KR101356568B1 - Non-flammable foam manufacturing method - Google Patents

Abstract

The present invention relates to a method for manufacturing non-flammable Styrofoam which prevents shape deformation. The method comprises: a foaming step (S10) which forms circular foamed bodies by foaming expandable polystyrene (EPS) resin grains; a coating step (S20) which forms coating layers by coating the surface of the plurality of foamed bodies, which are foamed in the foaming step (S10), with a flame retardant which gives adhesion and flame resistance; a molding step (S30) which forms molded products which are molded into a frame shape by injecting the plurality of foamed bodies, on which coating layers are formed, into a mold frame and pressurizing the same; and a hardening step (S40) which hardens the molded products manufactured in the molding step (S30) at room temperature and completes the molded products into finished products. The Styrofoam is completed by coating the surfaces of the circular foamed bodies, formed by foaming the EPS resin grains, with the flame retardant having excellent adhesion and flame resistance and completing the product into a frame shaped Styrofoam by injecting the foamed bodies, on which the flame retardant is coated, into the molding frame so that the inside and outside of the Styrofoam can be closed with the flame retardant and excellent flame resistance can be expected in the Styrofoam. In addition, the circular shaped foamed bodies maintain the shape by the flame retardant, which is coated on the surface of the foamed bodies in which the EPS grains are foamed, while easily combining with each other so that the completed Styrofoam can obtain air gaps inside the completed Styrofoam and includes excellent sound absorption and heat insulation functions. [Reference numerals] (S10) Foaming step; (S20) Coating step; (S30) Molding step; (S40) Hardening step

Description

Non-flammable styrofoam and its manufacturing method to prevent shape deformation {Non-flammable foam manufacturing method}

The present invention relates to a method for producing a nonflammable styrofoam in which deformation is prevented, and more particularly, a flame retardant having excellent adhesion and flame retardancy is formed on a surface of a round foam formed by foaming polystyrene (EPS) resin granules, and By inserting a large number of flame-retardant coated foam into a mold to form a styrofoam of the frame shape, the whole and inside of the styrofoam is sealed with a flame retardant to prevent the shape deformation that can be expected excellent flame retardant function will be.

In general, styrofoam has excellent insulation and sound absorption effect, and is widely used for thermal insulation or sound insulation, and such styrofoam is polystyrene (EPS: Expand poly Styrene) containing a foaming agent (butane and pentane gas) in polystyrene (PS) resin. Styrofoam is finally produced by foaming the raw materials and steaming the surfaces of the foamed granules to melt and bond with each other.

Therefore, the conventional styrofoam has a problem in that the surface of the polystyrene granules are melted together and bonded to each other, so that voids are poorly formed and the sound absorbing and insulating functions are low.

In addition, conventional styrofoam has a risk of human injury in the event of fire due to the toxic gas generated when it is exposed to a fire.As a result, polystyrene (PS), which is a raw material of styrofoam, together with a blowing agent (F, Cl, Br) The use of styrofoam, which imparted flame retardancy level 3 to the flame retardant foamed polystyrene (EPS) material contained.

However, Styrofoam of the flame retardant grade 3 level has a problem that toxic gas and combustion are generated like the problem of the conventional styrofoam after exposure to fire for a certain time, so that the development of styrofoam to further enhance the flame retardant performance As is necessary.

The present invention has been proposed to solve various problems as described above, the object of which is to form a flame retardant having excellent adhesion and flame retardant coating on the surface of the round-shaped foam formed by foaming polystyrene (EPS) resin granules, By inserting a large number of flame-retardant coated foam into the mold to form a styrofoam of the frame shape, the whole and inside of the styrofoam is sealed with a flame retardant to provide a non-flammable styrofoam manufacturing method that prevents shape deformation can be expected excellent flame retardant function. Is in.

Moreover, due to the flame retardant coated on the surface of the foamed polystyrene (EPS) granules, the spherical foams can be easily bonded to each other while maintaining the shape, so that the voids can be smoothly secured inside the finished styrofoam. It is to provide a non-combustible styrofoam manufacturing method that prevents shape deformation that can be expected sound absorption and insulation.

Non-combustible styrofoam production method according to an embodiment of the present invention for achieving the above object is a foaming step (S10) of foaming polystyrene (EPS: Expandable Polystyrene) resin granules to form a round shaped foam; And, the coating step (S20) to form a coating layer by coating a flame retardant to give adhesion and flame retardancy on the surface of the plurality of foams foamed in the foaming step (S10); And, the coating layer is formed through the coating step (S20) After inserting a plurality of foam into the molding die, forming step (S30) to form a molded article molded into a mold shape; And, curing the molded article produced in the molding step (S30) at room temperature to complete the finished product Including the step (S40);
The flame retardant is 60% by weight of sodium silicate, 10% by weight of fiber glass, 8% by weight of perlite, 5% by weight of mineral fiber, 2% by weight of foaming agent (surfactant), 3% by weight of bentonite, 3% by weight of titanium dioxide (TIO ₂ ), and 9% by weight of casein are sufficiently stirred to form a mixed solution,
The mixture is diluted by adding water, wherein the mixture and water are mixed at a weight ratio of 1: 5 to 6.

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The non-flammable styrofoam to prevent the shape deformation according to another embodiment of the present invention for achieving the above object is characterized in that the non-combustible styrofoam manufacturing method to prevent the shape deformation as described above.

According to the non-combustible styrofoam manufacturing method to prevent the shape deformation according to the present invention as described above, to form a flame retardant having excellent adhesion and flame retardant coating on the surface of the round foam formed by foaming polystyrene (EPS) resin granules, By adding a plurality of foams coated with a flame retardant to a mold to form a styrofoam of the frame shape, the entire interior and exterior of the styrofoam is sealed with a flame retardant has an effect that can be expected excellent flame retardant function.

Moreover, due to the flame retardant coated on the surface of the foamed polystyrene (EPS) granules, the spherical foams can be easily bonded to each other while maintaining the shape, so that the voids can be smoothly secured inside the finished styrofoam. Sound absorption and insulation function can be expected.

1 is a block diagram of a method for manufacturing a nonflammable styrofoam in which shape deformation is prevented according to an embodiment of the present invention.
FIG. 2 is a view for explaining a method of manufacturing a nonflammable styrofoam in which shape deformation shown in FIG. 1 is prevented
Figure 3 is a longitudinal cross-sectional view of the non-flammable styrofoam prevented shape deformation produced by the non-combustible styrofoam manufacturing method is shown in Figure 1

Non-flammable styrofoam and its manufacturing method of preventing shape deformation according to a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings. Detailed descriptions of well-known functions and constructions that may be unnecessarily obscured by the gist of the present invention will be omitted.

1 to 3 illustrate a non-flammable styrofoam and a manufacturing method for preventing shape deformation according to an embodiment of the present invention, Figure 1 is a block of a non-flammable styrofoam manufacturing method for preventing shape deformation according to an embodiment of the present invention. Figure 2 is a view for explaining a non-combustible styrofoam manufacturing method that prevents the shape deformation shown in Figure 1, Figure 3 is a shape deformation produced by a non-combustible styrofoam manufacturing method that prevents the shape deformation shown in Figure 1 The longitudinal cross section of the non-combustible styrofoam to be prevented is shown, respectively.

As shown in the figure, the non-combustible styrofoam manufacturing method 100 is prevented shape deformation according to an embodiment of the present invention foaming step (S10), coating step (S20), forming step (S30), and curing Step S40 is included.

As shown in Figure 1, the foaming step (S10) is a process of foaming polystyrene (EPS: Expandable Polystyrene) resin granules to form a round-shaped foam (10), by shooting a high temperature steam simply foamed into polystyrene grains do.

As shown in Figure 1 and 2a, the coating step (S20) is a coating layer 20 by coating a flame retardant to give adhesion and flame retardancy on the surface of the plurality of foams 10 foamed in the foaming step (S10) In the process of forming, in order to quickly coat the flame retardant on the surface of the foam it is preferable to spray the flame retardant in a spray method so that the coating layer of the flame retardant is formed on the surface of the foam.

Meanwhile, the flame retardant is 60% by weight of sodium silicate, 10% by weight of fiber glass, 8% by weight of perlite, 5% by weight of mineral fiber, 2% by weight of foaming agent (surfactant). %, Bentonite 3% by weight, titanium dioxide (TIO ₂ ) 3% by weight, casein (9% by weight) were sufficiently stirred to form a mixed solution,

The mixture is diluted by adding water, but the mixture and water are mixed by mixing in a ratio of 1: 5 to 6 by weight.

Here, the sodium silicate is used as an adhesive in the non-combustible styrofoam manufacturing method (100) in which the shape deformation of the present invention is prevented as an inorganic flame retardant, and the glass fiber and the mineral fiber are used in the role of viscosity and crosslinking to be segregated. Induces a solid adhesive structure of the non-flammable styrofoam (200) to prevent the shape deformation of the present invention is a finished product molded through the molding step (S30), the perlite and bentonite is used for improving the thermal insulation and sound absorption of the finished product The titanium dioxide can be expected to be a photocatalyst function to oxidatively decompose harmful substances and to clean the environment (effects of removing environmental pollution, antibacterial, deodorizing, etc.).

On the other hand, the casein is a protein, insoluble in water, was added to the sodium silicate and used as a flame retardant together with water by the hydrolysis reaction.

Therefore, the flame-retardant coated foam 10 made of the composition as described above can be expected to have an effect of preventing the deformation of the shape, as well as the flame resistance is strengthened even if exposed to the fire is not burned.

Meanwhile, as shown in FIG. 3, the foaming agent absorbs the non-combustible styrofoam 200 in which the micro foam 3 is formed inside the coating layer 20 coated on the surface of the foam 10 to prevent deformation of the present invention. And the thermal insulation function can be further enhanced.

As shown in Figure 1 and 2b, the forming step (S30) is a plurality of foams (10) having a coating layer 20 is formed through the coating step (S20) into the molding die 1, and then pressurized To form a molded article S molded into a frame shape.

That is, as shown in FIG. 2B, the plurality of foams 10 introduced into the mold 1 through the forming step S30 are concentrated together, and the coating layer 20 coated on the foam 10 is different from other foams. It is contacted with the coating layer 20 of 10 to be firmly fixed to each other to be molded into a molded article (S), the coating layer 20 formed on the foam 10 as shown in Figure 3 is a coating layer of another foam 10 Since the voids are naturally formed in the portion that is not in contact with the 20, the sound absorbing and insulating functions of the non-combustible styrofoam 200, in which the shape deformation of the present invention is prevented, may be maximized.

In addition, as shown in Figure 3 through the forming step (S30) the entire shape of the non-flammable styrofoam (200) to prevent the shape deformation of the present invention is coated and sealed with a flame retardant effect that can be expected excellent flame retardant function have.

As shown in Figure 1 and 2c, the curing step (S40) is a non-combustible styrofoam (200) to prevent the shape deformation of the present invention as a finished product by curing the molded product (S) produced in the molding step (S30) at room temperature ) Is the process of completing.

The non-combustible styrofoam manufacturing method 100, which is prevented from deformation of the shape according to the present invention made of the process as described above has excellent adhesion and flame retardancy on the surface of the foam 10 of the round shape formed by foaming polystyrene (EPS) resin granules By forming a flame retardant and coating a plurality of the foams 10 coated with the flame retardant into a molding die 1 to complete a mold 1 shaped styrofoam, the entire interior and the exterior of the styrofoam are sealed with the flame retardant to be excellent. The flame retardant function can be expected.

Moreover, due to the flame retardant coated on the surface of the foam 10 in which polystyrene (EPS) granules are foamed, the foamed shapes 10 of the spherical shape can be easily bonded to each other while maintaining the shape so that the voids inside the finished styrofoam. Since it can be secured smoothly, there is an effect that can be expected excellent sound absorption and thermal insulation.

Through the non-combustible styrofoam manufacturing method 100 to prevent the shape deformation of the present invention having the configuration as described above to produce a non-combustible styrofoam 200 to prevent the shape deformation as follows.

First, polystyrene (EPS: Expandable Polystyrene) resin granules are foamed to form a large number of rounded foams 10. (S10)

Thereafter, as shown in FIG. 2A, a flame retardant is sprayed onto the surface of the foam 10 so that the coating layer 20 of the flame retardant is simply formed on the surface of the foam 10. (S20)

Thereafter, as shown in FIG. 2C, a plurality of the foams 10 having the coating layer 20 formed therein are injected into the mold 1, and then press-molded into the shape of the mold 1. To form. (S30)

Thereafter, as shown in FIG. 2C, the molded article is recovered from the mold 1 and naturally formed to form a non-combustible styrofoam 200 that prevents deformation of the present invention as a finished product. (S40)

The non-combustible styrofoam 200 to prevent the shape deformation of the present invention prepared as described above [Example], the conventional general styrofoam [Comparative Example 1], flame retardant (F, Cl, Br) is added to a predetermined Conventional styrofoam having flame retardancy was named [Comparative Example 2], and the sound insulation and flame retardancy test were performed.

① Soundproof test

In the soundproof test, the interior walls and ceilings of the 3m × 5m × 2.3m standard were sealed with [Example], [Comparative Example 1] and [Comparative Example 2], respectively, and the cassette tape player having the maximum volume was When operating, the noise level from the room from one meter away from the 10 observers were evaluated, and the results as shown in Table 1 below.

[Table 1]

That is, it can be confirmed that the [Example] of the present invention has excellent soundproofing effect in comparison with the conventional [Comparative Example 1] and [Comparative Example 2]. This is because the noise is absorbed by the plurality of voids formed in the non-combustible styrofoam 200 to prevent the shape deformation of the present invention is determined that the results as described above.

② flame retardancy test

The flame retardancy test was performed three times the [Example] by the test method of the Korean Industrial Standard KS F 2271 to obtain the results as shown in Table 2 below.

[Table 2]

That is, the flame retardancy test results, it was confirmed that the non-combustible styrofoam 200 to prevent the shape deformation of the present invention is suitable for the flame retardant class 1, and also confirmed that the flame retardancy is very excellent from the test results.

Moreover, [Photo 1] below is a photograph in which [Example] of the present invention is exposed to fire, [Photo 2] is a photograph in which [Comparative Example 1] is exposed to fire, and [Photo 3] is a comparative example 2] is a photograph of exposure to fire, [Example] of the present invention is a state that only soot is formed, [Comparative Example 1] is a state that is slowly burned by the fire, [Comparative Example 2] is a state that is burned immediately by the fire As a result, it is possible to confirm the excellent flame retardancy of the nonflammable styrofoam 200 in which deformation of the present invention is prevented.

[Photo 1]

[Photo 2]

[Photo 3]

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is clearly understood that the same is by way of illustration and example only and is not to be construed as limiting the scope of the invention as defined by the appended claims. You will understand the point. It goes without saying that variations can be made by those skilled in the art without departing from the spirit of the present invention. Accordingly, the scope of claim of the present invention is not limited within the scope of the detailed description, but will be defined by the following claims and technical ideas thereof.

1. framework 2. void
3. Bubble
10. Foam 20. Coating Layer
S. Molded Products
100. Non-flammable styrofoam prevents shape deformation
200. Incombustible Styrofoam Manufacturing Method to Prevent Shape Deformation
S10. Foaming step S20. Coating step
S30. Molding step S40. Curing step

Claims (3)

Foaming step (S10) of foaming polystyrene (EPS: Expandable Polystyrene) resin granules to form a round-shaped foam (10);
A coating step (S20) of forming a coating layer (20) by coating a flame retardant to give adhesion and flame retardancy to the surfaces of the plurality of foams (10) foamed in the foaming step (S10);
Forming step (S30) of forming a molded article (S) molded in a mold shape by putting a plurality of foams (10) having a coating layer (20) formed through the coating step (S20) to the molding mold (1), and then pressurized. ; And
Including the curing step (S40) for curing the molded product (S) produced in the molding step (S30) at room temperature to complete the finished product;
The flame retardant,
60% by weight sodium silicate, 10% by weight fiber glass, 8% by weight perlite, 5% by weight mineral fiber, 2% by weight foaming agent (surfactant), bentonite A) 3% by weight, 3% by weight of titanium dioxide (TIO ₂ ), 9% by weight of casein (casein) is sufficiently stirred to form a mixed solution,
Diluted by adding water to the mixed solution, wherein the mixed solution and water are mixed in a ratio of 1: 5 to 6 by weight, the shape deformation is prevented styrofoam manufacturing method.
delete Non-combustible styrofoam (200) to prevent deformation, characterized in that the manufacturing method of claim 1.

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