KR100792101B1 - A monolithic thermal insulating and antishocking material and a preparation method thereof - Google Patents

Abstract

A monolithic thermal insulating and shock absorbing material is provided to cut off lightweight and heavyweight impact sound effectively, to have excellent thermal insulation performance and durability and to perform construction work conveniently. A monolithic thermal insulating and shock absorbing material is formed by piling up a surface material layer(10), a thermal insulating material layer(20), and an air layer-contained shock absorbing material layer(30) in order, wherein the surface material layer is composed of foamed polyethylene resins having low dynamic elastic modulus for interlayer noise and vibration control and formed to a thickness of 2~20mm in due consideration of sound insulation performance and surface strength, the thermal insulating material layer is composed of polyurethane and formed to a thickness of 10~50mm in due consideration of thermal insulation performance, and the shock absorbing material layer is composed of an air layer(32) formed of an air cap and formed to a thickness of 2~10mm and protection layers(31,33) welded to one or two sides of the air layer and formed to a thickness of 2~20mm to heighten surface strength and to prevent the damage of the air layer against heavy load. A manufacturing method of a monolithic thermal insulating and shock absorbing material comprises the steps of supplying a shock absorbing material layer to a double slate conveyor continuously in a roll type, discharging polyurethane reactant on the shock absorbing material layer, and placing a surface material layer on the polyurethane reactant, wherein the polyurethane reactant is hardened to the appointed thickness between the shock absorbing material layer and the surface material layer by showing foam reactions and resinification while passing through the double slate conveyor, and the shock absorbing material layer, the thermal insulating layer and the surface material layer are attached integrally by resinification.

Description

A monolithic thermal insulating and antishocking material and a preparation method

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a cross-sectional anatomical view of an integrated heat insulating buffer of an example of the present invention.

2 is a cross-sectional photograph of an integrated thermal insulation buffer of an example of the present invention.

Figure 3 is a photograph of an example of an air cap that can be used as the air layer of the buffer layer in the integrated thermal insulation buffer of the present invention.

Figure 4 is a schematic process diagram of a manufacturing method of the integral heat insulating buffer of the present invention.

<Description of Drawing Identification Code>

1-Insulation buffer 10-Surface layer 20-Insulation layer

30-buffer layer 31, 33-protective layer 32-air layer

The present invention relates to an integrated heat insulating buffer and a method for manufacturing the same, in which a surface material layer, a heat insulating material layer, and an air layer-containing buffer material layer are sequentially stacked. More specifically, the present invention has a low dynamic modulus value, which protects the insulation layer from external impact and primarily suppresses the transfer of interlayer noise, and has a low thermal conductivity to improve insulation performance. A heat insulating material layer and an air insulation-containing buffer material layer having a noise blocking ability in all areas of light weight / weight impact sound are integrally laminated with a heat insulating buffer material and a method for manufacturing the same.

In general, the impact sound of a multi-family house is divided into light impact sound and heavy impact sound. Lightweight impact sounds are impact sounds that occur when a light object is dropped or when a chair is dragged from the floor, and heavy impact sounds are impact sounds that occur when a heavy object falls, an adult walks on a heel, or a child runs. The impact sound has recently emerged as a social issue, even as a cause of conflict between generations up and down. In general, in the case of a light impact sound, there was a blocking effect as a conventional general shock absorbing material, but in the case of a heavy shock sound, the blocking effect was lower in the structure in which the shock absorbing material was constructed, rather than a bare slab in which the shock absorbing material was not constructed.

Recently, it has been legally mandated that new apartments must be constructed with a shock-absorbing structure in accordance with the recognition and management criteria for the floor-impact sound-blocking structure for multi-unit houses. Many buffers have been developed. Insulation material made of styrofoam material with low price competitiveness has been mostly constructed as a cushioning material. However, the insulation performance is barely satisfied and the performance is significantly reduced in terms of prevention of interlayer noise. In addition, rubber products such as EVA (ethylene vinyl acetate) may be used, but the thermal insulation performance is significantly reduced, exceeding the legal standard. On the other hand, in order to secure the floor impact sound blocking performance, products having several functional layers laminated are being developed, but it is difficult to commercialize it because of poor construction and durability due to adhesive bonding between layers during construction.

Recently, regulations on housing construction standards and building energy-saving design standards require insulation buffers with near-perfect sound insulation performance and excellent energy-efficient insulation. Therefore, while meeting these standards, the development of a heat insulating buffer having excellent workability and durability is required for commercialization.

The present invention solves the problems of the prior art as described above, it effectively blocks the light weight and heavy impact sound, has excellent heat insulation performance, and also forms an integrated laminated structure, the construction is very convenient and durable interlayer insulation buffer material The purpose is to provide. Another object of the present invention is to provide a manufacturing method that can provide a large amount of the thermal insulation buffer of the present invention by maximizing productivity by introducing a self-hardening continuous process rather than bond adhesive.

The object of the present invention as described above can be achieved by the thermal insulation buffer of the present invention described below and a method for producing the same.

The thermal insulation buffer of the present invention is an integral thermal insulation material in which a surface material layer, a heat insulation material layer, and an air layer-containing buffer material layer are sequentially stacked.

In the heat insulation buffer of the present invention, the surface material layer is made of foamed-polyethylene resin, and prevents damage due to external factors of the lower heat insulation material layer and has chemically inert properties, so that there is no fear of deterioration and good moisture resistance and chemical resistance. It is very suitable for forming the whole stone floor of apartments. In addition, the foamed-polyethylene resin has a very low dynamic elastic modulus as an intrinsic property, which is effective for preventing interlayer noise and vibration. In consideration of sound insulation performance and surface strength, the surface material layer preferably has a thickness of 2 mm to 20 mm. When the thickness is less than 2mm, it is weak to external impact and its dynamic elastic modulus is high, and the impact sound reduction performance is reduced.When it is more than 20mm, it must be constructed as slim as possible in the limited space of the ondol component layer to satisfy the proper effect. The disadvantage is that it only takes up space.

The insulation layer is made of polyurethane. Polyurethane is a polymer containing a urethane bond formed by the reaction of a polyol containing a hydroxyl group with an isocyanate (-NCO) and the reaction of a blowing agent with an isocyanate (-NCO). It has a low thermal conductivity and shows very good heat insulating properties. Polyurethane is mainly divided into PPG (polypropylene glycol) and MDI (4,4-dipenylmethan diisocianate). PPG is an ether polyol, chemical blowing agent, physical blowing agent, amine catalyst, metal catalyst, flame retardant, foaming agent. Etc. are liquid raw materials that are evenly dispersed without forming an interface with each other, and MDIs are largely divided into PURE MDI, MODIFIED MDI, and CRUDE MDI. In the present invention, CRUDE MDI which is liquid at room temperature is used. When the PPGs and MDIs are mixed with each other, the resinization reaction and the foaming reaction proceed, and a polyurethane is formed between 1 to 3 minutes after mixing. The reactant inflated by the foaming reaction is shaped like a bubble, and can be molded according to the shape of the outer jig, thereby representing the shape of the jig after curing.

In the present invention, the ratio of PPG to MDI is preferably 100 to about 130 by weight, and it is used according to the characteristics of PPG in the range of weight ratio, and also according to seasonal differences and product hardness. do.

The thickness of the heat insulating material layer is preferably 10 to 50 mm in consideration of the heat insulating performance. When the thickness is less than 10mm, the thermal insulation performance is not sufficient, and when the thickness exceeds 50mm, only the space is occupied without the space of the limited ondol component layer.

In the thermal insulation buffer of the present invention, the buffer layer is formed of an air layer and a protective layer heat-sealed on one side or both sides of the air layer. The air layer consists of a commonly used air cap. As the air cap, a commonly used packaging air cap may be used, but is easily broken by load and is not suitable as a cushioning material in itself. In order to compensate for this, in the buffer layer of the present invention, a protective layer is attached to one side or both sides of the air cap through heat fusion. Thermal fusion may be performed in a conventional manner, for example, when the protective layer and the air cap in a roll form continuously pass through the hot air blower and one side of the protective layer is slightly melted, it is immediately laminated with the air cap to form a pressing roller. By passing through, the molten portion of one side may be cured and thermally fused.

The cushioning material layer having a protective layer attached to the air cap may be reinforced with surface strength to prevent breakage of the air layer even under heavy loads. As the protective layer, a foamed polyethylene sheet, an independent foamed polyethylene foamed resin, a polyester nonwoven fabric, a polypropylene sheet, a bead method styrofoam, an extrusion method styrofoam, a fabric fabric, or the like may be used.

In the buffer layer, the thickness of the air layer is preferably 2 mm to 10 mm, and the thickness of the protective layer attached to one side or both sides of the air layer is preferably 2 mm to 20 mm. When the thickness is less than the lower limit, it is impossible to produce the sheet itself, and it is difficult to exert sufficient impact sound blocking performance, and when the thickness exceeds the upper limit, only a limited space of the ondol component layer is occupied.

The cushioning material layer of the present invention blocks the light weight and heavy impact sound very effectively.

Insulation buffer of the present invention configured as described above is more efficient than the conventional styrofoam, the insulation performance is improved by more than 40%, energy-efficient, the air layer-containing buffer material layer to effectively block not only light impact sound but also heavy impact sound very effective in actual field application Stable insulation and interlayer impact sound blocking performance can be maintained. In addition, the insulation buffer of the present invention has an integrated structure without using an adhesive, which is convenient for construction, thereby minimizing construction defects, and induces generation of formaldehyde and volatile organic compounds, which are harmful to human body, compared to the existing multilayer insulation buffer. It is an eco-friendly product that can be minimized.

The present invention provides a method of manufacturing an integrated thermal insulation buffer comprising the following steps, the method

The buffer layer is continuously supplied to the double slat conveyor in roll form,

Discharging the polyurethane reactant onto the buffer material layer,

And laminating the surface material layer in the form of a roll on the discharged polyurethane reactant,

Here, the polyurethane reactant is cured to a certain thickness through a foaming reaction and a resination reaction while passing through the double slat conveyor to form a heat insulating material layer between the buffer material layer and the surface material layer, and the buffer material layer and the heat insulating material layer by the resination reaction. , And the surface material layer are attached to each other to be integrated.

The buffer layer, the insulation layer, and the surface layer are as defined above.

Hereinafter, a manufacturing method will be described in detail based on the bar illustrated in the drawings.

As shown in the manufacturing process diagram of FIG. 4, the air layer-comprising buffer layer 30 in roll form is continuously supplied along the double slat conveyor, and the polyurethane reactant is discharged onto the supplied buffer layer 30. Polyurethane reactants are continuously discharged onto the buffer layer through the raw material stirring discharger installed on the double slat conveyor through the supply line with temperature controlled PPG and MDI in the polyurethane tank. The roll-like surface material layer 10 is laminated on top of the discharged polyurethane reactant with a constant tension such that wrinkles do not occur on the surface and continuously passes along the double slat conveyor. The polyurethane reactant discharged between the air layer-containing buffer material layer 30 and the surface material layer 10 is swelled through the foaming reaction and the resination reaction while passing through the double slat conveyor, and the upper buffer material layer 30 and the upper The surface material layer 10 is cured to a predetermined thickness. At this time, the buffer material layer 30, the heat insulating material layer 20, and the surface material layer 10 are attached to each other without the use of an adhesive and are integrated by the resination reaction. Therefore, the thermal insulation buffer according to the manufacturing method of the present invention has an environmentally friendly property such that formaldehyde and volatile organic compounds do not leach, unlike the interlayer insulation buffer of the general laminated structure. In addition, the polyurethane insulation layer formed by the foaming reaction is molded and cured according to the minute projection shape of the air layer included in the lower cushioning material, so that the load transmitted from above can be dispersed very effectively to maintain the air layer stably. In actual construction of the construction site for the follow-up process builders step on the thermal insulation buffer, the insulation buffer of the present invention can be protected even in this case the air layer. In other words, the integrated thermal insulation buffer according to the manufacturing method of the present invention can prevent the performance degradation of the thermal insulation buffer due to external factors.

In the manufacturing method of the present invention, the thickness of the polyurethane insulation layer 20 can be adjusted through a double slat conveyor. The double slat conveyor is driven by the upper slat conveyor and the lower slat conveyor at the same speed, and the upper slat conveyor is moved up and down. A certain space is formed in the middle, and the space between the cushioning material layer 30 and the surface material layer 10 is filled with the reactant of polyurethane inflated by the foaming reaction to determine the thickness of the entire insulation buffer material 1. . As described above, when the air layer-containing buffer layer 30, the polyurethane insulation layer 20, and the surface layer 10 are sequentially laminated and cured and passed through the double slat conveyor, the side and the cross section are fixed by the electric automatic cutting machine. Cut to specification to form finished product.

In the manufacturing method of the present invention, the product produced by continuous input from the input of the material to the last cutting has a very uniform performance, thereby minimizing the defects of construction during application of the multi-unit house, and injecting the conventional interlayer insulation buffer. Compared to the production method of mold type, there is an effect of improving productivity and reducing manpower.

Insulation buffer of the present invention is generally constructed on top of slab concrete. Conventional thermal insulation buffer material has a difficulty in construction that requires the construction of each layer of the laminated structure separately or to prevent the formation of formaldehyde and volatile organic compounds by integrating the laminated structure of the insulation buffer material using an adhesive during construction. Existed. On the contrary, since the insulation buffer of the present invention is manufactured in one piece without adhesive, it can be laid at a time and the seams can be simply connected by tape connection, and can be easily cut by a general portable knife. It can be easily cut and installed on site.

Integral insulation buffer of the present invention is more than 40% compared to the existing styrofoam insulation properties are excellent energy efficiency, and can effectively block not only light impact sound, but also heavy impact sound, and has a monolayered multilayer structure formaldehyde and volatile It is eco-friendly and minimizes construction defects without the occurrence of organic compounds, so it is possible to maintain a very stable thermal insulation and interlayer impact sound blocking performance when applied in actual field.

In addition, the production method of the thermal insulation buffer of the present invention enables to produce a large amount of integral thermal insulation buffer material without the use of an adhesive continuously using a double slat conveyor. The thermal insulation buffer produced by the manufacturing method of the present invention has the effect of the thermal insulation buffer of the present invention as described above.

Claims (5)

An integral thermal insulation buffer in which a surface material layer, a heat insulation layer, and an air layer-containing buffer layer are sequentially stacked. The surface material layer is composed of expanded polyethylene, The insulation layer is made of polyurethane, and The buffer layer is composed of an air layer and a protective layer heat-sealed on one side or both sides of the air layer, the air layer is made of an air cap and the protective layer is a foamed polyethylene sheet, free foam polyethylene foamed resin, polyester nonwoven fabric, polypropylene One or more selected from the group consisting of sheet, bead styrofoam, extrusion styrofoam and fabric fabric, Integral heat insulation buffer, characterized in that the adhesive is not used in the integral heat insulation buffer. According to claim 1, wherein the surface material layer has a thickness of 2mm ~ 20mm, the heat insulating material layer has a thickness of 10 ~ 50mm, the air cap has a thickness of 2mm ~ 10mm, the thickness of the protective layer is 2mm ~ 20mm Integral insulation buffer material. In the manufacturing method of the integral insulation buffer, the method The buffer layer is continuously supplied to the double slat conveyor in roll form, Discharging the polyurethane reactant onto the buffer material layer, And laminating the surface material layer in the form of a roll on the discharged polyurethane reactant, Wherein the polyurethane reactant is cured to a predetermined thickness through a foaming reaction and a resination reaction while passing through the double slat conveyor to form a heat insulating material layer between the buffer material layer and the surface material layer, and the buffer material layer, the heat insulating material layer, And the surface material layers are attached to and integral with each other. 4. The method of claim 3, further comprising cutting the side and cross sections of the integrally prepared thermal insulation buffer material to a predetermined size with a cutter to form a finished product. A buffer material comprising an air layer composed of an air cap and a protective layer thermally fused to one or both sides of the air layer, wherein the protective layer is a foamed polyethylene sheet, an independent foamed polyethylene foamed resin, a polyester nonwoven fabric, a polypropylene sheet, a bead method styrofoam And at least one buffer material selected from the group consisting of extrusion method styrofoam and fabric fabric.

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