KR101771773B1 - Three-layer sandwich composition panel - Google Patents

Abstract

A high-density foam layer having a first face material on the outer side and a second face material on the inner side; A low density foam layer in which a second face material is laminated on both sides; And a high density foamed layer in which a first face material is laminated on the outside and a second face material is laminated on the inside, and a laminated structure in which the laminated structure is sequentially stacked.

Description

Three-layer sandwich composite panel {THREE-LAYER SANDWICH COMPOSITION PANEL}

This invention relates to a sandwich composite panel having a three-layer sandwich composite panel having a high thermal conductivity and improving fire resistance and mechanical strength.

The most important factors required for building insulation are low thermal conductivity and fire resistance. Recently, as the energy environment policy has been strengthened, the permissible heat conduction rate of buildings is expected to be strengthened, and therefore, a building heat insulating material having high-performance insulation performance is attracting attention. However, the polystyrene expanded foam, which is mainly used as a conventional thermal insulation material, has a high thermal conductivity, and when the heat conduction ratio is strengthened, the thickness applied to the building becomes thick.

Alternatively, a thermosetting foam such as a urethane foam can be used, which has the best heat insulation performance of existing building insulation and has excellent fire resistance / heat resistance. However, the thermosetting foamed foam is superior in heat insulation and fire resistance / heat resistance to other insulation materials, but is rigid and has a severe friability and a poor flexural strength.

Therefore, there is a need for a sandwich composite panel excellent in heat insulation and durability regardless of the type of foam, since strength and weakness are different for each foam foam.

One embodiment of the present invention provides a three-layer sandwich composite panel that improves thermal insulation and mechanical strength.

Another embodiment of the present invention provides a three-layer sandwich composite panel having a high thermal insulation performance with a thermal conductivity of about 0.020 W / mK or less and a nonflammability equivalent to flame retardant grade 2.

In one embodiment of the present invention, a high-density foam layer in which a first face material is laminated on the outside and a second face material is laminated on the inside; A low density foam layer in which a second face material is laminated on both sides; And a high density foamed layer in which a first face material is laminated on the outside and a second face material is laminated on the inside, and a laminated structure in which the laminated structure is sequentially stacked.

The density of the high density foam layer may be from about 50 kg / m ³ to about 70 kg / m ³ .

The density of the low density foam layer may be from about 30 kg / m ³ to about 40 kg / m ³ .

The thickness of the high density foam layer may be from about 10 mm to about 30 mm.

The thickness of the low density foam layer may be from about 30 mm to about 150 mm.

The first face plate may comprise a face plate made of a metal.

The first face material can be used by combining a face material made of a metal and a glass scrim.

The thickness of the first face sheet may be from about 200 [mu] m to about 400 [mu] m.

The second face sheet may comprise glass islands or kraft paper.

And further includes an adhesive layer between the high-density foam layer and the low-density foam layer.

The adhesive layer may include an ethylene-vinyl acetate copolymer resin emulsion adhesive or an aqueous acrylic emulsion adhesive.

The thickness of the adhesive layer may be from about 1 mm to about 2 mm.

The low-density foam layer can control the thermal conductivity of the three-layer sandwich composite panel.

The high-density foam layer can control the flexural strength, impact strength or compressive strength of the three-layer sandwich composite panel.

The three-layer sandwich composite panel can improve fire resistance, heat resistance and mechanical properties, and is light and convenient for processing.

In addition, the three-layer sandwich composite panel does not use a fluorocarbon (HCFC) foaming agent, and does not have a risk of global warming by using environmentally friendly foaming agents such as hydrocarbons.

1 is a cross-sectional view of a three-layer sandwich composite panel according to an embodiment of the present invention.
2 is a cross-sectional view illustrating a three-layer sandwich composite panel according to another embodiment of the present invention.
3 is a cross-sectional view of each layer of a three-layer sandwich composite panel, which is another embodiment of the present invention, in terms of thermal conductivity and thickness.

Hereinafter, embodiments of the present invention will be described in detail. However, the present invention is not limited thereto, and the present invention is only defined by the scope of the following claims.

In one embodiment of the present invention, a high-density foam layer in which a first face material is laminated on the outside and a second face material is laminated on the inside; A low density foam layer in which a second face material is laminated on both sides; And a high density foamed layer in which a first face material is laminated on the outside and a second face material is laminated on the inside, and a laminated structure in which the laminated structure is sequentially stacked.

Since the three-layer sandwich composite panel includes a low density foam layer, the low thermal conductivity of the three-layer sandwich composite panel can be ensured and the mechanical properties of the three-layer sandwich composite panel can be secured by including the high-density foam layer. Therefore, the three-layer sandwich composite panel includes the foam layers of different densities, so that it can secure low thermal conductivity and fire resistance and flame retardancy as compared with the single-layer or two-layer sandwich composite panel.

1 is a cross-sectional view of a three-layer sandwich composite panel according to an embodiment of the present invention. 1, the sandwich composite panel 100 includes a high-density foam layer 10, a low-density foam layer 20, and a high-density foam layer 10. Specifically, a second face plate 12 is laminated on the inner side of the high-density foam layer 10 on the outer side of the high-density foam layer 10, and a second face plate 12 is formed on both sides of the low density foam layer 20 Respectively.

The high-density foam layer 10 and the low-density foam layer 20 may be formed by foaming one or more thermosetting resins from the group formed by polyurethane, epoxy, melamine, amino, and combinations thereof, and the thermosetting resin is not limited.

For example, the high-density foam layer and the low-density foam layer can be formed by crosslinking and foaming a thermosetting resin such as polyurethane to each other. For example, the polyurethane is a thermosetting resin crosslinked by reacting a polyol compound with a diisocyanate compound, and foamed simultaneously with crosslinking to form a low-density or high-density foam layer.

The polyurethane foam foam is superior in heat insulation and fire resistance / heat resistance to other heat insulation materials, but has a problem of being rigid and friable and having poor flexural strength. However, the polyurethane foam foam has a problem of low density foam The above problems can be overcome by laminating them on both sides of the layer.

The high-density foam layer 10 and the low-density foam layer 20 are formed by foaming a resin of the same or similar type. However, by controlling the flow rate and the production line speed at the time of foaming and controlling the foaming agent content, It is possible to form a high-density foam layer having a high density and a low-density foam layer having a low density.

The density of the high density foam layer 10 may be from about 50 kg / m ³ to about 70 kg / m ³ . A first face material may be laminated on the outer side of the high-density foam layer, and a second face material may be laminated on the inner side.

Specifically, by maintaining the density of the high-density foam layer within the above-mentioned range, it is possible to easily realize the effect of improving the mechanical strength and flame retardancy, and it is possible to reduce the problem of appearance breakage and tearing phenomenon. For example, when the density of the high-density foamed layer is more than about 70 kg / m ³ , the weight of the heat-insulating material including the high-density foamed layer increases, the cost of the raw material increases, and the heat insulation performance deteriorates.

The density of the low density foam layer 20 may be from about 20 kg / m ³ to about 40 kg / m ³ . And a second face sheet may be laminated on both sides of the low density foam layer. Specifically, by keeping the density of the low density foam layer within the above range, it is possible to easily realize a heat insulating effect of low thermal conductivity, and the weight of the heat insulating material including the low density foam layer is reduced, have.

The thickness of the high density foam layer 10 may be from about 10 mm to about 30 mm. When the thickness of the high-density foam layer is less than about 10 mm, the foam layer may be too thin and warpage may occur during production of the foam layer, and high mechanical strength can not be obtained. In addition, when it exceeds about 30 mm, the thermal conductivity may be lowered, the cost due to the weight increase may increase, and the handling may be deteriorated.

Also, the thickness of the low density foam layer 20 may be about 30 mm to about 150 mm. If the thickness of the low density foam layer is less than about 30 mm, the heat insulating performance can not be exhibited properly. If the thickness of the low density foam layer is more than about 150 mm, the thickness of the laminated structure stacked together with the high density foam layer may increase.

The thermal conductivity is a value expressed as a value of the insulation performance of a building exterior material such as a window, a door, a roof, a wall, etc. When a material having a unit area (m ² ) (W) transmitted from the outside to the inside and from the inside to the outside. The triple sandwich composite panel is characterized in that the heat conduction ratio is enhanced by simultaneously including the high density foam layer and the low density foam layer, and the heat conduction ratio can be enhanced by controlling the thickness of the foam layer having different densities.

The first face plate 11 may comprise a face plate made of a metal. The first face plate is bonded to the outer side of the high-density foam layer while the high-density foam layer is foamed. The first face plate may be made of a metal material such as aluminum, steel plate, or the like.

For example, the first face plate 11 may be made of aluminum. Since the aluminum material is rich in electrical and ductility, has a small specific gravity, is highly conductive in heat and electricity, and has high corrosion resistance in the air, it can be easily processed in various forms such as plate materials, wood materials, rods, wires, Various products widely distributed on the market will be applicable. In addition, by using an aluminum material for the first face plate, the three-layer sandwich panel can be improved in fire resistance as well as in appearance in appearance.

In addition, the first face plate 11 may be made of a combination of a face plate made of a metal and a glass scrim. By using a metal face plate and a glass scrim in combination, a heat reflection effect can be expected and the mechanical strength can be further increased.

The thickness of the first face plate 11 may be between about 200 [mu] m and about 400 [mu] m. By including the thickness of the first face plate in the above range, it is possible to easily perform the function of preventing the warp and shrinkage of the high density foam layer.

The second face plate 12 may comprise glass islands or kraft paper. The glass islands retained or krafted are excellent in adhesiveness. For example, the second face sheet is used both inside the high-density foam layer and on both sides of the low-density foam layer. By using the same face material, the high-density foam layer and the low-density foam layer can easily be bonded. Specifically, the thickness of the second face plate may be about 200 탆 to about 400 탆 similarly to the first face plate.

Further, when the adhesive layer is further included between the high-density foam layer and the low-density foam layer, the same face material as used on the inside of the high-density foam layer and on both sides of the low-density foam layer, It can be facilitated.

2 is a cross-sectional view illustrating a three-layer sandwich composite panel according to another embodiment of the present invention. The sandwich composite panel 100 includes a high density foam layer 10, an adhesive layer 30, a low density foam layer 20, an adhesive layer 30 and a high density foam layer 10.

A second face plate 12 is laminated on the inner side of the high face foam layer 10 and a second face plate 12 is laminated on both sides of the low density foam layer 20, .

The adhesive layer 30 may include an ethylene-vinyl acetate copolymer resin emulsion adhesive or an aqueous acrylic emulsion adhesive. The adhesive layer is a layer formed between the high-density foam layer and the low-density foam layer. The adhesive layer should be uniformly spread on all the surfaces of the high-density foam layer and the low-density foam layer after adhesion so that there is no slope between the two foam layers.

The adhesive layer includes an ethylene-vinyl acetate copolymer resin emulsion adhesive or an aqueous acrylic emulsion adhesive, so that the two foam layers can be airtightly bonded without inclination. The emulsion adhesive is excellent in adhesive strength, heat resistance, moisture resistance and the like, and it can easily overcome disadvantages of the adhesive using a solvent.

Specifically, after the bonding is completed by the adhesive layer, moisture is hardly escaped into the high-density foamed layer and the low-density foamed layer due to the airtightness of the adhesive layer. Therefore, Lt; RTI ID = 0.0 > 70 C < / RTI > to about < RTI ID = 0.0 > 90 C. < / RTI >

The thickness of the adhesive layer 30 may be about 1 mm to about 2 mm. By maintaining the thickness of the adhesive layer within the above range, the thickness of the outer layer of the foam layer can be minimized, and excellent heat insulation can be realized.

The low-density foam layer can control the thermal conductivity of the three-layer sandwich composite panel. In particular, the low density foam layer may have a thermal conductivity of from about 0.018 W / mK to about 0.020 W / mK, and the high density foam layer may have a thermal conductivity of from about 0.021 W / mK to about 0.023 W / mK. At this time, the thermal conductivity of the three-layer sandwich composite panel is about 0.020 W / mK or less, and the low-density foam layer can dominate the thermal conductivity of the three-layer sandwich composite panel.

3 is a cross-sectional view of each layer of a three-layer sandwich composite panel, which is another embodiment of the present invention, in terms of thermal conductivity and thickness. 3, the thermal conductivity of the high density foam layer is represented by? 1, the density of the high density foam layer X1, the density of the low density foam layer? 2, the thickness of the low density foam layer X2, the adhesive layer thermal conductivity? 3 and the adhesive layer thickness X3.

Table 1 below shows the thickness of the high-density foam layer, the thickness of the low-density foam layer, and the total thickness of the three-layer sandwich. At this time, assuming that the thermal conductivity of the high density foam layer is 0.022 W / mK and the thermal conductivity of the low density foam layer is 0.019 W / mK, the integrated heat conduction rate (q) passing through the three layers through the following [Formula 1] The calculated value was about 0.15 W / m ² K.

The integrated thermal conductivity (λTotal) is calculated by the following formula (2), and it is assumed that the thickness of the adhesive layer is 1 mm and the thermal conductivity of the adhesive layer is 0.2 W / mK.

At this time, the low-density foam layer and the high-density foam layer were formed using a foam layer (FINEpol Co., Ltd.) formed by foaming a polyurethane thermosetting resin.

[Formula 1]

[Formula 2]

Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 High density foam layer thickness (mm) 10 15 20 - 25 Low density foam layer thickness (mm) 109 101 92 127 - Triple Sandwich Composite Panel
Total thickness (mm) 131 133 134 127 25 λTotal
Thermal conductivity (W / mK) 0.0197 0.0199 0.0201 0.0190 0.022

Referring to Comparative Example 1, the thermal conductivity of the low-density foam layer was 0.019 W / mK, and the thermal conductivity of the high-density foam layer was 0.022 W / mK in Comparative Example 2, Which is higher than the thermal conductivity.

However, since the thermal conductivity (λTotal) of the triple sandwich composite panels of Examples 1 to 3 is 0.02 W / mK or less, it can be seen that the low density foam layer controls the thermal conductivity of the three-layer sandwich composite panel .

The high-density foam layer can control the flexural strength, impact strength or compressive strength of the three-layer sandwich composite panel. The three-layer sandwich composite panel can improve the overall mechanical strength such as the bending strength, the impact strength, and the compressive strength, which are weak points of the existing foam layer due to the rigidity of the high density foam layer.

Further, by using a three-layer sandwich composite panel including a high-density foam layer on both sides of the low-density foam layer, the friability phenomenon of the single-layer or two-layer sandwich composite panel can be compensated. Specifically, since the surface foam layer of the composite panel has a high density, heat applied to a certain area is received by a high-density foam layer resistant to heat, so that fire resistance and heat resistance are increased. Also, when the thermal conductivity of the high-density foam layer of the surface layer is about 0.022 W / mK, heat can not be transmitted to the internal low-density foam layer, which may also prevent internal damage due to internal heat generation. Therefore, when high heat resistance and high fire resistance are required, the thickness of the high-density foam layer can be increased and coped with.

While the high-density foam layer dominates the mechanical properties of the three-layer sandwich composite panel, the density of the three-layer sandwich composite panel is dominated by the density of the inner low-density foam layer, and the thickness of the inner low- density foam layer is adjusted And the density of the composite panel can be adjusted to favor transportation, processing and installation.

Therefore, the above-mentioned three-layer sandwich composite panel can improve refractoriness, heat resistance and mechanical properties, and is light and easy to process by including a dense foam layer controlling oyster shell strength, impact strength or compressive strength. In addition, the three-layer sandwich composite panel does not use a fluorocarbon (HCFC) foaming agent, and does not have a risk of global warming by using environmentally friendly foaming agents such as hydrocarbons.

As described above, the three-layer sandwich composite panel is formed by laminating high-density foam layers for controlling bending strength, impact strength, or compressive strength on both sides of a low-density foam layer for controlling thermal conductivity, By implementing enhanced physical properties through the high-density foam layer, it is possible to have improved fire resistance, heat resistance and mechanical properties over a one-layer, two-layer sandwich composite panel.

Hereinafter, specific embodiments of the present invention will be described. However, the embodiments described below are only intended to illustrate or explain the present invention, and thus the present invention should not be limited thereto.

< Experimental Example > - Physical properties of sandwich composite panels

A glass fiber paper was laminated on both sides of a low-density foam layer (FINEpol) having a thickness of 50 mm and a density of 35 kg / m &lt; ³ &gt; by using an ethylene-vinyl acetate copolymer emulsion adhesive on a polyurethane thermosetting resin foamed. Thereafter, a high-density foam layer (FINEpol Co., Ltd.) having a thickness of 20 mm and a density of 50 kg / m &lt; ³ &gt; was formed by foaming a polyurethane thermosetting resin on both sides of the glass islands through the adhesive, A three-layer sandwich composite panel was formed by laminating a metal face plate on the outer side of the high-density foam layer.

1) Compressive strength: The compressive strength of each of the low-density foamed layer and the high-density foamed layer and the compressive strength of the three-layer sandwich composite panel were measured by the method of KS M ISO 844.

2) Flexural Strength: The flexural strength of each of the low-density foamed layer and the high-density foamed layer and the flexural strength of the three-layer sandwich composite panel were measured by a 3-point bending test method.

3) Thermal conductivity: The bending strength of each of the low-density foamed layer and the high-density foamed layer and the flexural strength of the three-layer sandwich composite panel were measured by the method of KS L ISO 8301.

Low-density foam layer High-density foam layer Three-layer sandwich composite panel Compressive strength (N / cm ² ) 10.44 26.88 15.95 Flexural Strength (N / cm ² ) 28.17 115.65 51.48 Thermal conductivity (W / mK) 0.0190 0.022 0.0192

Referring to Table 2, the compressive strength and flexural strength were measured in the order of high-density foamed layer> three-layer sandwich composite panel> low-density foamed layer, in the case of thermal conductivity, low density foamed layer> three-layer sandwich composite panel> high density And the foam layer.

As described above, the high-density foam layer controls physical characteristics such as compressive strength and flexural strength. The low-density foam layer controls the thermal conductivity and is superior in heat resistance to the high-density foam layer. Therefore, the three-layer sandwich composite panel was formed into a three-layer sandwich composite panel in consideration of the excellent characteristics of each layer, and it can be understood that the three-layer sandwich composite panel exhibits excellent overall characteristics in terms of compressive strength, bending strength and thermal conductivity.

100: 3 layer sandwich composite panel
10: high-density foam layer
20: Low density foam layer
30: adhesive layer
11:
12:

Claims (14)

A high-density foam layer having a first face material on the outer side and a second face material on the inner side;
A low density foam layer in which a second face material is laminated on both sides; And
A high-density foam layer in which a first face material is laminated on the outer side and a second face material is laminated on the inner side;
The high-density foam layer and the low-density foam layer are formed by foaming a thermosetting resin,
Density of the high-density foam layer is 50 kg / m ³ to 70 kg / m ³ , the thickness is 10 mm to 30 mm,
The density of the low density foam layer is 30 kg / m ³ to 40 kg / m ³ , the thickness is 50 mm to 150 mm,
Wherein the second face sheet is a glass bead retaining or kraft paper
3 layer sandwich composite panel.
delete delete delete delete The method according to claim 1,
Wherein the first face material comprises a face material of metal
3 layer sandwich composite panel.
The method according to claim 1,
The first face material may be a metal face material and a glass scrim in combination
3 layer sandwich composite panel.
The method according to claim 1,
Wherein the thickness of the first face material is from 200 [mu] m to 400 [
3 layer sandwich composite panel.
delete The method according to claim 1,
And further comprising an adhesive layer between the high-density foam layer and the low-density foam layer
3 layer sandwich composite panel.
11. The method of claim 10,
Wherein the adhesive layer comprises an ethylene-vinyl acetate copolymer resin emulsion adhesive or an aqueous acrylic emulsion adhesive
3 layer sandwich composite panel.
11. The method of claim 10,
Wherein the thickness of the adhesive layer is 1 mm to 2 mm
3 layer sandwich composite panel.
The method according to claim 1,
The low-density foam layer controls the thermal conductivity of the three-layer sandwich composite panel
3 layer sandwich composite panel.
The method according to claim 1,
The high-density foam layer is used to control flexural strength, impact strength or compressive strength of the three-layer sandwich composite panel
3 layer sandwich composite panel.

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