KR101903122B1 - Quasi non-flammable composite panel and Method for manufacturing the same - Google Patents

Abstract

The present invention relates to a thermosetting resin-based composite panel having semi-incombustibility, comprising: an outer skin (20) formed by impregnating a base material laminated with paper (11) and a fabric (12) with melamine resin; And a core material 30 formed by impregnating the substrate with a phenol resin including triazole and being joined to the middle of the outer skin 20 in multiple layers.
Accordingly, the monomer of the thermosetting resin can be chemically functionalized to impart self-flame retardancy, and the surface strength and elasticity can be secured in accordance with the use of the gym finishing material while enhancing the design and the workability.

Description

TECHNICAL FIELD [0001] The present invention relates to a quasi-non-flammable composite panel and a manufacturing method thereof,

The present invention relates to a semi-incombustible panel, and more particularly, to a quasi-incombustible thermosetting resin composite panel for use as a finishing material for interior finishing or interior decoration of a building and a method of manufacturing the same.

Generally, melamine faced plywood, PVC vinyl, wood furniture, urethane foam finish materials are mainly used as finishing materials for interior finishing and interior decoration of buildings. In some cases, it may be used by adhering to a magnesium board. However, these finishing materials are advantageous in that various colors and designs can be created. However, there are problems such as peeling, cracking and curling due to environmental changes, and a large amount of poisonous gas is emitted when a fire occurs.

Reference may be made to Korean Patent Registration No. 0452486 (Prior Art 1), Japanese Patent Application Laid-Open No. 2000-135758 (Prior Art 2), etc., which are related to composite panels having incombustibility or flame retardancy.

Prior Art Document 1 discloses a flame retardant melamine resin impregnated layer formed by laminating a melamine resin impregnated paper obtained by impregnating a flake-like melamine resin impregnation solution with a shade paper; And a flame retarded phenolic resin impregnated layer formed by laminating a phenol resin impregnated paper obtained by impregnating a flame retardant phenolic resin impregnated liquid with kraft paper on the lower part of the flame retarded melamine resin impregnated paper layer. Therefore, it is anticipated that the effect of preventing a fire accident will be prevented.

The prior art document 2 is composed of an inorganic fiber base impregnated with a thermosetting resin, a molding sheet having a thermosetting resin layer containing aluminum hydroxide powder, etc., and the laminated base material and the sheet are thermo-pressed to produce a bright plate having a thickness of about 3 mm . Therefore, it is expected to have a suitable effect as a building interior and exterior material because it has flame retardancy and nonflammability while having sufficient strength at the lamination interface.

However, according to the above-mentioned prior art, it is difficult to adapt to other physical conditions when applied to a sports facility such as a gymnasium.

1. Korean Registered Patent No. 0452486 "Flame Retardant Sheet Using Flame Retardant Resin Composition and Method for Manufacturing the Same" (Date of Publication: Mar. 29, 2003) 2. JP-A-2000-135758 "Cosmetic material and method for manufacturing the same" (Publication date: May 16, 2000)

SUMMARY OF THE INVENTION It is an object of the present invention to overcome the above-mentioned problems of the prior art by providing a thermosetting resin composition which can chemically functionalize a monomer of a thermosetting resin to impart self-flame retardancy and secure surface strength and elasticity, Quasi-flammable thermosetting resin composite panel and a method of manufacturing the same.

Another object of the present invention is to form a layer of impregnated glass fiber material based on a flame-retardant thermosetting resin to a thickness of 3 mm or more through a molding technique.

In order to achieve the above object, according to one aspect of the present invention, there is provided a thermosetting resin-based composite panel having semi-flammability, comprising: an outer skin formed by impregnating a substrate laminated with paper and a fabric with melamine resin; And a core material formed by impregnating the base material with a phenol resin including triazole, and having a multi-layered intermediate layer bonded to the outer skin.

In the detailed construction of the present invention, the outer skin fabric is characterized in that at least one of the polyester fiber, the polyolefin fiber and the polyaramid fiber has a structure in which glass fibers or carbon fibers coated with an elastomer composite are spun.

As a modification of the present invention, the core portion may further include a plurality of through holes arranged regularly, and the outer skin may further include a groove formed in a continuous curved surface causing elastic deformation.

According to another aspect of the present invention, there is provided a method for producing a composite panel formed by the structure of claim 1, comprising the steps of: (A) repeatedly impregnating the outer skin and the core material using a roller having an emboss; (B) drying the outer skin and the core material at a temperature of 80 to 120 캜 until a volatilization amount (VC) is set; And (C) bonding the outer skin and the core part in a laminated state using a flame-retardant adhesive.

As a detailed construction of the present invention, a plurality of through holes are formed in the core material portion dried in the step (B), and the through holes are filled with the elastic material in the upsetting step (C).

As described above, according to the present invention, the monomers of the thermosetting resin can be chemically functionalized to impart self-flame retardancy, and the surface strength and elasticity can be secured in accordance with applications such as gym finishing materials while enhancing design and workability.

1 is a schematic view partially showing a main part of a composite panel according to the present invention;
2 is a schematic view partially showing a composite panel according to a modification of the present invention;

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

According to one aspect of the present invention, a composite panel based on a thermosetting resin having semi-incombustibility is proposed. The finishing materials for bonding magnesium boards to general melamine resins, PVC vinyl resins, wood coating foams, urethane foams, etc., which are applied to the interior of buildings, have the advantage of being able to create various colors and designs, but they have problems such as peeling, cracking and curling And a lot of poisonous gas is emitted when a fire occurs and it is directly connected to the damage of a large human life. Particularly, in the case of walls and floors of gymnasiums in which various kinds of ball games, gymnastics, and martial arts are played, physical properties to mitigate impacts are required in addition to quasi-incombustibility / flame retardancy.

According to the present invention, the outer skin (20) is formed by impregnating a substrate (11) and a fabric (12) laminated with melamine resin. A paper 11 such as a kraft paper having a high strength and a fabric 12 woven with an elastic fiber are used as the base 10 of the outer skin 20. The melamine impregnation solution is prepared by adding colloidal silica or vitrified Fritz and flame retardant to the melamine solid.

In addition, according to the present invention, a core member 30 formed by impregnating a substrate with a phenol resin containing a triazole is bonded in the middle of the outer skin 20 in multiple layers. The substrate of the core member 30 uses at least one of the paper 11 and the fabric 12 of the outer skin 20. A PF resin is synthesized in the presence of an acid catalyst using various organic acids and inorganic acids, and a propargyl halide (bromide or the like) is then reacted therewith to obtain a phenol resin substituted with propargyl, It is preferable to add an inorganic filler so as to enhance the flame retardancy in the course of the composition. As the inorganic filler, a material selected from calcium carbonate (CaCO ₃ ), silicon dioxide (SiO ₂ ), aluminum hydroxide (Al (OH) ₃ ), magnesium oxide (MgO), aluminum oxide (Al ₂ O ₃ )

At this time, a triazole group is introduced into the PF resin to discharge the flame-retardant nitrogen under the combustion condition, and the thermal rearrangement reaction to the indole structure excellent in the heat resistance characteristic through the rearrangement of the molecules, Of flame retardancy. For the application to the actual process, triazole can be converted quantitatively to 'triazoles' through 'click chemistry'.

As a detailed configuration of the present invention, the fabric 12 of the outer skin 20 may have a structure in which at least one of a polyester fiber, a polyolefin fiber, and a polyaramid fiber is formed by spun glass fiber or carbon fiber coated with an elastomer composite . Polyester fibers, polyolefin fibers, and polyaramid fibers have high whiteness as well as strength, heat resistance and elasticity, and are not easily yellowed. Glass fiber and carbon fiber have high strength and high flame retardancy. The elastomer composition increases the adhesion while permitting elastic deformation. In any case, when the fibers are formed into a twisted yarn and woven with the fabric 12, the affinity with the paper 11 is good and the elasticity of the final product can be enhanced through impregnation with melamine resin or phenol resin.

In the modification of the present invention, the core member 30 further includes a plurality of through holes 42 arranged regularly, and the outer skin 20 is provided with a groove (not shown) formed by a continuous curved surface causing elastic deformation 46). The through-hole 42 forms a space elastically stretchable and contractible by an external force, thereby alleviating an impact acting on the body in a gym wall or the like. The grooves 46 are formed by connecting spherical surfaces of the same size vertically, horizontally, and curvedly arranged in a densely arranged manner, and form a space elastically expanded and contracted by an external force in the same manner as the through holes 42. In the process of forming the outer skin 20, the recesses 46 are integrally formed when the mold is pressed.

According to another aspect of the present invention, a method for manufacturing a composite panel formed by the structure of claim 1 is proposed.

The step (A) of the present invention proceeds to a process of repeatedly impregnating the outer skin 20 and the core member 30 by using a roller having an emboss. The outer skin 20 and the core member 30 are immersed several times in an independent process. In this process, the emboss roller causes rapid and accurate penetration of the impregnation liquid onto the substrate 10. That is, since the inside air of the paper 11 and the fabric 12 is removed, the resin sufficiently penetrates to obtain a state of uniformity even in appearance.

The step (B) according to the present invention is performed by drying the outer skin 20 and the core member 30 at a temperature of 80 to 120 ° C until the volatile content (VC) is set. For drying, forced drying using a dryer is preferred, but not limited thereto. Important conditions in the drying process are the resin content (RC) to be applied and the volatile content (VC) remaining after drying. The proper temperature range is varied according to the material and thickness of the outer skin 20 and the core material portion 30 and the drying speed (rpm) for realizing the set RC and VC values is maintained. The amount of volatilization (VC) of the outer skin 20 and the core portion 30, which have been dried, is preferably less than 5%, based on the weight of the substrate 10.

On the other hand, in the step (A), the overall speed is adjusted so that the substrate can be sufficiently immersed in the resin, though the productivity is influenced by the drying rate of the step (B) in consideration of the mass production flow in which a series of processes are continuously performed.

The step (C) according to the present invention proceeds to a process of bonding using the flame-retardant adhesive 15 in a state in which the outer skin 20 and the core member 30 are laminated. Examples of flame-retardant adhesives include melamine cyanurate, magnesium hydroxide, pyrophosphate, zeolites and sodium silicate. In this way, besides the adhesiveness and flame retardancy, it exhibits the environmental friendliness, water resistance, heat insulation property and the like required for the gymnasium.

More specifically, in order to make a finish material finished product having a thickness of 3.0 mm using a flame-retardant thermosetting resin, at least seven core pieces 30 are laminated and stacked, and the core material 30 (30 The adhesive 15 is added as necessary in this process and the pressure plate (glossy or embossed) is raised to complete a laminate. Then, the laminate is put into a molding press and molded by applying heat and pressure. The molding conditions are as follows: the temperature is 125 to 135 ° C, the pressure is 145 to 155 kgf / cm 2, and the holding time is maintained at 15 to 25 minutes.

In the detailed construction of the present invention, a plurality of through holes 42 are formed in the core material 30 dried in the step (B), and an elastic material 44 is attached to the through holes 42 in the up-down step (C) And is filled. It is preferable that the through hole 42 is formed in a semi-dry state before being completely dried to have a diameter corresponding to the end use application. As the elastic material 44, natural rubber, nitrile rubber, acrylic rubber, urethane rubber, fluorine rubber, silicone rubber and the like can be selectively used. When high impact resistance and thermal stability are required, an acrylonitrile-butadiene rubber-styrene (ABS) resin composition having flame retardancy can be added.

Therefore, since the manufacturing process does not include bromine or chlorine, no harmful chemical substances are discharged in the combustion process, which is environment-friendly, harmless to human body, and improved in heat resistance and flame retardancy. It is possible to expand the application by improving physical properties such as flame retardancy and elasticity even though the appearance is similar to that of conventional HPL or other flame retardant products.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit and scope of the invention. It is therefore intended that such variations and modifications fall within the scope of the appended claims.

10: substrate 11: paper
12: Fabric 15: Adhesive
20: outer skin 30: core material part
42: Through hole 44: Elastic material
46: groove

Claims (5)

A composite panel based on a thermosetting resin having quasi-incombustibility and buffering properties:
An outer skin (20) formed by impregnating a substrate laminated with a paper (11) and a fabric (12) with melamine resin; And
And a core part (30) formed by impregnating the base material with a phenol resin containing triazole and being joined in multiple layers in the middle of the outer skin (20)
The fabric 12 of the outer skin 20 has a structure in which at least one of a polyester fiber, a polyolefin fiber, and a polyaramid fiber is made of glass fiber or carbon fiber coated with an elastomer composite,
The core member 30 further includes a plurality of through holes 42 arranged regularly and the outer skin 20 further includes a groove 46 formed in a continuous curved surface causing elastic deformation Semi-flammable thermosetting composite panel. delete delete A method for manufacturing a composite panel formed by the structure of claim 1, comprising:
(A) repeatedly impregnating the outer skin (20) and the core portion (30) using a roller having embossing;
(B) drying the outer skin 20 and the core member 30 to a set volatile content (VC) at a temperature of 80 to 120 ° C; And
(C) bonding the outer skin (20) and the core member (30) in a laminated state using a flame retardant adhesive (15). The method of claim 4,
Wherein a plurality of through holes 42 are formed in the core material 30 dried in the step B and the through holes 42 are filled with the elastic material 44 in the up-and-down step C, (JP) METHOD FOR MANUFACTURING COMBUSTIBLE TEMPERATURE RESIN COMPOSITE PANEL

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