KR100701277B1 - A Wallboard Material with Carpet and Flame-Retardant Layer - Google Patents

Abstract

An interior construction material having a carpet layer and a flame-retardant functional layer is provided to secure both sound absorption and flame retardant properties and to make the structure thin. A flame-retardant interior construction material(20) having a carpet layer(21) is composed of the carpet layer provided with a pile(211) for forming a uniform curved surface by continuously aligning ridges and gullies and made of nylon 6, nylon 66, PP(Polypropylene), PTT(Polytrimethylene Terephthalate), or PET(Polyethylene Terephthalate) fibers; a functional layer(C) containing a flame retardant; an absorbing layer(23) combined to the carpet layer; and an adhesive layer(22) for bonding the carpet layer and the absorbing layer. The carpet layer has an effective surface area of 20~150m^2 to the absorbing layer of 1m^2.

Description

A wallboard material with carpet and flame-retardant layer

Figure 1 shows a cross section of a building material according to the invention.

The present invention relates to an interior building material having a carpet layer and a functional layer, specifically a carpet layer of nylon 6, nylon 66, polypropylene, polytrimethylene terephthalate or polyethylene terephthalate fiber, the carpet layer comprising a flame retardant material It relates to a material for indoor construction.

 Wall, ceiling and floor materials require robustness and functionality. Robustness means that the material can be formed together with other materials to maintain the required shape for a certain period of time. And functionality is required to improve the usability of the internal environment depending on the space where the material is used. In general, the material for robustness is not highly demanded because there is no diversity required in that it is limited and not exposed to the outside. However, the material for the functional material can be changed depending on the required function and the high selectivity due to the difference in the effect depending on the material.

Commonly required functions for wall, ceiling and floor materials are sound absorption, insulation, flame retardant or flame retardant. In addition, antibacterial or deodorant and decorative properties may be required depending on the use of the used space.

Sound absorption means that some of the sound incident on the material is absorbed in the material without being transmitted or reflected. When sound is generated from one side of the material, the sound that is not reflected corresponds to the absorption or transmission of the material. Since all of these unreflected sounds appear to be absorbed, the ratio of sound energy that appears to be apparently absorbed to the incident sound energy is called sound absorption ratio.

Interior building materials should have sound absorbing and vibration absorbing as well as other additional functions. These additional functions are required for the efficiency of the space used and, for example, these functions include the prevention of harmful gases that cause antibacterial, deodorant, flame retardant and sick house syndrome. These functions, in addition to building materials, are becoming essential functions with the development of new building materials.

The method of forming the functional layer on the indoor building material includes a method of applying a coating agent and a method of adding a material having a function necessary for the material and adding it in the form of a composition. Alternatively, the two methods may be used in combination to add a functional material to an adhesive or a coating to coat a wall material.

Prior art related to building materials having a functional is 10-2002-0084252 "Building finishing material using a ceramic composite and a method of manufacturing the same". The proposed invention aims at generating negative ions, reducing heating and cooling costs, neutralizing toxic and antibacterial, insect repellent, and soundproofing effects. And the building finish according to the proposed invention is a silica bead formed a fine hollow in the body; It includes a composite ceramic mixed with the hollow silica beads in a predetermined volume ratio.

Another prior art related to functional building materials is WO2004 / 085151 "Functional members, methods for making them and coating liquids". The proposed invention aims to provide a functional member having excellent humidity control function, removal of toxic chemicals and unpleasant living odors, antifouling property, contamination concealment and flammability. And a functional member according to the proposed invention, comprising: a first layer formed on a combustible substrate and comprising a dried material comprising an inorganic porous body and an organic emulsion; And an inorganic filler fixed over the entire surface of the first layer by an organic adhesive, wherein the glass transition temperature of the glass in the organic emulsion is from -5 ° C to -50 ° C; The organic adhesive in the second layer is characterized in that the amount of 30 to 300 parts by volume relative to 100 parts by volume of the inorganic filler.

The invention presented or known does not disclose materials for interior construction in which a flame retardant is added to the material itself. In particular, it does not disclose an interior building material in which the carpet layer used as the sound absorbing function layer of the building material includes a flame retardant material.

The present invention proposes a building material wherein the carpet layer used as the sound absorbing functional layer comprises a flame retardant material.

It is an object of the present invention to provide a building material comprising a carpet layer having a flame retardant and sound absorption function simultaneously, including a flame retardant material.

According to a preferred embodiment of the present invention, the building material according to the present invention comprises a carpet layer of nylon, polypropylene (PP), polytrimethylene terephthalate (PTT) or PET (Polyester) fibers having uniformly distributed bends; And a functional layer comprising a flame retardant; And an absorbent layer bonded to the carpet layer; And an adhesive layer for bonding the carpet layer and the absorbent layer.

According to another suitable embodiment of the present invention, the flame retardant functional layer may be formed by treating the pile layer with a flame retardant of nitrogen-based phosphorus compound condensate or Thio urea-based condensate component by dipping or spraying.

According to another suitable embodiment of the present invention, an inorganic metal hydroxide compound, a phosphorous flame retardant or an acrylic flame retardant may be mixed with the base resin and treated in a pre-coating or backing process.

According to another suitable embodiment of the present invention, the inorganic metal hydroxide compound may be any one of aluminum hydroxide, magnesium hydroxide or a mixture thereof.

According to another suitable embodiment of the present invention, the ratio of the inorganic metal hydroxide compound to the polyvinyl chloride (PVC) or SBS (styrene butadiene styrene) resin used in the backing process may be 1: 0.5 to 3.

According to another suitable embodiment of the present invention, the particle size of the inorganic metal hydroxide compound may be 0.5 to 2.0 ㎛.

According to another suitable embodiment of the present invention, the inorganic metal hydroxide compound may be in the form of nanoparticles.

According to another suitable embodiment of the present invention, a better flame retardant effect can be obtained by using a combination of two methods of forming a flame retardant functional layer on the surface of the carpet layer and adding a flame retardant to a pre-coating or backing process.

In the following the invention is described in detail using the non-limiting examples.

1 shows a cross section of a building material comprising a carpet layer with flame retardant and sound absorption functions according to the invention.

Referring to FIG. 1, the material 20 may include a coating layer including a carpet layer 21, a composition having a function such as antibacterial, flame retardant and harmful substance removal; An adhesive layer 22 made of a material such as synthetic resin; Sound absorbing layer 23 in foam form; And a dustproof layer 24 made of a dustproof material such as rubber felt as required.

In FIG. 1, carpet layer 21 is composed of pile 211 and bubble paper 212, and pile 211 in carpet layer 21 is nylon 6, nylon 66, polypropylene (PP), polytrimethylene tere. It may be phthalate (PTT, Polytrimethylene terephthalate) or polyethylene terephthalate (PET) bulky continuous filament (BCF) fibers. Nylon BCF is characterized by excellent strength, abrasion resistance and elasticity, and excellent chemical resistance, microbial resistance and electrical insulation. PP BCF fibers, unlike other fibers, have a water content of zero and an extremely low absorption rate. These PP BCF fibers are characterized by low static absorption and excellent in stain resistance and antibacterial resistance without generating static electricity. PET BCF fibers have good shape stability and flame retardancy. The carpet layer 21 of the sound insulation material 20 according to the invention can be formed of a generally known known carpet, but is preferably formed of nylon, PP, PTT or PET fibers due to the respective advantages presented.

In addition, the bulky continuous filaments (BCF) can be prepared by any method known to those skilled in the art. Preferably a plurality of BCF yarns are cable twisted and heat set together and then weave to the primary back side. The latex adhesive and the secondary backside are then applied. Cut pile style carpets or loop pile style carpets with pile heights of approximately 2-20 mm can be made. At this time, the weight of the carpet is 400 to 4000g / m ² .

The form of the pile of the carpet layer of the present invention is not particularly limited, but may be any form such as a cut pile or a loop pile. In addition, the carpet used for the carpet layer of the present invention may be used in a state in which a lapping prevention latex is coated on the bottom surface of the bubble paper, or may be used in a form completed until backing as necessary.

The carpet layer 21 according to the invention has the advantage of excellent negative absorption effect since the effective surface area is much larger than the surface layer of the known wall material. The effective surface area may be the area of the directly reaching portion without being reflected or scattered when light or sound is incident perpendicularly to the material plane.

Although the specific surface area represents an area for unit weight, the effective surface area is related to the apparent surface area, and the sound absorption performance of the sound absorbing product is more correlated with the effective surface area than the specific surface area. This effective surface area may have a larger value if the surface is not flat and has curvature. If the material surface has a roughness, it becomes difficult to measure the effective surface area substantially. Therefore, the effective surface area needs to be determined according to a certain method with respect to the cross-sectional area of the material. In this patent, the surface area value of the fiber existing in the unit area of 1 m ² of the sound absorbing layer is defined as the effective surface area (m ² ). The effective surface area of the carpet layer material used in the present invention was suitably 20-1500 m ² . If the effective surface area is less than 20m ^{2, the} sound absorbing effect is small and unsuitable. If the effective surface area is more than 150m ² , too much fiber per unit area or the length of pile is required to be woven.

When the soundproof material having the carpet layer is installed on the wall or ceiling, the thickness of the carpet layer 21 should be limited or the density should be limited in consideration of the weight and sound absorption performance of the product related to space autonomy or ease of construction. There is. The thickness of the carpet layer may be 2-20 mm, preferably 5-10 mm is suitable, and the density of the carpet layer material is 50-300 kg / m ³ . If the thickness or density of the carpet is less than the set range, the sound absorbing function is not sufficient, and if it exceeds the set range, it takes up a lot of space and it is difficult to secure the light weight, which is not preferable.

In addition, the soundproof material 20 according to the present invention has a functional layer (C) for improving flame retardancy is formed on the surface of the pile 211 of the carpet layer 21, or formed on the surface of the bubble paper 212, preferably the upper Can be. Such functional layers C may be coated on the carpet layer. Alternatively, the material having the corresponding function may be added to the carpet for the carpet layer 21 by mixing with a pile anti-latex latex at the bottom of the bubble in the manufacturing process or mixed with the forming material of the adhesive layer 22. Can be formed.

The carpet layer 21 of the invention may preferably be in the form of a pile fabric and may comprise a flame retardant material according to the invention. The carpet layer 21 is flame retardant by pre-coating a carpet manufactured in the form of a cut file or by adding a flame retardant material in a backing process or by forming a flame retardant coating layer by dipping or spraying the pile layer. It is formed from the material. Precoating of the carpet is made of SBR latex and calcium carbonate. In the backing process, polyvinyl chloride (PVC) or SBS (styrene butadiene styrene) resin and calcium carbonate are used as reinforcing materials, and inorganic flame retardant materials are added to further improve flame retardancy. The inorganic flame retardant material may include metal oxides such as magnesium hydroxide, aluminum hydroxide, calcium hydroxide or mixtures thereof. Among the materials presented, aluminum hydroxide should be added in a significant amount to make it sufficiently flame retardant compared to other inorganic flame retardant materials. However, in the case of pre-coating, since a thin coating layer is formed, it is difficult to improve flame retardancy. Therefore, aluminum hydroxide needs to be used in admixture with other inorganic flame retardant materials. The metal hydroxide compound added for flame retardancy in the pre-coating or backing process may be 50 to 300 parts by weight based on 100 parts by weight of the SBR latex or PVC resin. If less than 50 parts by weight is used, the flame retardant effect is not sufficiently exhibited, and if more than 300 parts by weight there is a fear that the physical properties of the coated surface or backing surface occurs. Aluminum hydroxide in the metal hydroxide compound is advantageously used in admixture with other inorganic flame retardant materials. In this case, the mixing ratio of the other inorganic flame retardant material with respect to aluminum hydroxide may be 8 to 4: 2 to 6. The other flame retardant material may preferably be magnesium hydroxide. The particle diameter of the compound of the metal hydroxide used as the flame retardant material may be 0.5 to 2.0 ㎛. Alternatively, the use of nanoparticle-sized flame retardant materials has the advantage that the dispersibility is improved to prevent degradation of mechanical properties of the resin layer.

In addition, as the flame retardant material that can be used for the backing layer, an acrylic flame retardant may be used in addition to the metal hydroxide compound.

In addition to the method of imparting flame retardant to the backing process, the method of imparting flame retardancy to the surface of the carpet layer may treat the nitrogen-based phosphorus compound condensate or the thio urea condensate component by padding or spraying. There is also a good flame retardant effect can be obtained when the two methods are used in combination.

A key technical feature of the present invention is that the surface of the carpet layer 21 is formed with a constant curved surface, which has a large surface area compared to the finishing material of a known building material. The large surface area of the outer finish is quite advantageous in terms of functional release, due to the increase in the surface area of the coating of the sound absorbing, appearance forming, antibacterial and noxious substance removal components. The pile or bubble coated layer of the present invention is a layer that can exhibit other functions except sound absorption and vibration prevention. Other functions include such things as water repellent, removal of harmful components, flame retardant, tint formation, antibacterial, electromagnetic wave absorption and anion or ultraviolet radiation emission.

In the adhesive layer 22 of the present invention, various types of well-known thermoplastic resins may be used, and for example, those selected from acrylic resins, polyurethane resins, polyolefin resins and low melting point PET resins may be in the form of powder, pellets or hot melt films. Can be applied. The thermoplastic resin powder is sprayed on one side to which the carpet layer and the sound absorbing layer are attached, or the pellets are arranged at regular intervals or arranged in the form of a hot melt film, and heated and melted so that the carpet layer and the sound absorbing side are closely contacted and pressed. At this time, the polyolefin-based resin may be polyethylene, polypropylene, ethylene-vinyl acetate resin (EVA resin) and the like, and the hot melt film is preferably used hot melt film with holes punctured at regular intervals for smooth sound absorption performance of the final product. Do. Since the adhesive layer 22 is for bonding the carpet layer 21 and the sound absorbing layer 23, there is no particular limitation in form and material. However, the thinner the thickness, the more advantageous it can be formed to a thickness of 1 to 6 mm. Substantially direct contact between the carpet layer 21 and the sound absorbing layer 23 is advantageous for the absorption of sound and vibration or shock.

The sound absorbing layer 23 of the present invention may be made of any known sound absorbing and shock absorbing material, but preferably may be formed of mineral wool, urethane foam, melamine foam or felt, nonwoven fabric. . The sound absorbing layer 23 has sound absorption or shock and vibration absorption functions. Substantially the sound may be partially absorbed by the carpet layer 21 and the rest may be removed by the sound absorbing layer 23. Shock and vibration absorptions are equally exhausted, partly by the carpet layer 21 and partly by the sound absorbing layer 23. Since the sound absorbing layer 23 forms an inner layer of the soundproof material 20, problems such as appearance or generation of fine materials may not occur. However, it should be formed taking into account the complete absorption of sound and shock or the complete blocking of transmission to the outside. Therefore, the sound absorbing layer 23 needs to have a suitable thickness and strength. The sound absorbing layer 23 can be thick enough compared to the carpet layer 21 and must be small enough in strength. The thickness for sufficient absorption of sound or shock and vibration is 10 to 50 mm, preferably 20 to 30 mm, and the density of the absorbent layer is suitably 50 to 300 kg / m ³ . If the thickness or density of the absorber layer is less than the set range, the sound absorbing function is not sufficient, and if the thickness exceeds the set range, it takes up a lot of space and is difficult to secure the light weight, which is not preferable.

The present invention also includes a dustproof layer 24 made of a dustproof material, such as rubber felt, as needed.

<Property evaluation method>

1) Evaluation of effective surface area

The effective surface area of the carpet layer is cut into a 0.01 m ² area of 10 cm in length and width, respectively, and then the weight of the fiber is cut off as close as possible to the fiber at the top of the bubble paper.

Take a portion of the chopped fibers and measure the specific surface area (m ² / g) by nitrogen adsorption according to standard ASTM D3663-92 based on the Brunauer-Emmett-Teller (BET) method and cut the fibers at 0.01 m ² The effective surface area (m ² ), which is the surface area value of the fiber present in 1 m ² , was obtained by multiplying the weight (g) by 100.

The effective surface area of polyethylene terephthalate (PET) felt has a value of 1 per m ² since the surface is a two-dimensional plane with no bending.

2) Evaluation of Sound Absorption Rate

When the negative energy incident on the surface of the sound absorbing material is Ei and the negative energy reflected on the surface is Er, the sound absorption rate α is defined as follows.

 α = 1- (Er / Ei)

Absorption rate was measured by the reverberation chamber method sound absorption rate measured in the reverberation chamber in which the conditions close to random incidence were realized according to KS F 2805 standard. Marked as.

3) flame retardant

 The LOS (Limited Oxygen Index) was evaluated by testing with the KS M 3032 standard.

Example 1

A carpet woven in 1233den / 68fila PET BCF cut cut form was coated with a latex and backed by bonding to a secondary PP bubble using PVC resin as a carpet layer. Metal hydride flame retardants were added in the backing process. A carpet layer was prepared by adding 300 parts by weight of calcium carbonate and 100 parts by weight of a metal hydroxide compound to 100 parts by weight of the PVC resin as the backing process. As the metal hydroxide compound flame retardant material, commercially available ALCAN SF-7 (average particle diameter 1.2 µm) and aluminum hydroxide and MAGDANT (average particle diameter 1.1 µm) magnesium hydroxide were used, respectively. The mixing ratio of aluminum hydroxide and magnesium hydroxide was adjusted to 3: 7.

The thickness of the carpet layer backing up with the flame retardant added is 9 mm and the density is 195 kg / m ³ .

As the absorbent layer, melamine foam having a thickness of 25 mm and a density of 12 kg / m ³ was used.

Adhesion between the carpet layer and the absorbent layer was applied by spreading the polyethylene powder at 400g / m ² on the back side of the carpet layer, heating and melting with 150 ° C. hot air, and passing the cooling pressure roll while superimposing the absorber layer material.

Example 2

Instead of treating the metal hydroxide flame retardant in the backing process, a flame retardant (NICCA FINONE N-16, Nika Korea) consisting of Thio urea-based condensate was sprayed onto the woven carpet by spraying and drying at 120 ° C, 150 ° C, and 3 ° C. Manufactured in the same manner as in Example 1, except that mining was cured.

Example 3

In the same manner as in Example 1, the metal hydroxide compound is also used in the backing process and additionally prepared by applying the flame retardant of Example 2 (NICCA FINONE N-16, Nika Korea) by spraying 30% aqueous solution.

Comparative Example 1

It was prepared in the same manner as in Example 2 except for using a PET compressed felt having a thickness of 10 mm and a density of 190 kg / m ³ instead of a carpet layer.

Table 1

Effective surface area (㎡) Flame Retardant (LOI) Sound absorption rate (α) Example 1 69 28 0.78 Example 2 69 27 0.79 Example 3 69 30 0.79 Comparative Example 1 One 24 0.74

As can be seen from Table 1, in Example 1 of the present invention, a sound absorbing material for indoor construction having a carpet layer having excellent sound absorption and improved flame retardancy is obtained. Compared to Example 1 and Example 2, which were flame retardant in one manner, Example 3, which was a combination of two methods, showed the best flame retardancy.

On the other hand, Comparative Example 1 is a case in which PET compressed felt is used on the surface instead of the carpet layer, and the sound absorbing performance is slightly lowered, and the flame retardant effect is not sufficient, so it is not preferable as a wall or ceiling interior material.

It has been described in detail using the embodiments presented above. The presented embodiments are illustrative and can be made by those skilled in the art to various modifications and modifications to the disclosed embodiments without departing from the spirit of the present invention. Such modifications and variations are not intended to limit the scope of the invention.

The building material according to the present invention has the advantage that a separate flame retardant treatment is not required for the building material, including the flame retardant material of the cafe layer. Therefore, the building material according to the present invention has the advantage that it can be manufactured in a thin thickness while having sound absorption and flame retardancy.

Claims (7)

A fire retardant interior building material comprising a carpet layer, Carpet layers of nylon 6, nylon 66, polypropylene, polytrimethylene terephthalate or polyethylene terephthalate fibers with piles arranged in a row with acid and valleys to form a uniform curved face; A functional layer comprising a flame retardant; An absorbent layer bonded to the carpet layer; And A fire retardant interior building material comprising an adhesive layer bonding the carpet layer and the absorbent layer, wherein the effective surface area of the carpet layer is from 20 to 150 m 2 for 1 m 2 of absorbent layer. The material of claim 1, wherein the functional layer including the flame retardant is formed by treating the surface of the carpet layer with a dipping or spraying method on a surface of the carpet layer. The material according to claim 1, wherein the carpet layer is provided with an inorganic metal hydroxide compound or an acrylic flame retardant in a pre-coating or backing process to impart flame retardancy. The material of claim 3, wherein the inorganic metal hydroxide compound is selected from aluminum hydroxide, magnesium hydroxide, or a mixture thereof. The material of claim 3, wherein the ratio of the inorganic metal hydroxide compound to the polyvinyl chloride or styrene butadiene styrene resin used for the backing is 1: 0.5 to 3 by weight. The material of claim 4, wherein the inorganic metal hydroxide compound has a particle size of 0.5 to 2.0 μm. The material of claim 4, wherein the inorganic metal hydroxide compound is in the form of nanoparticles.

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