was cooled to 40 ° C. and filtered through a 200 mesh filter to remove impurities and left for 1 day after packing. Solid content of the finally produced water-soluble acrylic resin was 19.1%, pH 2.0, acid value 740, and viscosity ^a) was 152 poise.

a) Viscosity: Brookfield Viscometer, RVT, 25 ° C., Sp No. Measured with 3

Preparation Example 2

Preparation of Water Soluble Acrylic Resin Polymer

2677.11 g of ionized water was added to a 5-liter four-necked flask equipped with a thermometer, and the temperature was raised to 85 ° C. When the temperature is maintained at 85 ° C., nitrogen is injected for 5 minutes, the reaction part is placed in a nitrogen atmosphere, and nitrogen is removed. Dissolve 18.9 g of ammonium persulfate in 121.1 g of deionized water, insert into a reactor, and age for 30 minutes. 458.4 g of acrylic acid and 184.6 g of methyl methacrylate are added dropwise thereto for 120 minutes, and then maintained for 1 hour. The reactor was cooled to 40 ° C. and filtered through a 200 mesh filter to remove impurities and left for 1 day after packing. Finally, the water-soluble acrylic resin prepared was 19.1% solids, pH 2.4, acid value 527, viscosity ^a) was 288 poise.

Example 1

The acrylic polymer of Preparation Example 2 alone was used as the coating agent.

Example 2

135 g of an aqueous 10% dimethylethanolamine solution was added dropwise to 500 g of the water-soluble acrylic polymer prepared in Preparation Example 1 to adjust the pH to 4.0 to 4.5. Solids of the finally prepared coating was 18.2%, pH 4.3.

Example 3

10 g of CaCl _{2 and} 10 g of Al ₂ (SO ₄ ) ₃ were added to 500 g of the water-soluble acrylic polymer prepared in Preparation Example 1, followed by stirring for 30 minutes. PH of the finally prepared coating was 2.1.

Example 4

20 g of ZnO was added to 500 g of the water-soluble acrylic polymer prepared in Preparation Example 2, followed by stirring for 30 minutes. The reaction between ZnO and the polyacrylic acid polymer caused chelation as Zn ²⁺ ions reacted with two carboxyl groups (-COO-). PH of the finally prepared coating was 2.5.

Example 5

140 g of a 10% dimethylethanolamine aqueous solution was added dropwise to 500 g of the water-soluble acrylic polymer prepared in Preparation Example 1, and 10 g of CaCl ₂ was added thereto, followed by stirring for 30 minutes. PH of the finally prepared coating was pH 4.3.

Example 6

501.3 g of distilled water, 1.6 g of Optigel LX (Bentonite system), 90.5 g of talc, and 1.6 g of antifoaming agent (BYK 024, BYK Co., Ltd.) were placed in a 2 L cup, and a Mill Base was prepared while strongly dispersing for 30 minutes using a high speed disperser. Thereafter, 215 g of a water-soluble acrylic polymer having a solid content of 19.1% and 144.9 g of distilled water specified in Preparation Example 1 were sequentially added and stirred for 30 minutes. The prepared coating agent had a pH of 2.9, a pigment / binder ratio of 2.1 / 1, and a pigment volume concentration of 40.0%.

Example 7

501.3 g of distilled water, 1.6 g of Optigel LX (Bentonite system), 90.5 g of talc, and 1.6 g of antifoaming agent (BYK 024, BYK Co., Ltd.) were placed in a 2 L cup, and a Mill Base was prepared while strongly dispersing for 30 minutes using a high speed disperser. Thereafter, 215 g of a water-soluble acrylic polymer having a solid content of 19.1% specified in Preparation Example 1, 144.9 g of distilled water, and 20 g of dimethylethanolamine were sequentially added and stirred for 30 minutes. PH 5.1, pigment / binder ratio of the prepared coating agent was 2.1 / 1, the pigment volume concentration was 40.0%.

Comparative Example 1

Melamine-Formaldehyde Resin Coating

Cytek's melamine-formaldehyde resin Aerotru 23 was used as a coating.

Comparative Example 2

Urethane Water Dispersion Coatings

20 g of polyester polyol (molecular weight 2000), 12.4 g of dimethyl propionic acid (DMPA), 12.4 g of N-methylol pyrollidon (NMP), 29 g of hexamethylene diisocyanate (HMDI) and dibutyltin dilaurate (DBTDL) 0.6 g is added and the temperature is raised to 90 ° C. After 4 hours, measure NCO%, measure NCO%, and neutralize by adding TEA (Triethylamine) within 4.5%. After about 30 minutes, water (DIW) is added over 10 minutes, and after 30 minutes, ED (ETHYLENE DIAMINE) is added as a chain extender. When water is added, it goes from a low viscosity state to a high viscosity state and maintains a low viscosity state again. After that, hold for about 1 hour and filter it with 400 mesh. The water dispersion resin thus prepared has a solid content of about 35%, and a stable water dispersion coating agent having 10 to 200 cps is obtained.

Comparative Example 3

Manufacture of acrylic emulsion polymerization coating

Into a 5-liter four-necked flask equipped with a thermometer, DIW 1998.8g, CO-436 (Rhodia) 1.9g, MMA (Methylmethacrylate) 30.8g were added and the temperature was raised to 80 ° C. When the temperature is maintained at 80 ° C., nitrogen is injected for 5 minutes to make the reaction part nitrogen, and then nitrogen is removed. 0.72 g of sodium persulfate (SPS) is dissolved in 10.3 g of DIW, and then injected into the reactor and aged for 30 minutes. An initiator solution of 0.5 g of SPS dissolved in 25.2 g of DIW was added dropwise for 10 minutes, and an emulsifier solution of 3.2 Mg of MMA 506g, 410 g of St (Styrene), and 3.2 g of CO-436 was added dropwise to 772.8 g of DIW simultaneously for 2 hours and 30 minutes. Mature. The reactor was cooled to 40 ° C. and filtered through a 200 mesh filter to remove aggregates and left for 1 day after packing. Solid content of the finally prepared emulsion was 24.4% and particle size was 107nm.

Experimental Example

72 parts by weight of rock wool, 3.6 parts by weight of starch, 9.1 parts by weight of attapulgite, 0.1 parts by weight of polyacrylamide, 2.8 parts by weight of organic fibrous paper, 0.4 parts by weight of wax emulsion, 0.7 parts by weight of liquid coagulant, defective product recycled powder Broke (13.2 parts) by weight and blended to form a 50% water content, and then sprayed 0.2kg per square foot of coating on one side of the molding and dried for 90 minutes at 100 ℃. Most of the water evaporates, leaving the resin as a high solids material with viscoelastic properties that adhere to the fibers in an essentially uncured state. After processing and cutting, a rock wool ceiling plate having a thickness of 15 mm was manufactured, and sag properties a and b (Sag A and B), flame retardancy, and formaldehyde release rate were measured. As the coating agent, the coating agents specified in Examples 1 to 7 and Comparative Examples 1 to 3 were used, and the measurement results are shown in Table 1 according to the following physical property measurement method.

<Method of measuring physical property>

1.Sag measurement (A)

1) Place the prepared rockwool ceiling plate (60 × 60㎝) on the square grid and read the initial instructions (a) with the dial gauge.

2) After leaving the specimen under the constant temperature and humidity conditions of 50 ℃ / RH95% / 24hr, take it out and read the instructions (b) again with the dial gauge.

3) The sag value is calculated according to Equation 1 below.

2. Sag measurement (B)

1) Place the prepared rockwool ceiling plate (60 × 60㎝) on the square grid and read the initial instructions (a) with the dial gauge.

2) Repeat the specimen standing four times for 17 hours at 50 ° C / RH95% and 7 hours at 23 ° C / RH50%. Remove and read the instructions (b) again with the dial gauge.

3) Sag value is calculated according to Equation 1 below.

Sag = a-b

3. Flame retardant

1) Substrate test: Burn the ceiling plate specimen (50 × 40 × 40cm) in the furnace adjusted to 750 ℃ according to KSF 2271 and the temperature rise during combustion should not exceed 800 ℃.

4. Formaldehyde Release Rate

1) Collect the air from the chamber on the 7th day after placing the specimen in the small chamber according to the small chamber method.

2) Collected air is analyzed (HPLC).

3) The concrete test method shall be tested by the small chamber method established by the Air Cleaning Association, and the result shall be judged on the 7th day.

Sag A (mm) Sag B (mm) Flame Retardant (℃) Formaldehyde Release Rate (mg / ㎡h) Example 1 1.7 2.2 38 0 Example 2 1.6 2.1 36 0 Example 3 1.8 2.2 37 0 Example 4 1.7 2.1 36 0 Example 5 1.5 2.1 39 0 Example 6 1.6 2.0 39 0 Example 7 1.6 2.3 36 0 Comparative Example 1 1.7 2.0 38 0.22 Comparative Example 2 3.1 3.8 42 0 Comparative Example 3 2.8 3.4 49 0

As described above, it was confirmed from the above results that a coating agent using a water-soluble acrylic resin or a resin having no formaldehyde emission was used to prepare a rock wool ceiling plate having stable sag resistance and flame retardant properties as a coating agent.

Claims (10)

A water-soluble acrylic resin polymer having an acid value of 300 to 850 KOH / mg obtained by solution polymerization of an unsaturated ethylenic mono carboxylic acid monomer alone or the monomer and an unsaturated ethylenic monomer in an aqueous phase by radical reaction with a water-soluble initiator and having a pH of 2 It is -6, The coating composition for rock wool ceilings containing no formaldehyde. The coating composition of claim 1, wherein the water-soluble acrylic resin polymer has a weight average molecular weight of 10,000 to 500,000. The coating composition of claim 1, wherein the composition further comprises a neutralizer or a metal ion-containing material. The method of claim 3, wherein the neutralizing agent is monoethanolamine, diethanolamine, diethylaminoethanol, ammonia, trimethylamine, triethylamine, tripropylamine, dimethylethanolamine, morpholine, sodium hydroxide, potassium hydroxide One or more selected from the group consisting of the side, lithium hydroxide and sodium carbonate, the dosage is 0.1 to 100 parts by weight relative to 100 parts by weight of the acrylic resin polymer solid-free cotton wool fabric Plated coating composition. The method of claim 3, wherein the metal ion-containing material is selected from the group consisting of oxides, hydroxides, sulfur oxides and chlorides containing calcium ions, aluminum ions, zinc ions, the dosage is the acrylic resin polymer solids It is 0.1-100 weight part with respect to 100 weight part, The coating composition for rock wool ceilings containing no formaldehyde. The method of claim 1, wherein the unsaturated ethylenic monocarboxylic acid monomer is acrylic acid, methacrylic acid, vinylbenzene acid, isopentyl benzene acid, crotonic acid, acryloxypropionic acid, methacrylicoxy-propionic acid, acryloxaacetic acid, methacrylic One or more selected from the group consisting of oxyacetic acid, monomethylmaleate, monomethylitaconate, and monomethylfumarate, the amount of which is 50 to 100 on a solids basis for the total monomers used in the acrylic resin polymerization. A coating composition for rock wool ceilings containing no formaldehyde, characterized in that the weight%. The method of claim 1, wherein the unsaturated ethylenic monomer is styrene, vinyl toluene, ethylene, vinyl acetate, vinyl chloride, vinylidene chloride, acrylonitrile, acrylamide, methacrylamide, methyl methacrylate, methyl acrylate, ethyl Acrylate, ethyl methacrylate, butyl acrylate, butyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, benzyl acrylate, benzyl methacrylate, lauryl acrylate, lauryl methacrylate Latex, palmityl acrylate, palmityl methacrylate, stearyl acrylate, and stearyl methacrylate, one or more selected from the group consisting of solids relative to the total monomers used in the acrylic resin polymerization Rockwool ceiling plate containing no formaldehyde, characterized in that 0.1 to 50% by weight as a guide The coating composition. The coating composition of claim 1, wherein the composition further comprises a thickener, an extender pigment, and an antifoaming agent. A method of using the coating composition for rockwool top plate, wherein the coating composition for rockwool top plate according to any one of claims 1 to 8 is applied within a range of 0.005 to 5 kg per rock floor ceiling plate. Rockwool ceiling plate characterized in that the coating composition for rock wool ceiling plate according to any one of claims 1 to 8.