KR101478147B1 - Composite material for cable tray and method of producing the same - Google Patents

Abstract

The present invention provides a composite material for a cable tray. The composite material includes: a plurality of planar sheets made of woven or nonwoven glass fiber; and a resin layer laminated between the planar sheets. The resin layer includes 20-50 parts by weight of a hollow ceramic filler with respect to 100 parts by weight of a thermosetting resin. Therefore, the composite material for a cable ray has excellent corrosion resistance when compared to a conventional metal material. The thermosetting resin is used for the composite material; and thus the composite material has heat resistance and heat blocking properties even when exposed to heat at high temperatures. Moreover, the composite material is lighter than the prior metal material and thus can be easily installed, repaired, and maintained. The composite material can maintain mechanical strength same with that of a metal material.

Description

Technical Field [0001] The present invention relates to a composite material for cable trays,

More particularly, the present invention relates to a cable tray having heat resistance and fire resistance and a manufacturing method thereof.

Generally, cable trays are installed along a ceiling, floor or wall with large and small diameter cables for supplying power supply, fluid, etc. to apartment houses, power plants, factories and public facilities. The cable tray is installed in the distribution line to fix the cable and prevent the cable from being exposed to the outside, thereby improving the appearance and protecting the cable.

As an example of such a cable tray, Korean Utility Model Appln. Utility Model No. 20-0313751 discloses that a cover is fastened to a cable tray using a fastening means such as a clamp to protect the cable tray from foreign substances. Since the cable tray is installed keeping the uncoated metal surface intact, it is easily corroded from contamination of other metals and contaminants during salting or production, especially when it is installed in an offshore structure or a ship, The lifetime of the tray is shortened and the maintenance cost is increased.

Japanese Patent Application Laid-Open (kokai) No. 4-19935 discloses a process for molding a lignified wood sheet such as a sheet by impregnating a wood powder and a cellulose-based fine powder into a thermoplastic resin impregnated with a urea resin system and dry- A method of molding a wood veneer panel is disclosed in which a veneer is remade to attach a veneer on a pallet made of a synthetic resin having a cut surface in a thickness direction and pressing the veneer into a predetermined shape. However, in this case, the production process for regenerating the composite material is troublesome, and when exposed to high temperature as a thermoplastic resin, deformation and pyrolysis are generated.

The present invention relates to a tray for fixing and supporting a cable, in which corrosion is generated by salt water or salt, in addition to a commonly used ground building, and in particular, a cable tray for use in ships and marine floating facilities having heat resistance and fire resistance And a method for producing the same.

In order to attain the above object, the present invention provides a thermosetting resin composition comprising: a plurality of plate-shaped sheets made of woven or nonwoven glass fiber; and a resin layer laminated between the plate-shaped sheets, And 20 to 50 parts by weight of a ceramic filler.

The hollow ceramic filler may be selected from the group consisting of a cray airgel, a silica airgel, a hollow glass, a hollow fly ash, a hollow alumina, and a mixture thereof.

The thermosetting resin may be a phenol resin or a melamine resin.

And the average diameter of the hollow ceramic filler is 10 [mu] m to 500 [mu] m.

The plate-shaped sheet may be characterized in that glass fibers are woven in a glass chopped strand mat type.

The cable tray composite may have a thickness of 7 mm to 11 mm.

Mixing a hollow ceramic filler, a thermosetting resin and a curing agent to prepare a composite resin solution; There is provided a method of manufacturing a composite material for cable trays, comprising the steps of: supporting a plurality of plate-shaped sheets made of woven or nonwoven glass fibers on the composite resin solution and contacting and laminating; and curing the laminated structure.

The laminating step may be characterized in that 50 to 70% by volume of the glass fiber and 30 to 50% by volume of the composite resin solution are laminated.

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According to the present invention, the composite material for cable trays is superior in corrosion resistance to a cable tray of a conventional metal material, and has heat resistance and heat shielding property even when exposed to high temperatures by using a thermosetting resin and a hollow ceramic filler. In addition, the composite material for cable trays can be made lighter than conventional metal materials, thus facilitating installation and maintenance, and maintaining the same mechanical strength as that of a metal material.

1 is a three-dimensional configuration diagram of a cable tray composite material according to an embodiment of the present invention.
Figure 2 is a time-temperature curve as set forth in ASTM E 119, the fire resistance standard for cable trays.
3 is a schematic view of a fire resistance test apparatus.

Hereinafter, the composite material for a cable tray according to the present invention and its manufacturing method will be described in more detail.

The composite material for cable trays according to the present invention comprises a plurality of plate-shaped sheets made of woven or non-woven glass fiber and a resin layer laminated between the plate-shaped sheets, wherein the resin layer has a hollow shape with respect to 100 parts by weight of the thermosetting resin And 20 to 50 parts by weight of a ceramic filler.

The hollow ceramic filler may be selected from the group consisting of a cray airgel, a silica airgel, a hollow glass, a hollow fly ash, a hollow alumina, and a mixture thereof.

The thermosetting resin may be a phenol resin or a melamine resin.

The hollow ceramic filler may be characterized by an average diameter of 10 to 500 탆.

The plate-shaped sheet may be characterized in that glass fibers are woven in a glass chopped strand mat type.

The composite material for a cable tray may have a thickness of 7 mm to 11 mm.

The present invention also relates to a method for producing a composite resin solution, comprising the steps of: preparing a composite resin solution by mixing a hollow ceramic filler, a thermosetting resin and a curing agent; Supporting a plurality of plate-shaped sheets made of woven or non-woven glass fiber on the composite resin solution, contacting and laminating them; And curing the laminated structure. The present invention also provides a method for manufacturing a composite material for cable trays.

The step of laminating may be characterized by laminating 50 to 70% by volume of glass fiber and 30 to 50% by volume of the composite resin solution.

 At this time, if the volume ratio of the glass fiber and the composite resin solution is out of the above range, there may be a problem that the heat shielding ability and heat resistance of the composite material are reduced.

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When the product is produced through the above steps, it is structurally strong and has the advantage of increasing the working speed and mass-producing the products having the same dimensions.

The composite material for cable trays manufactured according to the present invention is superior in heat resistance and heat shielding property and has the same mechanical strength as a conventional metal material for cable trays.

Hereinafter, the present invention will be described in more detail with reference to the following examples. However, the scope of the present invention is not limited to the following examples.

BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is a view showing a state in which layers of a composite material for a cable tray according to an embodiment of the present invention are separated. FIG. Referring to the drawings, a resin layer is laminated on upper and lower surfaces of a plate-shaped sheet provided with glass fibers.

The plate-like sheet can be produced by pressing a glass fiber, but it can be selected as a glass fiber strand type in which a glass fiber is pulled and pressed to weave.

A fiber made of one strand is called a filament, and 50 to 200 strands of the filament are strands, and the strand is cut into a thin sheet to form a strand mat.

The content of the resin layer impregnated in the glass fiber is increased in the plate-shaped sheet of such a flat land mat structure, and the contained resin dissolves in hot press molding to fill the grooves in the upper and lower portions of the upper and lower plate- .

The resin layer improves thermal resistance and heat resistance of the composite material for cable trays, mixes a thermosetting resin with a hollow ceramic filler, and a hardening agent is added thereto. Thereafter, the plate-shaped sheet is carried and laminated. The hollow of the hollow ceramic filler exhibits a heat conduction blocking function.

The hollow ceramic filler is characterized by being composed of a metal oxide such as silica, alumina, fly ash or the like, or a wall of a metal oxide composite. After the lamination, the composite material for cable tray is prepared by curing it.

The hollow ceramic filler is produced by extracting hollow ceramics. The hollow ceramic filler is a high heat-resistant heat-resistant filler capable of containing an air layer without breaking its shape even at a temperature of 1000 ° C or higher. It is superior in durability, heat resistance, .

< Example  1> Hollow ceramic Filler  Change in input

20 parts by weight, 30 parts by weight, 40 parts by weight and 50 parts by weight of a hollow ceramic filler were added to 100 parts by weight of a phenol resin as a thermosetting resin in the production of a resin layer, Weight ratio of 10: 1 to prepare a composite resin solution containing hollow ceramic fillers of different weights. A plate-shaped sheet (glass woven fabric and glass fiber) was supported on the composite resin solution so as to be brought into contact with the composite resin solution, and the mixture was cured as it was to produce a composite material for a cable tray. Wherein the plate-like sheet may be a glass woven or glass fiber, and the glass woven material is WR570-100 sold by Owens Corning, Korea.

&Lt; Example 2 > Change in Volume Ratio of Plate Sheet and Resin Layer

A resin layer was prepared by making a hollow ceramic filler 50 parts by weight based on 100 parts by weight of the phenol resin and setting the volume ratio of the plate-like sheet and the resin layer to 7: 3. Further, the volume ratio of the plate-like sheet to the resin layer was set to 6: 4 to prepare a resin layer.

&Lt; Example 3 > Change in thickness of composite material for cable tray

A hollow ceramic filler was used in an amount of 50 parts by weight based on 100 parts by weight of the phenol resin, and the plate-like sheet was supported on the composite resin solution to prepare composite materials having thicknesses of 7 mm, 9 mm and 11 mm.

< Comparative Example  1> Hollow ceramic Filler  compare

In the production of the resin layer, a phenol resin was selected as a thermosetting resin, glass spheres H40 (hereinafter referred to as &quot; glass spheres &quot;) purchased from Sinosteel Maanshan Institute of Mining Research Co., H40), 30 parts by weight, 40 parts by weight and 50 parts by weight were added to prepare a composite resin solution.

For comparison, the Q-Cell 5020 glass sphere (QC-5020), Seokyung CMT perlite (perlite) and Seokyung CMT fly ash And 20 parts by weight, 30 parts by weight, 40 parts by weight and 50 parts by weight were added, respectively, to prepare five types of composite resin solutions.

The plate-like sheet was supported on each of the composite resin solutions to prepare a composite material having a volume ratio of the plate-like sheet and the resin layer of 5: 5 in a thickness of 9 mm.

< Experimental Example  1> Flammability test of composite materials

Each of the composite materials obtained through the examples was exposed to a flame at 900 to 1100 占 폚 for 1 hour, and the temperature of the opposite side of the flame was measured with an infrared temperature sensor. The heat shielding ability was measured by subtracting the temperature of the side not exposed to the flame on the side exposed to the flame.

The results of the experiment were excluded when the surface melted due to exposure to the flame for 1 hour, rugged, punctured, or the surface was exploded.

Hollow ceramic Filler  Depending on the input volume Train terminal  ability Hollow bead concentration (wt%) Hollow ceramic filler diameter 60 탆
Heat capacity (℃) Hollow Ceramic Filler Diameter 103㎛
Heat capacity (℃) 20 670 640 30 700 670 40 710 690 50 715 700

When the diameter of the bead was 60 탆 in 50 parts by weight of the hollow ceramic filler with respect to 100 parts by weight of the phenol resin, the highest heat capacity was exhibited.

Heat blocker  Depending on the type Train terminal  ability Input concentration (wt%) Hollow ceramic The filler  Of the loaded composite material
Train terminal  Ability (℃) H40 Of the composite material Train terminal  Ability (℃) QC -5020 &lt; / RTI &gt; Train terminal  Ability (℃) Pearlite  Heat capacity of inserted composite (℃) Fly Ash  Heat capacity of inserted composite (℃) 20 670 495 505 515 540 30 700 Thermal breakage Thermal breakage 515 560 40 710 Thermal breakage Thermal breakage - High viscosity 50 715 Thermal breakage Thermal breakage - High viscosity

Here, when the hollow ceramic filler was administered, the highest heat capacity was exhibited.

Depending on the thickness of the composite material Train terminal  ability Hollow Ceramic Filler Concentration (wt%) Heat capacity (℃) of composite material with thickness of 7mm Heat capacity (℃) of composite material with thickness of 9mm Heat capacity (℃) of the composite material with a thickness of 11 mm 50 660 715 740

Here, the highest heat shielding capability was obtained when the thickness of the composite material was 11 mm.

The plate-like sheet and the resin layer At a volume ratio  Following Train terminal  ability Hollow ceramic filler input concentration (wt%) When the volume ratio of the plate-shaped sheet and the composite resin layer is 5: 5, When the volume ratio of the plate-like sheet and the composite resin layer is 6: 4, When the volume ratio of the plate-like sheet and the composite resin layer is 7: 3, 50 715 690 660

When the volume ratio of the plate-like sheet to the resin layer was 5: 5, the highest heat capacity was exhibited.

< Experimental Example  2> Fireproof performance of cable tray made of composite material for cable tray

Fig. 2 is a time-temperature curve specified in ASTM E 119, which is a fire resistance standard of a cable tray, and Fig. 3 is a schematic diagram of a fire resistance test apparatus.

Referring to FIG. 2 and FIG. 3, when the composite material for a cable tray in which the hollow ceramic filler is mixed is exposed to a flame for one hour in accordance with the fire resistance standard, the temperature inside the cable tray should not exceed 177 degrees.

The fire resistance of the cable trays manufactured through the fire resistance testing apparatus was measured in a plurality of sensor channels as shown in the following table.

Table 5. Floor surface temperature over time of manufactured cable tray

The cable trays fabricated with the composite material for cable trays were confirmed to meet all of the fire resistance specifications.

Through this experiment, it was confirmed that the composite material prepared by supporting the plate sheet in the composite resin solution containing the hollow ceramic filler has excellent heat shielding ability.

While the invention has been described with reference to a limited number of embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. Accordingly, the true scope of the present invention should be determined by the technical idea of the appended claims.

10: plate-shaped sheet 20: composite resin layer
100: composite material for cable tray 200: cable tray
210: Cable tray bottom surface 300: Temperature detection system
400: sensor channel 500: flame nozzle

Claims (9)

A plurality of flat sheets made of woven or nonwoven glass fibers; And
And a resin layer laminated between the plate-shaped sheets,
The volume ratio of the plate-like sheet to the resin layer is 5: 5,
Wherein the resin layer comprises 20 to 50 parts by weight of a hollow ceramic filler based on 100 parts by weight of the thermosetting resin and the hollow ceramic filler comprises hollow glass and hollow fly ash,
Wherein said composite material for cable tray has a thickness of 11 mm.
delete The method according to claim 1,
Wherein the thermosetting resin is a phenol resin or a melamine resin.
The method according to claim 1,
Wherein the hollow ceramic filler has an average diameter of 10 탆 to 500 탆.
The method according to claim 1,
Wherein the plate-shaped sheet is formed by weaving glass fibers into a chopped strand mat.
delete A hollow ceramic filler, a thermosetting resin and a curing agent to prepare a composite resin solution;
A plurality of plate-shaped sheets made of woven or non-woven glass fiber are laminated on the composite resin solution by being supported on the plate-shaped sheet and the resin layer at a volume ratio of 5: 5 by volume; And
And curing the laminated structure, comprising the steps of:
Wherein the resin layer comprises 20 to 50 parts by weight of a hollow ceramic filler based on 100 parts by weight of the thermosetting resin and the hollow ceramic filler comprises hollow glass and hollow fly ash,
Wherein the composite material for cable tray has a thickness of 11 mm. delete delete

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