KR100828949B1 - Anti-flammable board and manufacturing method thereof - Google Patents

Abstract

A method for manufacturing a flame resistant board is provided to produce a flame resistant board having improved flame resistance, heat insulation property, water resistance and strength. A method for manufacturing a flame resistant board comprises: a step(S10) of forming a coating layer for forming micropores on the surface of beads impregnated with a foaming agent and a flame retardant; a step(S20) of providing the beads with a desired level of steam pressure to cause the beads to foam, thereby forming a plurality of foamed particles; a step(S40) of melting the foamed particles to form a board having micropores among the foamed particles; a step(S50) of injecting a solution of flame retardant into the micropores in the board; and a step(S60) of drying the board to obtain a flame resistant board.

Description

Flame retardant board and manufacturing method thereof

1 is a flow chart showing a flame retardant board manufacturing method according to an embodiment of the present invention.

Figure 2 is a side view showing a fabric mill forming an injection hole in the board.

3 is a cross-sectional view showing a board in which an injection hole is formed.

4 is a cross-sectional view showing a state in which the flame retardant is injected using a nozzle.

5 is a cross-sectional view showing a board according to the prior art.

6 is a cross-sectional view showing a state in which a flame retardant is injected into the board of FIG.

7 is a cross-sectional view showing a board manufactured through the method of FIG.

8 is a cross-sectional view showing a state in which a flame retardant is injected into the board of FIG.

9 is a photograph showing a state of performing a combustion test.

10 and 11 are photographs showing the combustion test results for the flame retardant board manufactured by the method of FIG.

12 is a photograph showing a combustion test result for a flame retardant board according to the prior art.

<Explanation of symbols for main parts of the drawings>

110: punching device 112: roller portion

114: slotting pin 116: protrusion

120: board 122: foamed particles

124: injection hole 126: void

130: nozzle

The present invention relates to a flame retardant board manufacturing method.

In general, styrofoam is widely used as an insulator for insulating walls and sandwich boards used as walls of buildings. However, styrofoam does not have fire resistance, so there is a problem that the building is easily burned down when a fire occurs in the building.

In order to solve this problem, a conventional flame retardant coating made of a liquid is applied to the outer surface of the styrofoam insulating material, and used as a heat insulating material, or before the foaming of the styrofoam insulating material, the foam is coated with a flame retardant coating on the surface of each foamed granule. It is used as a heat insulating material.

By the way, the insulation material coated with the flame retardant paint on the outer surface of the styrofoam did not penetrate the flame retardant paint to the inside of the heat insulating material, there is a problem that the flame retardant paint is not applied on any one side as it is used to cut the insulation material is exposed to the fire as it is. . In addition, since the insulating material coated with the flame retardant paint on the surface of the foamed granules performs the foaming work, there was a problem in that the flame retardant paint was lost or the fired granules inside the flame retardant paint melted in case of fire.

In consideration of these points, after molding the styrofoam, a method of filling a flame retardant into the styrofoam has been attempted, but the flame retardant is not sufficiently filled, and there is a problem in that it is not evenly filled.

The present invention provides a method of manufacturing a flame retardant board having not only high strength but also high flame retardant performance by sufficiently filling and evenly filling a flame retardant solution inside a flame retardant board.

According to an aspect of the invention, the step of forming a coating layer comprising an inorganic flame retardant material on the surface of the beads impregnated with a blowing agent and flame retardant; Foaming the beads to form a plurality of foam particles; Supplying steam to the plurality of foam particles to form a board having a predetermined shape; Injecting a flame retardant into the voids between the plurality of foam particles; And it can provide a flame retardant board manufacturing method comprising the step of drying the board.

Prior to forming the board, the step of maturing the foam particles so that the content of the blowing agent is 4.5 to 3.9 percent, the step of forming the board, the steam pressure of 0.30 to 0.60 kgf / cm ² to the foam particles Feeding 4.5 to 10 seconds; It can be carried out through the step of supplying the foam particles with a steam pressure of 0.35 to 0.60 kgf / cm ² for 3.5 to 6.5 seconds.

The diameter of the foam particles may be 2.5mm to 5.0mm, the flame retardant may be made of an inorganic material to block the fire by preventing the inflow of oxygen in the fire, and after the drying step, the weight ratio of the inorganic material to the board is 60 to 80 percent.

In addition, the flame retardant may include a material that adsorbs a gas generated during combustion, such as silica.

Other aspects, features, and advantages other than those described above will become apparent from the following drawings, claims, and detailed description of the invention.

Hereinafter, a preferred embodiment of a method for manufacturing a flame retardant board according to the present invention will be described in detail with reference to the accompanying drawings, in the following description with reference to the accompanying drawings, the same or corresponding components are given the same reference numerals and Duplicate explanations will be omitted.

1 is a flowchart illustrating a method of manufacturing a flame retardant board according to an embodiment of the present invention.

First, a coating layer containing an inorganic flame retardant material is formed on a surface of a bead impregnated with a blowing agent and a flame retardant (S10). By using a method of polymerizing by adding a blowing agent or the like to the styrene monomer, it is possible to provide beads impregnated with a blowing agent and a flame retardant. In addition, the beads may be impregnated with a blowing agent in various ways.

In this bead, an inorganic flame retardant material may be used to form a coating layer. Through such a coating, it is possible to prevent the occurrence of blocking during foaming, it is possible to shorten the molding time, improve the adhesion, release properties and the like.

In addition, by forming the coating layer to be resistant to moisture, it is possible to ensure the water resistance, to reduce the sensitivity of the beads to steam, and to reduce the friction coefficient of the surface of the foam particles after foaming, while providing a micro void The flame retardant may be easily filled.

Next, the beads are foamed to form a plurality of foam particles (S20). When steam is supplied to the beads impregnated with the blowing agent, the beads may be foamed by the blowing agent to form foam particles.

At this time, the diameter of the foam particles is preferably 2.5mm to 5.0mm. If the size is smaller than 2.5mm, the voids are formed when forming the board, the friction coefficient of the surface is high, it may be difficult to efficiently enter the flame retardant. In addition, when the size is larger than 5.0mm, the friction coefficient and strength of the surface is too low, there is a risk of brittleness.

In order to form the foam particles having such a size, it is possible to use a method for adjusting the pressure of the steam provided to the beads and the time the steam is provided.

The foam particles thus formed may be used to form a board having a predetermined shape (S40), and the step S30 of aging the foam particles may be performed prior to forming the board.

Maturation of the foam particles as a process for reducing the amount of blowing agent remaining in the foam particles, it may be carried out through a method for storing the foam particles for a predetermined time in a well ventilated place.

This maturation allows the content of blowing agent to be from 3.9 percent to 4.5 percent. If the content of the blowing agent exceeds 4.5 percent of the foamed particles, the fusion between the foamed particles may become too strong in the process of forming the board by providing steam to the foamed particles, making it difficult to obtain sufficient voids, more than 3.9 percent If it is small, because the fusion between the foam particles is not made sufficiently there is a fear that the strength of the produced board is lowered.

As such, in order to control the content of the blowing agent in the foam particles, a method of controlling the aging time may be used.

Next, steam is supplied to the plurality of foam particles to form a board having a predetermined shape (S40). Since the foaming particles are still contained in the foamed particles, when the foamed particles are put in a mold of a predetermined shape and steam is supplied, the foamed particles have a tendency to foam again by the foaming agent. Due to this tendency, each of the foamed particles is fused with adjacent foamed particles, and by this fusion, a board corresponding to the shape of the mold can be formed.

To this end, the foam particles may be supplied with a steam pressure of 0.30 to 0.60 kgf / cm ² for 4.5 to 10 seconds (S41), and then a steam pressure of 0.35 to 0.60 kgf / cm ² for 3.5 to 6.5 seconds (S42). ). Under the conditions outside the above-mentioned conditions, there may be a problem that the voids between the foamed particles are too small to be sufficiently injected into the flame retardant, or that the voids are too large and the mechanical strength of the board may be degraded, causing easy breakage. Because there is.

Next, a flame retardant is injected into the space inside the board, that is, the plurality of foam particles (S50). The process of filling the flame retardant in the board will be briefly described with reference to FIGS. 2 to 4.

FIG. 2 is a side view showing a fabric mill forming an injection hole in a board, FIG. 3 is a cross-sectional view showing a board on which an injection hole is formed, and FIG. 4 is a cross-sectional view showing a flame retardant solution injected using a nozzle. 2 to 4, the drilling device 110, the roller portion 112, the slotting pin 114, the protrusion 116, the board 120, the foam particles 122, the injection hole 124, Void 126 and nozzle 130 are shown.

First, the injection hole 124 is drilled in the board 120 (S51). Injection hole 124 may be formed on both sides of the board 120 as shown in FIG. Of course, the injection hole 124 may be formed only on one surface of the board 120 according to design needs.

The injection hole 124 may be drilled by the punching device 110 shown in FIG.

The roller part 112 is rotatably installed, and a plurality of slotting pins 114 are mounted at predetermined intervals along the outer circumferential surface thereof, and the injection hole 124 has a predetermined depth on the surface of the board 120 passing therebetween. Can be formed. The roller portion 112 may be configured to rotate by a separate driving means such as a motor, or may be configured to rotate naturally by the feed force of the board 120 applied to the slotting pin 114.

Slotting pin 114 may be formed in a plurality spaced apart a predetermined interval along the outer peripheral surface of the roller portion (112). Each slotting pin 114 may be formed extending in the direction perpendicular to the axis of the roller portion 112, the length and thickness of the injection hole 124 to be formed in the board 120 and the width It can be formed to correspond to.

The protrusion 116 is formed at the end of the slotting pin 114 and protrudes backward in the rotational direction. This is to prevent a part of the slotting pin 114 from being pressed by the back side of the injection hole 124 in the process of drawing by rotation after being inserted into the heat insulating material.

The board 120 in which the injection hole 124 is formed by the above-described method is shown in FIG. 4.

In the present embodiment, the drilling device 110 as shown in FIG. 3 is provided as a means for forming the injection hole 124, but in addition to the injection hole in the board 120 using a variety of means such as a blade (not shown) 124 may be formed.

On the other hand, when forming the injection hole 124 on both sides of the board 120, the injection hole 124 formed on both sides may be formed so that the depth is the same. When the depths of the injection holes 124 on both sides of the board 120 are formed to be the same, the process of forming the injection holes 124 can be simplified, and when one side and the other side of the board 120 are reversed in the manufacturing process. This is because there is no change in the function of the flame retardant board 120.

Next, a flame retardant is injected into the board 120 (S52). The flame retardant may be filled in the air gap 126 and the injection hole 124 in the board 120. The nozzle 130 may be used to inject a flame retardant into the board 120. By contacting the nozzle 130 to one surface or both surfaces of the board 120 and applying pressure to the nozzle 130, the flame retardation is caused to the void 126 inside the board 120 and the void 126 around the injection hole 124. You can inject liquid. By forming the injection hole 124 prior to injecting the flame retardant, the surface resistance of the board 120 can be lowered, so that the flame retardant can be easily injected.

The flame retardant injected into the board 120 may be made of an inorganic material. When the flame retardant of the inorganic material is injected into the board 120, the foam particles 122, which is an organic material, may be trapped in the inorganic diaphragm, and thus, moisture may penetrate or be contained in the foam particles 122. By being able to block the release of the blowing agent and the penetration of external air, it is possible to suppress the degradation of the mechanical strength and thermal insulation performance over time. In addition to the thermal insulation performance of the board 120 itself, the inorganic material diaphragm can once again block heat transfer and loss, thereby improving the thermal insulation performance.

In addition, the flame retardant may include silica and other absorbent materials. By including the silica component in the flame retardant, it is possible to reduce the amount of gas such as carbon monoxide, carbon dioxide, etc. generated during combustion by utilizing the gas adsorption of the silica component.

Next, the flame retardant exposed on the surface of the board 120 may be removed (S53). After the flame retardant is sufficiently infiltrated into the board 120 using the nozzle 130, the flame retardant remaining on the surface of the board 120 may be removed using a roller.

In order to remove the flame retardant exposed on the surface of the board 120, a method of compressing the board 120 by a predetermined thickness using a roller (not shown) may be used. The extra flame retardant liquid discharged at this time can also be recovered and recycled again.

On the other hand, when the board 120 is compressed using a roller (not shown), the thickness of the board 120 may be deformed, and thus, when the board 120 is to be produced with an accurate thickness and width, the board 120 is not pressed and the surface is not pressed. Only flame retardant exposed to

Next, a negative pressure is provided to the board 120 (S54). This is to provide a vacuum or near-negative pressure to the board 120 to separate the flame retardant into water and a flame retardant inorganic material. This is because by providing a negative (-) pressure to the board 120 to separate the flame retardant into water and a flame retardant inorganic material, it is possible to increase the drying efficiency of the board 120.

That is, the high specific gravity of the flame retardant minerals contained in the flame retardant liquid is to be left inside the board 120 while the low specific gravity water is to escape to the outside of the board 120. Through this, it is possible to significantly shorten the drying time delay due to the high heat capacity of the water.

Next, the flame retardant exposed on the surface of the board 120 may be removed (S55). After providing the negative pressure to separate the flame retardant, the surface of the board 120 is to be processed again. Since the thickness of the board 120 may be deformed when the board 120 is compressed using a roller (not shown), the roller 120 may be used without compressing the board 120 when a precise thickness and width are to be produced. As described above, only the flame retardant exposed on the surface may be removed.

After the flame retardant is injected into the board 120 using the above method, the board 120 into which the flame retardant is injected is dried (S60). By drying the board 120, it is possible to prevent the flame retardant or flame retardant inorganic material injected into the board 120 from leaking to the outside.

Drying of the board 120 may be accomplished by providing microwaves to the loaded board 120. By providing a microwave to the board 120, it is possible to cause the vibration of water molecules to induce the evaporation of water.

However, when only the microwave is provided to the board 120, water vapor generated by the heating is filled in the board 120, so that the humidity inside the board 120 may be increased, thereby reducing the drying efficiency. In order to prevent this, the water vapor of the board 120 may be discharged to the outside. By discharging the water vapor inside the board 120 to the outside to keep the humidity inside the board 120 low to improve the drying environment of the board 120 to increase the drying efficiency.

On the other hand, after this drying is done, the weight ratio of the inorganic material in the board 120 may be 60 to 80 percent. If the weight ratio of the inorganic material is less than 60 percent, the flame retardant performance is lowered, and if the weight ratio is greater than 80 percent, it is difficult to handle the product, the production is difficult, and there is a fear that the problem of low strength.

5 is a cross-sectional view showing a board according to the prior art, Figure 6 is a cross-sectional view showing a state in which a flame retardant is injected into the board of FIG. In addition, Figure 7 is a cross-sectional view showing a board manufactured by the method of Figure 1, Figure 8 is a cross-sectional view showing a state in which a flame retardant is injected into the board of FIG.

5 and 6, in the case of the board according to the prior art, it can be seen that the voids between the foam particles are not enough, the flame retardant is not sufficiently, evenly injected into the voids.

On the other hand, referring to Figures 7 and 8, in the case of the board manufactured according to the present embodiment, it can be seen that the voids between the foam particles is sufficiently secured, the flame retardant can be sufficiently, evenly injected.

This effect can be confirmed through FIGS. 9 to 12. 9 is a photograph showing a state in which the combustion test, Figures 10 and 11 are photographs showing the results of the combustion test for the flame retardant board manufactured by the method of Figure 1, Figure 12 is a combustion for a flame retardant board according to the prior art It is a photograph showing a test result.

In order to test the performance of the flame retardant board manufactured according to the present embodiment, the experiment was conducted by directly applying a flame to the board as shown in FIG. 9.

As a result, in the case of the flame-retardant board manufactured according to the present embodiment, as shown in Figure 10, the foam particles of the portion to which the thermal power is applied melted, the inorganic material around the foam particles does not melt, but the skeleton like honeycomb shape Could keep. Heat and fire are blocked by the inorganic material to prevent the inflow of fire into the interior, and as shown in FIG. 11, it was confirmed that deformation and thickness of the board hardly occur.

On the other hand, in the case of the board according to the prior art, as shown in Figure 12, it could be confirmed that the change in the deformation and thickness of the board could not be prevented from entering the fire inside.

The flame retardant board manufacturing method according to an embodiment of the present invention has been described above, and many embodiments other than the above-described embodiment exist within the claims of the present invention.

According to a preferred embodiment of the present invention as described above, by forming a coating layer containing an inorganic flame retardant material in the beads and foaming to form foam particles, by adjusting the content of the foaming agent in the foam particles and steam supplied to the foam particles By securing voids between the foamed particles and allowing the flame retardant to be sufficiently injected into the voids between the foamed particles, it is possible to provide a flame retardant board having improved flame retardancy, heat insulation, water resistance and strength.

Claims (6)

Forming a coating layer for forming fine pores on the surface of the beads impregnated with the blowing agent and the flame retardant; Foaming the beads to supply the steam pressure at a predetermined pressure to the beads to form a plurality of foam particles; Fusing the plurality of foam particles to form a board on which the micro voids are formed between the plurality of foam particles; Injecting a flame retardant into the micropores in the board; And Drying the board to produce a flame retardant board comprising the step of manufacturing a flame retardant board. The method of claim 1, Before the board forming step, Further comprising the step of aging the foam particles so that the content of the blowing agent is 3.9 to 4.5 percent, The board forming step, Supplying the foamed particles with a steam pressure of 0.30 to 0.60 kgf / cm ² for 4.5 to 10 seconds; Method for producing a flame-retardant board comprising the step of supplying the steam particles of 0.35 to 0.60 kgf / cm ² for 3.5 to 6.5 seconds. The method according to claim 1 or 2, The diameter of the foam particles is 2.5mm to 5.0mm, And a weight ratio of the inorganic material contained in the flame retardant to the board is 60 to 80 percent. The method according to claim 1 or 2, The flame retardant is dried in the board by the drying step, so that an inorganic material remains. The flame-retardant board is a flame-retardant board manufacturing method, characterized in that in the fire, the board is melted and the inorganic material remains to form a honeycomb structure to prevent the inflow of air from the outside to block fire. The method of claim 4, wherein After the drying step, the flame retardant board is made of a flame retardant board, characterized in that consisting of 20 to 40% by weight of the board and 60 to 80% by weight of the inorganic material. A flame retardant board manufactured by using a plurality of foam particles formed by forming a coating layer for forming fine pores on a surface of a bead impregnated with a blowing agent and a flame retardant, and foaming the beads, A board formed by fusing the plurality of foam particles to form the micro voids between the plurality of foam particles; Including flame retardant is injected into the fine pores, The diameter of the foam particles is 2.5mm to 5.0mm, the weight ratio of the inorganic material contained in the flame retardant to the board is a flame retardant board, characterized in that 60 to 80 percent.

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