KR102006809B1 - Fiber-reinforced composiite pannel and manufacturing method thereof - Google Patents

Abstract

In order to solve the above problems, the present invention comprises the steps of manufacturing a face material comprising at least one prepreg; Preparing a composite panel by forming a core material by laying a core material between the prepared pair of face plates and then foaming the core material; And aging the composite panel; wherein the prepreg comprises carbon fiber, the method of manufacturing a fiber reinforced composite panel.
In another aspect, the present invention is a core (core plate) comprising at least one of polyurethane (Polyurethane) and polyisocyanurate (Polyisocyanurate); And a face plate formed on the front and rear surfaces of the core material and including at least one prepreg including carbon fiber.

Description

FIBER-REINFORCED COMPOSIITE PANNEL AND MANUFACTURING METHOD THEREOF

The present invention relates to a fiber-reinforced composite panel and a method for manufacturing the same, and more particularly, to a fiber-reinforced composite panel and a method for manufacturing the fiber reinforced composite panel that can improve the heat insulation and flame retardancy, and can suppress flame propagation in the event of a fire.

Recently, large-scale fires occurred in various areas such as Uijeongbu fire, Cheonan-Butane gas plant fire, and Busan Haeundae complex shopping mall, and it is pointed out that the sandwich panel used in the past is composed of materials that are easily burned. .

Panels are generally used for building exterior wall finishing materials, and conventional panels are made of steel, such as aluminum, magnesium, iron, the front panel and the back panel.

The steel plates constituting the front plate and the back plate have a property of easily propagating a flame or a heat source in the event of a fire, so if the core (core material) disposed between the front plate and the back plate catches fire, It has the property of spreading quickly to materials. In addition, steel plate has a problem in construction safety because of its high weight.

In order to solve this problem, an attempt has been made to replace the core material with a material such as glass wool or mineral wool, which is a non-combustible material. However, the glass wool, mineral wool, etc. correspond to non-combustible materials, but the insulation performance is very low, so the thickness should be more than twice as compared to the case of using a general urethane material. Safety is a problem, and because the physical strength is poor, additional work is required for construction, there is a problem that the construction is complicated.

That is, the conventional panel is a problem of fire insulation of the front plate and the back plate corresponding to the face plate (face plate), poor thermal insulation performance of the core material corresponding to the core (core plate) and unnecessary weight increase problem.

The present invention is to improve the problems of the conventional panel as described above, and to provide a fiber-reinforced composite panel and a method of manufacturing the carbon fiber in the face material in order to block the propagation of the flame or heat source when a fire occurs.

In addition, the present invention is to provide a fiber-reinforced composite panel and a method of manufacturing the same by applying a face plate containing carbon fiber to improve the safety and durability in construction of the fiber-reinforced composite panel by achieving a light weight.

In another aspect, the present invention is to provide a fiber-reinforced composite panel and a method of manufacturing the surface of the face material is modified by plasma treatment to improve the flame retardancy and improve the adhesion between the core material and the face material.

In addition, the present invention provides a fiber-reinforced composite panel and a method of manufacturing the same by using a vacuum bag molding (VACUUM BAG MOLDING) step to maintain the prepreg form during the molding process to improve the workability and improve the physical properties of the molded article To provide.

In another aspect, the present invention is to provide a fiber-reinforced composite panel and a method for manufacturing the same, which can be achieved at the same time to improve the insulation, in-plane shear strength, axial compression strength, distribution pressure strength and flame retardancy.

In order to solve the above problems, the present invention comprises the steps of manufacturing a face material comprising at least one prepreg; Preparing a composite panel by forming a core material by laying a core material between the prepared pair of face plates and then foaming the core material; And aging the composite panel; wherein the prepreg comprises carbon fiber, the method of manufacturing a fiber reinforced composite panel.

For example, the manufacturing of the face material may include a vacuum bag molding step.

For example, the prepreg may further include at least one of a blend of carbon fiber and glass fiber, a blend of carbon fiber and aramid fiber, and a mixture of carbon fiber and steel sheet.

For example, the core material may include at least one of polyurethane and polyisocyanurate.

For example, the manufacturing of the composite panel may further include modifying the surface of the face material by plasma treatment before depositing the core material between the pair of face plates manufactured. It may be performed on the surface containing the prepreg formed.

In another aspect, the present invention is a core (core plate) comprising at least one of polyurethane (Polyurethane) and polyisocyanurate (Polyisocyanurate); And a face plate formed on the front and rear surfaces of the core material and including at least one prepreg including carbon fiber.

For example, the face material may include a surface whose surface is modified by plasma treatment, and the plasma treatment may be performed on a surface on which a prepreg including the carbon fiber is formed.

For example, the prepreg may further include at least one of a blend of carbon fiber and glass fiber, a blend of carbon fiber and aramid fiber, and a mixture of carbon fiber and steel sheet.

For example, the thermal insulation measured by KS F 4724 is 2.0 m ² K / W or more, the in-plane shear strength measured by KS F 4724 is 900 N / m or more, and the axial compressive strength measured by KS F 4724 is 4900. N / m or more, the distribution pressure intensity measured by KS F 4724 is 680 N / mm ² or more and the total amount of heat released after 10 minutes of heating start measured by KS F ISO 5660-1 (cone calorimeter method) is 8 MJ / It may include at least any one of m or less.

Fiber-reinforced composite panel according to the present invention, by including the carbon fiber in the face material can minimize the damage caused by the fire by blocking the propagation of the flame or heat source during the fire.

In addition, the fiber-reinforced composite panel according to the present invention, by applying a face material containing carbon fiber instead of a steel sheet to achieve a light weight, it is possible to improve the safety and durability in construction of the fiber-reinforced composite panel.

In addition, the fiber-reinforced composite panel according to the present invention, the surface of the face material is modified by a plasma treatment to improve the adhesion between the core material and the face material can be improved flame retardancy and construction stability can be greatly improved.

In addition, the fiber-reinforced composite panel according to the present invention, by manufacturing a face using a vacuum bag molding (VACUUM BAG MOLDING) step to maintain the prepreg form during the molding process can improve the workability and improve the physical properties of the molded article.

In addition, the fiber-reinforced composite panel according to the present invention, the heat insulating property, in-plane shear strength, axial compression strength, distribution pressure strength and flame retardancy can all be improved and at the same time reduced in weight.

1 is a cross-sectional view showing a fiber reinforced composite panel according to an embodiment of the present invention.
Figure 2 is a cross-sectional view showing a laminated member of the fiber reinforced composite panel according to an embodiment of the present invention.
Figure 3 shows a vacuum bag for producing a face of the fiber-reinforced composite panel according to an embodiment of the present invention.
Figure 4 is a flow chart showing a method of manufacturing a fiber-reinforced composite panel according to an embodiment of the present invention.
5 shows a plasma processing process according to an embodiment of the present invention.
6 to 9 are graphs showing surface element change (EDS) measurement results of a face plate subjected to a plasma treatment process according to an embodiment of the present invention.
10 to 11 show the results of Atomic Force Microscope (AFM) on the surface of the face plate subjected to the plasma treatment process according to an embodiment of the present invention.

The present invention is not limited to the embodiments disclosed below, but can be implemented in various different forms, only this embodiment to make the disclosure of the present invention complete and to those skilled in the art to fully understand the scope of the invention It is provided to inform you.

Where an element is referred to herein as being located above another element 'above' or 'below', this means that the element is located directly above another element 'above' or 'below' or there is no additional element between them. Include all meanings that may be intervened. In the present specification, the term 'upper' or 'lower' is a relative concept set at an observer's viewpoint, and when the observer's viewpoint is different, 'upper' may mean 'lower', and 'lower' means 'upper'. It may mean.

Like reference numerals in the drawings indicate substantially the same elements as each other. Also, the singular forms “a,” “an,” and “the” include plural expressions unless the context clearly indicates otherwise. Or combinations thereof, it is to be understood that they do not preclude the presence or addition of one or more other features or numbers, steps, operations, components, parts or combinations thereof.

As described above, when a large fire occurs, a flame and a heat source are propagated by a composite panel which is an essential component of a building material, thereby causing a great loss of life. Accordingly, the inventors of the present invention have attempted to manufacture a panel that can minimize human damage in the event of a fire, and was able to complete the present invention by repeating related experiments. Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.

1 is a cross-sectional view showing a fiber reinforced composite panel according to an embodiment of the present invention.

Referring to FIG. 1, the fiber reinforced composite panel may include core plates 20 and face plates 10 formed on the front and rear surfaces of the core 20.

Figure 2 shows a laminated member of the fiber reinforced composite panel according to an embodiment of the present invention, referring to Figure 2, the laminated member 100 constituting the face member 10 is composed of a prepreg 110 (Fig. 2 (a)) or the cover sheet 120 may be formed on the upper and lower portions of the prepreg 110 (FIG. 2 (b)), the lower portion (FIG. 2 (c)) or the upper portion (FIG. 2 (d)). have. For example, the fiber-reinforced composite panel according to the embodiment of the present invention has a prepreg 110 including carbon fibers to improve the physical properties of the molded article by improving the adhesion between the face member 10 and the core member 20. The surface may be plasma treated, and in this case, the stacking member 100 may apply the configuration of FIG. 2 (a) or 2 (d).

At this time, the laminated member 100 is vacuum assisted resin transfer molding (Vacuum Assisted Resin Transfer Molding, VaRTM), vacuum bag molding (Vacuum Oven Molding), autoclave molding (Autoclave molding) and compression molding It can be manufactured using any one of (Compression Molding), a specific method will be described later.

The prepreg 110 may be formed in the case of constituting the face plate 10 of the composite panel for building materials, it may be formed after impregnating the textile fabric in advance. The material of the prepreg 110 is at least one of carbon fiber, blend of carbon fiber and glass fiber, blend of carbon fiber and aramid fiber, and mixture of carbon fiber and steel sheet, for example, aluminum. It may include, and may further include a thermosetting resin such as epoxy, polyimide, phenol. That is, the fiber-reinforced composite panel according to the present invention is a prepreg 110 constituting the face member 10 is composed of a single layer or a plurality of layers of carbon fiber (carbon fiber) or consists of a multi-layer containing a carbon fiber conventional steel sheet Compared to the face plates used, it can cut down the propagation of flames or heat sources in the event of a fire, which can significantly reduce the human injury caused by the fire.

The stacking thickness of the prepreg 110 may be 0.5 mm to 40 mm, and when the stacking thickness is less than 0.5 mm, the mechanical strength of the stacking member 100 may be significantly degraded. As the thickness of 100 is too thick, hardening reaction may not proceed sufficiently due to uneven heat transfer inside the stacking member 100, so that the physical strength of the stacking member 100 may be inferior, or the molding time increases. The efficiency can be lowered.

The cover sheet 120 may be formed by, for example, impregnating melamine resin in a shape paper made through gravure printing on paper, and when the cover sheet 120 is manufactured using the melamine resin, It may be easy. In addition, the cover sheet 120 formed through gravure printing may be easily formed in a variety of patterns. That is, the cover sheet 120 may include a color and design desired by the user by using melamine resin. In addition, when the melamine sheet is used as the cover sheet 120, the adhesive force with the prepreg 110 including the carbon fiber is improved, so that the density of the face member 10 is improved, so that the durability of the melamine sheet can be greatly improved. have.

Figure 3 shows a vacuum bag for producing a face of the fiber-reinforced composite panel according to an embodiment of the present invention.

In the conventional panel manufacturing, a press molding method was used. In the case of press molding, the viscosity of the epoxy resin decreased as the temperature inside the mold increased, so that it was difficult to improve the physical properties of the manufactured panel. Were frequently used, and the prepreg containing carbon fiber could be poor in physical properties. Therefore, the inventors of the present invention to manufacture a fiber-reinforced composite panel using a prepreg containing carbon fiber, improve the workability in the manufacturing process and the physical properties of the manufactured fiber-reinforced composite panel, for example, insulation, in-plane shear strength In order to improve the axial compressive strength, distributed compressive strength and flame retardancy, vacuum bag molding was performed. Hereinafter, a specific configuration will be described.

The vacuum bag 30 is a device for manufacturing the face plate 10 by a vacuum bag molding method, and includes a lower mold 190, a sealant 140, a release member 130, and a laminated member. 100, an upper mold 150, a breather 160, a vacuum film 170, and a vacuum valve 180 may be included.

The lower mold 190 is a part for manufacturing a molded article, and may include a metal or glass material such as iron and aluminum, and may be formed in a flat plate shape.

The sealant 140 is a member that bonds the members to each other. For example, the sealant 140 may perform an adhesive function for sealing. The material of the sealant 140 may include a soft material, for example, a soft or high viscosity liquid rubber composition. The sealant 140 may perform a function of preventing leakage between the plurality of adhesive parts. For example, the sealant 140 may be installed at a portion where the vacuum film 170 and the lower mold 190 contact with each other and sealed to seal the inflow and outflow of air. Can be blocked. In addition, the sealant 140 may maintain a pressure state inside the vacuum bag 30. For example, the sealant 140 may be uniformly adhered to the prepreg 110 constituting the face material 10 by keeping it at a low pressure state. ) Durability can be improved.

The release member 130 may facilitate the demolding operation after the molding process of the face member 10 is completed. For example, the release member 130 may be formed of a release film coated by adding an inorganic particle having an antistatic effect with a silicone composition to one or both sides of the polyester film (PET), Peel Ply It may be formed as. The release member 130 may have a uniform peeling force, residual adhesive strength, and antistatic performance, and may perform a temporary support and an adhesive layer protection function as an adhesive component material. At this time, the release film may serve as a functional film to be easily peeled from the product after the molding process.

The stacking member 100 is composed of the prepreg 110 (Fig. 2 (a)) or the upper and lower portions of the prepreg 110 (see Fig. 2 (a) to 2 (d) as described above) (b)), the cover sheet 120 may be formed on the lower portion (Fig. 2 (c)) or the upper portion (Fig. 2 (d)).

The upper mold 150 may correspond to the lower mold 190, and may include a metal or glass material such as iron and aluminum, and may be formed in a flat plate shape.

The breather 160 may perform a function of uniformly distributing the pressure of the vacuum film 170 therein. In addition, the breather 160 may perform a function of absorbing the resin flowing out of the prepreg 110 during molding, and may include, for example, a nonwoven fabric capable of absorbing the flowing resin, and provided with pores. It may include a structure.

The vacuum film 170 may perform a function of forming the vacuum bag 30, and the lower mold 190, the release member 130, the stacking member 100, the upper mold 150, and the breather 160. After the installation is finally performed to control the vacuum state.

The vacuum valve 180 may perform a function of sealing the air from being introduced after the air inside the vacuum bag 30 is discharged to the outside by a vacuum pump (not shown), and the vacuum film 170 and the breather ( 160 may be formed between.

For example, the face plate 10 manufactured by the above-described vacuum bag 30 may be modified by a plasma treatment. For example, the carbon fiber prepreg of the face plate 10 may be modified by using atmospheric pressure plasma. The formed surface may be modified, and specific plasma processing methods and results will be described later. That is, the face plate 10 including the carbon fiber is formed with irregularities on the surface to improve the physical adhesive force with the core material 20, and the chemical adhesive force is improved by the hydroxyl group (C = OH) formed by plasma treatment of carbon Insulation property, in-plane shear strength, axial compressive strength, distribution pressure strength of fiber-reinforced composite panels manufactured according to the present invention are improved, and the total amount of heat released by heating is reduced, so it can be used as an excellent building insulation material. It is possible to minimize the occurrence of damage caused by fire by blocking the propagation of the heat source.

The core plate 20 is formed between the face plate 10 to function and serve as insulation, sound insulation, sound insulation, and heat insulation, and the core material 20 may be formed by being foamed after being applied between the face plate 10. have. The core material may be a urethane-based resin, and may include, for example, at least one of polyurethane and polyisocyanurate. Conventional composite panels used polyurethane (PU) as a heat insulating material, but polyurethane has a problem that it is vulnerable to fire due to poor heat resistance. However, the inventors of the present invention greatly improved the flame retardancy compared to the case of using a conventional polyurethane by applying polyisocyanurate (PIR). Specifically, referring to Scheme 1 below, the polyisocyanurate starts the reaction at a temperature of 60 ° C. or more under PIR catalyst conditions, and the final shape of the reaction includes three isocyanate groups, thereby isocyanurate ring. A ring structure can be formed, and heat resistance to flame retardancy can be greatly improved by such a ring structure. On the other hand, the PIR reaction can be confirmed using a FORMAT System which is a foam rise tester.

<Scheme 1>

However, in the case of PIR, the adhesive force with the face plate 10 including the carbon fiber according to the present invention was found to be somewhat inferior to that of the PUF, and the inventors of the present invention modified the surface of the face plate 10 by plasma treatment or PIR. Insulation property, in-plane shear strength, axial compressive strength, distribution of the fiber-reinforced composite panel manufactured by improving the adhesive force of the face material 10 and the core material 20 by modifying the ester polyol used as the main component It was able to be used as an excellent building insulation material by improving the stiffness and reducing the total amount of heat emitted by heating, and minimized the damage caused by the fire by blocking the propagation of flame or heat source in the event of fire.

The core material may further include a polyol, a flame retardant, a foam stabilizer, a catalyst, a foaming agent, and a curing agent. For example, 20 to 25 parts by weight of polyol, 1 to 10 parts by weight of flame retardant, foam stabilizer, and the like based on 100 parts by weight of core material It may include 1 to 5 parts by weight of the catalyst, 1 to 10 parts by weight of the blowing agent, and 50 to 60 parts by weight of the curing agent.

Polyols are initiators such as polyfunctional alcohols or aromatic amines having two or more hydroxyl groups (-OH) or amine groups (Amine group,-NH2) and propylene oxide (Propylene Oxide, PO) in the molecule. Or ethylene oxide (Ethylene Oxide, EO) can be obtained by the reaction under appropriate conditions. As polyols, polyether polyols and polyester polyols can be used, and the present invention was able to improve flame retardancy by increasing the content ratio of the curing agent by increasing the content of ester polyol.

Flame retardants are chemicals that inhibit or delay the combustion process, and include halogen compounds, phosphorus compounds, and nitrogen compounds. The present invention can improve the flame retardant effect by blocking the oxygen transfer by breaking the urethane bond by combustion and forming a carbonized layer (char) through the dehydrogenation / dehydration reaction by introducing a phosphorus-based flame retardant. On the other hand, if the flame retardant is less than 1 part by weight, the flame retardant effect may be insignificant, and when the flame retardant is greater than 10 parts by weight, the mechanical strength of the core material may be weakened, thereby deteriorating the physical properties of the fiber reinforced composite panel.

The foam stabilizer serves as a surfactant, and may serve to help hydrophilization of the foaming agent for mixing the core material with other compositions such as a foaming agent. For example, a silicone-based or the like may be used. When the content of the foam stabilizer is less than 1 part by weight, it is difficult to mix the foaming agent with the core material and the curing agent because the foaming agent does not have a hydrophilic function. When the content exceeds 10 parts by weight, the core material 20 and The adhesive force of the face member 10 may be poor.

The blowing agent may serve to form bubbles in the composition of the core material by the heat of reaction generated as the physical blowing agent, and may use a low thermal conductivity and a low boiling point. For example, the blowing agent may use an aliphatic hydrocarbon having 1 to 8 carbon atoms. Conventionally, there has been a problem of global warming due to ozone layer destruction using freon gas or HCFC (hydro-chloro-fluoro-carbon) as a blowing agent. The burden can be eliminated. For example, hydrocarbons such as HFC (hydrofluorocarbon), isopentane and cyclopentane may be used as the blowing agent, and may be selected in consideration of thermal conductivity and boiling point of the blowing agent.

Isocyanate refers to a chemical substance containing an isocyanate group (-NCO) in two or more benzene rings and combines with a polyol to cause a polyurethane reaction. The thermal stability of the ring structure of Isocyanate can be improved by inducing PIR reaction by injecting excessive amount of hardener in the manufacture of core material PIR foam.

The catalyst refers to a material that changes the reaction rate rapidly or slowly without being consumed or changed in the reaction process. In general, an amine catalyst and a trimerization catalyst used in polyurethane may be used. That is, the present invention can increase the overall reaction activity by using the amine catalyst, it is possible to improve the flame retardancy by inducing the PIR reaction using the trimerization catalyst.

Meanwhile, depending on the components of the core material or the foaming conditions, the independent foam ratio of the core material cured foam to be formed may be determined. In the present invention, the closed cell content of the core material cured foam may be 50% or more, for example, 80% or more. The independent bubble ratio defines a fraction of closed bubbles among the bubbles formed in the unit area. When the independent bubble ratio is less than 50% in the present invention, the remaining gas remains in the core material cured foam and outgassing. ), And the structural strength is significantly lowered, which may lower the physical properties of the composite panel for building materials.

Figure 4 is a flow chart showing a method of manufacturing a fiber-reinforced composite panel according to an embodiment of the present invention.

Referring to Figure 4, the method of manufacturing a fiber-reinforced composite panel according to an embodiment of the present invention step of manufacturing a face member 10 including at least one prepreg 110 (S100), the pair prepared Forming the core material 20 between the surface material 10 of the foam and then foamed to form a core material 20 to produce a composite panel (S200) and the step of aging the composite panel (S300), the prepre Leg 110 may include carbon fibers.

The manufacturing of the face member 10 including the at least one prepreg 110 (S100) includes forming the laminated member 100 constituting the face member 10 as described above with reference to FIG. 2. For example, it may be composed of the prepreg 110 (Fig. 2 (a)) or the top and bottom (Fig. 2 (b)), the bottom (Fig. 2 (c)) or the top of the prepreg 110 The stacking member 100 may be formed by stacking the cover sheet 120 (FIG. 2 (d)). At this time, the size of the cover sheet 120 may be made larger than the size of the prepreg 110 5 mm to 20 mm, the size of the cover sheet 120 is less than 5 mm than the size of the prepreg 110 In this case, the vacuum film 170 and the prepreg 110 may stick to each other during the vacuum molding, and when the size is larger than 20 mm, the process may be uneconomical due to waste of unnecessary materials or the cover sheet 120 may be prepreg. Wrapping the side of the 110 may cause a problem that the non-uniform molded article is produced. At this time, the prepreg 110 is at least one of the carbon fiber, the blend of carbon fiber and glass fiber, the blend of carbon fiber and aramid fiber (mixed carbon fiber and steel plate) as described above By including it, it is possible to significantly reduce the human injury caused by the fire by blocking the propagation of the flame or heat source in the event of a fire.

Step S100 of manufacturing the face member 10 including at least one prepreg 110 may include a vacuum bag molding step, for example, the above-described vacuum bag (Vacuum Bag) 30 may be applied. That is, the step of manufacturing the face member 10 (S100) is a step of preparing a laminated member 100; Installing the lower mold 190 on the lower side of the stacking member 100; Installing an upper mold 150 on the upper side of the laminated member 100; Installing breather 160 above the upper mold 150; Installing the vacuum film 170 above the breather 160; Sealing the portion where the vacuum film 170 and the lower mold 190 contact with the sealant 140; Installing the vacuum valve 180 between the vacuum film 170 and the breather 160; Using a vacuum pump connected to the vacuum valve to make a space in which the lower mold 190 and the vacuum film 170 are coupled to a vacuum state, and closing the vacuum valve 180 to maintain a vacuum state; And performing a curing process.

At this time, the step of forming a release member 130 between the laminated member 100 and the upper mold 150 may be further included, the size of the release member 130 is 5 mm to 20 mm than the size of the laminated member 100 If the size of the release member 130 is less than 5 mm larger than the size of the stacking member 100, the problem that the vacuum film 170 and the stacking member 100 stick together during vacuum molding may occur. If it is larger than 20 mm, the process may be uneconomical due to waste of unnecessary materials or the release member 130 may surround the side surface of the stacking member 100, thereby causing a problem in that a non-uniform molded article is manufactured.

In addition, a space in which the lower mold 190 and the vacuum film 170 are combined is made into a vacuum state by using a vacuum pump connected to the vacuum valve, and the vacuum valve 180 is closed to maintain the vacuum state with the vacuum valve 180. By using a vacuum pump (not shown) connected to the lower mold 190 and the vacuum film 170, the interior of the vacuum bag is defined as a combined space to make a vacuum state, and close the vacuum valve 180 to maintain a vacuum state Can be. On the other hand, as the vacuum film 170 and the lower mold 190 through the vacuum maintaining step to make the inside of the vacuum bag 30 combined with a vacuum state or a pressure lower than atmospheric pressure, the lower mold 190 And the upper mold 150 can be made to press the laminated member 100.

The curing step may be performed by heating the vacuum bag 30 for 30 to 60 minutes at 70 ℃ to 90 ℃ conditions; And curing for 75 to 120 minutes at 110 ° C. to 140 ° C. conditions.

The epoxy resin impregnated in the prepreg 110 is heated to a resin flow phenomenon at about 80 ° C. by heating the vacuum bag 30 at the 70 ° C. to 90 ° C. for 30 to 60 minutes. By the evenly distributed in the stacking member 100 and the vacuum bag 30 can be bonded between the prepreg (110). When the heating condition is less than 70 ℃ hardly changes in the viscosity of the resin hardly occurs, the durability of the face plate 10 may be inferior, if the flow is more than 90 ℃ the flow of the resin is not smooth smooth adhesion between the prepreg 110 As this worsens, the durability of the face member 10 may be poor.

The curing of the epoxy resin through the curing step for 75 minutes to 120 minutes at 110 ° C. to 140 ° C. may result in the laminated member being integrated to form a face member 10. If the curing conditions are less than 110 ° C or more than 140 ° C, the curing may not proceed smoothly and the durability of the face member 10 may be poor.

On the other hand, after the vacuum state holding step, if the molding is completed through the step of performing a curing process, the laminated member 100 is formed in an integrated plate form, the surface may be manufactured to have a smooth surface with almost no bubbles. At this time, in order to improve the adhesion between the core member 20 and the face member 10 to be described later, the surface of the face member 10 may be modified. As a method of modifying the surface of the face member 10, there are methods such as surface polishing, corona discharge, oxidation treatment, plasma treatment, etc., minimizing the deterioration of physical properties of the treated product, and forming the activation functional groups on the surface according to the type of treatment gas. Plasma treatment can be performed in that surface irregularities can be formed by sputtering or the like. At this time, oxygen, nitrogen, argon, etc. may be used as a gas of atmospheric pressure plasma treatment, and hydroxyl groups (C = OH) may be formed from carbon of carbon fibers included in the face plate 10 to enable hydrogen bonding with the epoxy resin. It is possible to form irregularities on the surface of the face member 10 itself. That is, the face material 10 is a surface modification through plasma treatment, while improving the adhesion to the core material 20 while maintaining the physical properties of the product, the thermal insulation properties, in-plane shear strength, axial compressive strength, distribution of the fiber-reinforced composite panel manufactured It can be used as an excellent building insulation material by improving the stiffness and reducing the total amount of heat emitted by heating, and can minimize the damage caused by fire by blocking the propagation of flame or heat source in case of fire.

Forming the core material 20 between the prepared pair of face material 10 and then foaming to form a core material 20 to produce a composite panel (S200) as described above to use a urethane-based resin as the core material It may include, for example, at least any one of polyurethane (Polyurethane) and polyisocyanurate (Polyurethane), and may further include a foam stabilizer, foaming agent, curing agent and additives, for example, core material 20 to 25 parts by weight of polyol, 1 to 10 parts by weight of a flame retardant, 1 to 5 parts by weight of a foam stabilizer and a catalyst, 1 to 10 parts by weight of a blowing agent, and 50 to 60 parts by weight of a curing agent based on 100 parts by weight.

Specific configuration of the polyol, flame retardant, foam stabilizer, foaming agent, curing agent, catalyst used in the step of foaming the core material between the pair of face plates 10 to form a cured foam may be applied to the above-described bar.

The volatile organic compound (VOC) may be removed through the step S300 of aging the composite panel, and one or a plurality of aging steps may be performed. The aging step may be carried out by storage at room temperature, or may be performed in an oven for 10 minutes or more under a condition of less than 75 ℃.

Looking at a specific embodiment as follows.

Production Example  One: Cotton  Produce

A laminated member was formed by laminating a melamine sheet (Printech LPM, Korea) cover sheet and carbon fiber prepreg (WSN3K, SK Chemical, Korea). At this time, after cutting the melamine sheet and the carbon fiber prepreg, 2 ply (2 ply) of carbon fiber prepreg was laminated, and one melamine sheet was laminated on the carbon fiber prepreg. Thereafter, the face plate was manufactured by performing a molding process in an oven through the vacuum bag forming step using the above-described vacuum bag. The molding process was performed at 80 ° C. for 30 minutes and then cured at 125 ° C. for 90 minutes.

Production Example  2: Heartwood  formation

The core material was laid between a pair of face plates and then foamed. 20 to 25 parts by weight of polyol, 1 to 10 parts by weight of flame retardant, 1 to 5 parts by weight of foam stabilizer and catalyst, 1 to 10 parts by weight of blowing agent, and 50 to 60 parts by weight of curing agent were used to induce the core material to the PIR reaction. A high temperature compression process was performed for 4 to 10 minutes at ˜50 ° C. to form a core, which is a cured foam, between the pair of face plates.

Example  1: fiber reinforced Composite Panel  Produce

After forming a core material between a pair of face plates according to Preparation Example 2, a fiber-reinforced composite panel was produced through a aging step for 30 minutes at 30 ~ 50 ℃ conditions.

Example  2-1: Cotton  Surface plasma  process

Atmospheric pressure plasma treatment was performed on the face plate manufactured in Preparation Example 1 as shown in FIG. 5, and specifically, atmospheric pressure plasma treatment was performed on the surface on which the carbon fiber prepreg was formed. A glow-discharge etching system equipped with a 13.56 MHz RF-generator (Max Power: 650 W) was used, and a N ₂ gas using a nitrogen collector was used as a treatment gas. In addition, the plasma treatment was performed for 30 seconds at a 150 W output power and 10 L / min gas injection amount.

Example  2-2: Cotton  Surface plasma  process

Plasma treatment was performed under the same conditions as in Example 2-1, except that the atmospheric plasma treatment was performed for 60 seconds in Example 2-1.

Example  2-3: Cotton  Surface plasma  process

Plasma treatment was performed under the same conditions as in Example 2-1, except that the atmospheric plasma treatment was performed for 90 seconds in Example 2-1.

Comparative example  One

A panel was manufactured in the same manner as in Example 1, except that the iron plate was used instead of the carbon fiber composite face material as the face material in Example 1.

Experimental Example  1: fire resistance test

The carbon fiber reinforced composite panel prepared according to Example 1 and the iron panel prepared according to Comparative Example 1 were subjected to a test for compliance with the semi-combustible material according to the Ministry of Land, Infrastructure and Transport. Two test methods were performed: cone calorimeter (KS F ISO 5660-1) and gas hazard (KS F 2271).

First, heat was applied for 10 minutes using a cone calorimeter in accordance with KS F ISO 5660-1, and the total amount of heat emitted from the test specimen was checked, but the total amount of heat released was 8 MJ / m 2 or less. Second, the average behavioral downtime of the test rats was measured by gas hazard evaluation according to KS F 2271.

Referring to Table 1 below, in the case of Comparative Example 1 using the iron plate, the iron plate prevents heat, and thus has a low calorific value in the cone calorimeter test for measuring the total amount of heat emitted. In the case of Example 1, the total amount of heat released was measured relatively. However, in the case of the gas hazard test, the average stop time of the test rat was longer in Example 1 than in Comparative Example 1. That is, the fiber-reinforced composite panel according to the present invention compared to the conventional iron panel is significantly improved fire resistance (fire resistance) can significantly lower the damage to life due to harmful gases in the event of fire.

Fire resistance test How to measure Measures Example 1 Comparative Example 1 Cone calorimeter KS F ISO 5660-1 5.0 0.9 Gas Hazard KS F 2271 15 minutes 11 minutes

Experimental Example  2: fiber reinforced Of composite panel  Physical property test

Insulation properties, in-plane shear strength, axial compressive strength, distribution pressure strength, and weight reduction degree for the fiber reinforced composite panel prepared according to Example 1 were measured, respectively, and the results are shown in Table 2 below.

The test of KS F 4724 refers to the physical property specifications for wallboards produced at the factory with steel material on the surface and insulation inside.

How to measure Required Property Measures Example 1 Comparative Example 1 Insulation (m ² K / W) KS F 4724 1.1 2.9 2.3 In-plane shear strength (N / m) KS F 4724 850 956 1022 Axial Compressive Strength (N / m) KS F 4724 4900 4952 18157 Distribution pressure strength (N / m ² ) KS F 4724 650 704 3646 Light weight (based on metal panel) Reduction of weight on standard panel basis over 10 41% 100%

The thermal insulation indicates the degree of resistance to heat perfusion at room temperature. At this time, the heat permeation rate (W / m ² K) represents the amount of heat flowing from one fluid to the other fluid through the unit surface area in the unit time, when both fluids of the solid wall is a unit temperature difference, heat permeation resistance (m ² K / W ) Is expressed as the inverse of the thermal permeability.

The in-plane shear strength and the axial compressive strength indicate physical strength at the side of the fiber-reinforced composite panel (the surface perpendicular to the surface where most of the face and the core contact), and the in-plane shear strength is the length of the fiber-reinforced composite panel. The load is applied in the lateral side, and the axial compressive strength corresponds to the load in the lateral side of the fiber reinforced composite panel.

The distribution pressure strength indicates the physical strength at the front surface of the fiber-reinforced composite panel (a surface parallel to the surface where most of the surface material and the core material contact).

The weight reduction shows the relative weight ratio of the weight of the fiber-reinforced composite panel according to one embodiment of the present invention per 100% by weight of the conventional composite panel according to Comparative Example 1 using an iron plate as a face material.

That is, as shown in Table 2, the fiber-reinforced composite panel according to the present invention has a thermal insulation measured by KS F 4724 2.0 m ² K / W or more, in-plane shear strength measured by KS F 4724 900 N / m or more, axial compressive strength measured by KS F 4724 4900 N / m or more, distributed pressure strength measured by KS F 4724 680 N / mm ² or more and KS F ISO 5660-1 (cone calorimeter method) It can be confirmed that the total amount of emitted heat for 10 minutes after the start of heating is satisfied by 8 MJ / m or less, thereby minimizing the occurrence of damage by fire by blocking the propagation of a flame or a heat source during a fire. In addition, the fiber-reinforced composite panel according to the present invention achieves higher weight compared to a panel using a conventional iron plate and at the same time satisfy the physical properties of KS F 4724, which is a domestic regulation using steel materials, construction stability and durability of the fiber-reinforced composite panel itself It can be seen that this can be greatly improved.

Experimental Example  3-1: Fiber Reinforcement Of composite panel plasma  By treatment Cotton  Surface modification test

The surface element change (EDS) measurement results of the face plate according to Example 1 and Examples 2-1 to 2-3 are shown in Tables 4 and 6 (Example 1), FIG. 7 (Example 2-1), and FIG. 8 (Example 2-2) and FIG. 9 (Example 2-3), respectively. Specifically, elemental analysis of the fiber surface was performed by using X-ray photoelectron spectroscopy (XPS) to confirm the carbon fiber surface activity state according to the plasma treatment time. 9 is shown.

On the other hand, the binding energy for each functional group for Scan A to E described in Figures 6 to 9 are shown in Table 3.

Peak Scan a Scan b Scan C Scan d Scan E Functional group sp ² C C-OH COOH sp ³ C C = O Binding Energy (eV) 284.6 286.2 288.6 285.2 287.4

Element Example 1 Example 2-1 Example 2-2 Example 2-3 carbon(%) 82.23 80.51 79.85 79.63 Oxygen(%) 12.21 14.42 14.71 14.79

As shown in Table 4 and FIGS. 6 to 9, the composition ratios of carbons of Examples 2-1, 2-2, and 2-3, which performed plasma treatment, were lower than those of Example 1, which did not perform plasma treatment. On the other hand, it can be seen that the composition ratio of the hydroxyl group is high. In addition, in Examples 2-1, 2-2, and 2-3, the composition ratio of carbon decreases as the plasma treatment time increases, while the composition ratio of the hydroxyl group increases as the treatment time increases. On the other hand, it can be seen that the composition ratio of the hydroxyl group rapidly increases until the plasma treatment time reaches 60 seconds, and then a small increase thereafter.

That is, the fiber-reinforced composite panel according to the present invention improves the chemical adhesion between the face material and the core material by hydrogen bonding by hydroxyl group by modifying the surface of the face material by plasma treatment, the thermal insulation, in-plane shear strength, It can be used as an excellent building insulation material by improving axial compressive strength and distribution pressure strength and reducing total emission heat by heating.It can minimize the damage caused by fire by blocking the propagation of flame or heat source in case of fire. can confirm.

Experimental Example  3-2: Fiber Reinforcement Of composite panel plasma  By treatment Cotton  Surface modification test

In order to confirm the degree of surface irregularities of the face plate according to Example 1 and Examples 2-1 to 2-3, Atomic Force Microscope (AFM) was measured, which is illustrated in FIGS. 10 (Example 1) and 11 (Example 2). -2), respectively.

As shown in Fig. 10 and 11, it can be confirmed that as the plasma treatment on the surface of the face material, the irregularities generation and roughness improved by the sputtering action of nitrogen gas.

In other words, the fiber-reinforced composite panel according to the present invention by modifying the surface of the face material by plasma treatment to produce irregularities on the surface, improve the roughness of the core material and the face material by improving the roughness, thereby improving the heat insulation, in-plane Shear strength, axial compression strength, distribution pressure strength is improved, and total heat released from heating can be reduced, so it can be used as an excellent building insulation material.It minimizes the damage caused by fire by blocking the propagation of flame or heat source in case of fire. can do.

As described above, the detailed description of the present invention has been made by the embodiments with reference to the accompanying drawings, but the above-described embodiments will be described by referring to preferred examples of the present invention.

It should be understood that the present invention is not limited only to the above embodiments, and the scope of the present invention should be understood as the following claims and equivalent concepts.

10: cotton
100: laminated member
110: prepreg
120: cover sheet
130: release member
140: sealant
150: upper mold
160: breather
170: vacuum film
180: vacuum valve
190: lower mold
20: heartwood
30: vacuum bag

Claims (10)

In the method for producing a flame retardant fiber reinforced composite panel,
Manufacturing a face plate including at least one prepreg;
Forming irregularities on the surface of the face material by modifying the surface of the pair of face plates;
Preparing a composite panel by installing a core material between the pair of face plates having the surface modified and then foaming to form a core material; And
Aging the composite panel;
Including,
The core material includes a polyol, a foam stabilizer, and a blowing agent,
The prepreg includes carbon fiber,
The flame-retardant fiber-reinforced composite panel, the insulation measured by KS F 4724 2.0 m ² K / W or more, the in-plane shear strength measured by KS F 4724 900 N / m or more, the axis measured by KS F 4724 Directional compressive strength of 4900 N / m or more, distribution compressive strength measured by KS F 4724 680 N / mm ² or more and total 10 minutes after initiation of heating measured by KS F ISO 5660-1 (cone calorimeter method) A method for producing a flame-retardant fiber-reinforced composite panel, the heat release rate of 8 MJ / m ² or less.
The method according to claim 1,
The step of manufacturing the face material comprises a vacuum bag molding (Vacuum Bag Molding) step, a method for producing a flame-retardant fiber reinforced composite panel.
The method according to claim 1,
The prepreg further comprises at least any one of a mixture of carbon fibers and glass fibers, a mixture of carbon fibers and aramid fibers, and a mixture of carbon fibers and a steel sheet, manufacturing a flame retardant fiber reinforced composite panel Way.
The method according to claim 1,
The core material comprises at least one of polyurethane (Polyurethane) and polyisocyanurate (Polyisocyanurate), the method of manufacturing a flame-retardant fiber-reinforced composite panel.
The method according to claim 1,
Modifying the face material surface further comprises modifying by plasma treatment,
The plasma treatment is performed on the surface on which the prepreg containing the carbon fiber is formed, a method for producing a flame retardant fiber reinforced composite panel.
The method according to claim 5,
The reforming of the plasma treatment may include performing an atmospheric pressure plasma treatment process using nitrogen (N 2) gas for 30 seconds to 90 seconds, wherein the flame retardant fiber reinforced composite panel is prepared.
Core plates including at least one of polyurethane and polyisocyanurate; And
Face plates formed on the front and rear surfaces of the core material and including at least one prepreg including carbon fiber;
Including,
The core material is formed by foaming after the core material is installed between a pair of the face material is the surface is modified by irregularities,
The core material includes a polyol, a foam stabilizer, and a blowing agent,
The insulation measured by KS F 4724 is 2.0 m ² K / W or more, the in-plane shear strength measured by KS F 4724 is 900 N / m or more, and the axial compressive strength measured by KS F 4724 is 4900 N / m. The distribution pressure intensity measured by KS F 4724 is not less than 680 N / mm ² and the total amount of heat released after 10 minutes of heating start measured by KS F ISO 5660-1 (cone calorimeter method) is 8 MJ / m ² or less. , Flame retardant fiber reinforced composite panel.
The method according to claim 7,
The face material includes a surface modified by plasma treatment,
The plasma treatment is performed on the surface on which the prepreg containing the carbon fiber is formed, flame retardant fiber reinforced composite panel.
The method according to claim 7,
The prepreg further comprises at least any one of a mixture of carbon fibers and glass fibers, a mixture of carbon fibers and aramid fibers, and a mixture of carbon fibers and a steel sheet, flame retardant fiber reinforced composite panel.
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