KR102057228B1 - Composition for manufacturing aluminum composite panel core material and method for manufacturing master batch chip for manufacturing aluminum composite panel core material and aluminum composite panel using same - Google Patents

Abstract

The present invention is 14 to 16% by weight polyethylene (PE) -based thermoplastic resin; 75 to 77% by weight of inorganic flame retardant; 2-3% by weight of organic flame retardant; 3 to 5 weight percent compatibilizer; 1 to 2 weight percent of internal lubricant; 0.2 to 0.3 weight percent antioxidant; 1-2 wt% of a mixture comprising talc and calcium carbonate in a weight ratio of 1: 1; 0.5-1 weight percent polyethylene wax; As for the composition for manufacturing an aluminum composite panel core material comprising; and acrylic carbon fiber 0.05 ~ 1% by weight.
By including a linear polyolefin resin having a relatively high melt index (MI) and a polyolefin elastomer (POE) polarized by graft polymerization, it is possible to maximize compatibility with inorganic flame retardants to maximize moldability and a non-halogen flame retardant. It can be used as a material for aluminum composite panel core material that is eco-friendly and meets semi-combustible standards because it does not generate toxic gas in case of fire.

Description

COMPOSITION FOR MANUFACTURING ALUMINUM COMPOSITE PANEL CORE MATERIAL AND METHOD FOR MANUFACTURING MASTER BATCH CHIP FOR MANUFACTURING ALUMINUM COMPOSITE PANEL CORE MATERIAL AND ALUMINUM COMPOSITE PANEL USING SAME}

The present invention provides an aluminum composite panel comprising a composition for producing a semi-combustible aluminum composite panel core material, a method for producing a master batch chip for producing an aluminum composite panel core material using the composition, and a core material manufactured by extruding the master batch chip. It is about a manufacturing method.

Aluminum composite panel is generally a building material for interior and exterior building materials consisting of a five-layer structure of aluminum / adhesive layer / core material / adhesive layer / aluminum.

Background of the multi-layered structure as described above has a problem that the cost of the aluminum material with a thickness of 3mm is high and the specific gravity is low, so the advantages of building materials are inferior. Therefore, instead of reducing the aluminum thickness to 0.5mm or less, polyethylene (polyethylene, This is because it adopts a structure in which aluminum is bonded using low-cost thermoplastic resins such as PE) and polypropylene (PP).

The aluminum composite panel as described above has a specific gravity of 1.2 to 1.5, which is about 40% lighter than the same thickness aluminum plate, greatly contributing to the weight reduction of building materials, and is the most advanced form of interior and exterior materials in high-rise buildings. There is no groundbreaking construction material.

In addition, the aluminum composite panel has the characteristics of design, durability, sound insulation, insulation, workability, and light weight, so that the construction method is in line with the trend of changing from a wet method using soil and cement with water to a dry method such as steel frame assembly. Demand is constantly growing.

However, due to the flammability of the plastic core material in case of fire has been limited in its use range.

Accordingly, aluminum composite panel exterior materials, which are semi-combustible products by adding various inorganic flame retardants to core materials, have been released, but are not satisfactory in actual effect and test results.

In the early stages, PVC cores were used, but hydrogen chloride, etc., were generated in a large amount, and PE materials also used as inorganic materials such as metal oxides. have.

The reason why it is vulnerable to the fire even when inorganic materials are added to PE or the like as described above is that semi-combustibility is secured when more than 80% by weight of inorganic materials are injected into the core material, but the cracks are formed as the core itself has brittlettles. It is difficult to handle due to the increase in specific gravity, and due to the increase in specific gravity, it is impossible to mass-produce by extrusion process of general aluminum and other composite panels due to the high weight and poor flowability during extrusion. Because it can not be used.

Meanwhile, antimony-based and DBDPO, which are representative flame retardants replacing inorganic materials, cannot be used due to environmental problems, and thus, metal oxides having excellent role in delaying fire and nonflammability of residues are commercialized.

Korean Patent Publication No. 10-2006-0103575 (published: 2006.10.04.) Korea Patent Registration No. 10-1382045 (Registration Date: 2014.03.31) Korean Patent Registration No. 10-1741722 (Registration Date: May 24, 2017)

The present invention is to solve the above-mentioned problems of the prior art, and has sufficient quasi-non-flammability and at the same time has a flexibility in the process of forming a sheet-like core material through extrusion, so that no crack occurs, and also mass production It is an object of the present invention to provide a composition for producing an aluminum composite panel core material and a master batch chip for producing an aluminum composite panel core material and a method for producing an aluminum composite panel which can be used.

In order to solve the above problems, the present invention, polyethylene (PE) thermoplastic resin 14 to 16% by weight; 75 to 77% by weight of inorganic flame retardant; 2-3% by weight of organic flame retardant; 1-2 wt% of a compatibilizer; 1 to 2 weight percent of internal lubricant; 0.2 to 0.3 weight percent antioxidant; 1-2 wt% of a mixture comprising talc and calcium carbonate in a weight ratio of 1: 1; 0.5-1 weight percent polyethylene wax; And it proposes a composition for producing an aluminum composite panel core material comprising;

In addition, the polyethylene (PE) -based thermoplastic resin is characterized in that the low density polyethylene (LDPE) having a melt index (MI) 3 or more.

In addition, the inorganic flame retardant is characterized in that the magnesium hydroxide (Mg (OH) ₂ ) having a particle size of 5000 mesh or more (2.6 ㎛ or less). At this time, it is preferable that the surface of the magnesium hydroxide particles is coated with sodium stearate.

In addition, the organic flame retardant is characterized in that the melamine phosphate flame retardant.

In addition, the compatibilizer is characterized in that the MAH-g-POE graft polymerized maleic anhydride (MAH) in a polyolefin elastomer (POE). In this case, the polyolefin elastomer (POE) is preferably an ethylene-1-octene copolymer (ethylene-1-octene copolymer).

In addition, the internal lubricant is characterized in that the calcium stearate (calcium stearate) or sodium stearate (sodium stearate).

In addition, the composition for manufacturing an aluminum composite panel core material further comprises 1 to 2% by weight of one or more selected from ethylene / propylene / diene terpolymer (EPDM) and ethylene / propylene copolymer (EPM) as necessary. do.

In addition, as shown in FIG. 1, the present invention provides a method for preparing the above-described aluminum composite panel core material using the composition for manufacturing an aluminum composite panel core material, comprising: (a) 14 to 16 wt% polyethylene (PE) -based thermoplastic resin; 75 to 77% by weight of inorganic flame retardant; 2-3% by weight of organic flame retardant; 1-2 wt% of a compatibilizer; 1 to 2 weight percent of internal lubricant; 0.2 to 0.3 weight percent antioxidant; 1-2 wt% of a mixture comprising talc and calcium carbonate in a weight ratio of 1: 1; 0.5-1 weight percent polyethylene wax; And 0.05 to 0.1 wt% of acrylic carbide fibers;

(b) kneading the mixture mixed in step (a);

(C) proposes a method for producing a master batch chip for producing a composite aluminum core panel material comprising the step of (b) extruding the mixture kneaded to produce a master batch chip in the form of pellets (pellet).

Furthermore, as shown in FIG. 2, the present invention provides a method of manufacturing a core material for an aluminum composite panel, comprising: (d) extruding the master batch chip in pellet form to produce a core material in sheet form. ; And (e) adhering a surface reinforcing material made of aluminum to both surfaces of the sheet-like core material.

The composition for producing an aluminum composite panel core material according to the present invention comprises a linear polyolefin resin having a relatively high melt index (MI) and a polyolefin elastomer (POE) polarized by graft polymerization, thereby making it compatible with inorganic flame retardants. It can be used as the material of aluminum composite panel core material which is eco-friendly and meets non-combustible standard because it does not generate toxic gas in fire including non-halogen flame retardant.

In addition, the composition for manufacturing an aluminum composite panel core material according to the present invention includes a modified rubber-based resin having good compatibility with an inorganic flame retardant, thereby increasing flexibility of the aluminum composite panel product, thereby forming a rounded construction site when constructing a product. It can be applied and mass-produced in the form of a sheet, which is very useful and widely used as a material for building exterior material core material, heat insulation fireproof door accessory material, shipbuilding interior material core material, roof insulation material sheet material, and the like.

1 is a flow chart showing each step of the manufacturing method of a semi-combustible master batch chip for manufacturing an aluminum composite panel core material according to the present invention.
Figure 2 is a flow chart showing each step of the aluminum composite panel manufacturing method comprising a semi-combustible core material according to the present invention.
3 is a view showing an example of a conventional installation line for producing an aluminum composite panel by performing only the sheet-shaped core material and the bonding process of the aluminum sheet.
4 is a pellet type master batch chip for producing an aluminum composite panel core material according to the present invention, and then using the pellet type master batch chip, a sheet-shaped core material is produced and an aluminum sheet is bonded to the aluminum composite panel. It is a figure which shows an example of the new installation line to manufacture.

In describing the present invention, when it is determined that detailed descriptions of related known functions or configurations may unnecessarily obscure the gist of the present invention, the detailed description thereof will be omitted.

Embodiments according to the concepts of the present invention may be variously modified and have various forms, and specific embodiments will be illustrated in the drawings and described in detail in the present specification or application. However, this is not intended to limit the embodiments in accordance with the concept of the present invention to a particular disclosed form, it should be understood to include all changes, equivalents, and substitutes included in the spirit and scope of the present invention.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. Singular expressions include plural expressions unless the context clearly indicates otherwise. As used herein, the terms "comprise" or "having" are intended to indicate that there is a feature, number, step, action, component, part, or combination thereof that is described, and that one or more other features or numbers are present. It should be understood that it does not exclude in advance the possibility of the presence or addition of steps, actions, components, parts or combinations thereof.

EMBODIMENT OF THE INVENTION Hereinafter, this invention is demonstrated in detail.

Composition for producing an aluminum composite panel core material according to the present invention, polyethylene (PE) thermoplastic resin 14 to 16% by weight; 75 to 77% by weight of inorganic flame retardant; 2-3% by weight of organic flame retardant; 1-2 wt% of a compatibilizer; 1 to 2 weight percent of internal lubricant; 0.2 to 0.3 weight percent antioxidant; 1-2 wt% of a mixture comprising talc and calcium carbonate in a weight ratio of 1: 1; 0.5-1 weight percent polyethylene wax; And 0.05 to 0.1% by weight of acrylic carbide fibers.

The polyethylene (PE) -based thermoplastic resin has a melt index (MI) of 3 or more and has excellent flowability when heated above a predetermined temperature, and thus has excellent compatibility with metal hydroxides such as magnesium hydroxide, which is an inorganic flame retardant, and preferably has a melt index (MI). It may be made of low density polyethylene (LDPE) of 3) or more.

Preferably, the inorganic flame retardant is magnesium hydroxide (Mg (OH) ₂ ) having a decomposition temperature of about 2 times higher than that of an aluminum-based inorganic flame retardant, and more preferably, has a particle size of 5000 mesh or more (2.6 μm or less), and a thermoplastic resin. In consideration of compatibility with the surface of the particles may be magnesium hydroxide (Mg (OH) ₂ ) coated with sodium stearate (sodium stearate).

On the other hand, it is preferable that the organic flame retardant is a melamine phosphate flame retardant as a non-halogen organic flame retardant.

The melamine phosphate flame retardant is formed by the reaction of the phosphorus compound and the melamine-based compound, for example, melamine pyrophosphate, melamine polyphosphate, melamine pyrophosphate metal salt and melamine pyrophosphate metal salt, cyclic benzyl phosphate It may be selected from the group consisting of.

In addition, the compatibilizer is preferably MAH-g-POE in which maleic anhydride (MAH) is grafted polymerized to a polyolefin elastomer (POE) in consideration of compatibility with the inorganic flame retardant.

In this case, an example of the polyolefin elastomer (POE) may include ethylene-1-octene copolymer.

In addition, the composition for preparing an aluminum composite panel core material according to the present invention includes an internal lubricant and an antioxidant for water resistance and chemical resistance, and the internal lubricant includes calcium stearate or sodium stearate. As the antioxidant, amine-based antioxidants, especially aromatic secondary monoamines, are suitable, and such aromatic secondary monoamines include phenyl-beta-naphthylamine, phenyl-p-naphthylamine, and diphenyl. Amines, alkyl diphenylamines each containing one or two alkyl substituents having up to about 16 carbon atoms, alkyl or aralkyl containing one or two alkyl or aralkyl groups each having up to about 16 carbon atoms Substituted phenyl-beta-naphthylamines, each containing one or two alkyl or aralkyl groups having up to about 16 carbon atoms Alkyl or aralkyl which can be substituted phenyl -p- naphthylamine, and similar compounds.

In addition, the composition for preparing an aluminum composite panel core material according to the present invention includes talc and calcium carbonate having a lubricating component for reducing the extrusion load in the T-die during extrusion and at the same time serving as a flame retardant and a filler in the above contents.

In addition, the acrylic carbide fiber is formed by firing and carbonizing acrylic fiber, for example, a large amount of acrylic fiber manufactured by a conventional process after heat-treatment flame resistance process in air, and heat-treated in a vacuum state to form a carbonized acrylic fiber After the preparation, the acrylic hydrocarbon fiber may be a hydrocarbon acrylic nonflammable flame retardant fiber obtained by heat treatment in a nitrogen atmosphere.

In addition, the non-flammable acrylic carbide fibers preferably have a fibril length of about 0.020 to 0.10 mm or less.

In addition, the composition for preparing an aluminum composite panel core material according to the present invention includes polyethylene wax, which is an external lubricant, in order to reinforce and disperse bonds between the inorganic flame retardant and the PE-based thermoplastic resin, to improve extrudability, and to form a metal.

Furthermore, the composition for producing an aluminum composite panel core material according to the present invention may be prepared by using at least one of ethylene / propylene / diene terpolymer (EPDM) and ethylene / propylene copolymer (EPM) to further increase the flexibility of the core material. 1 to 2% by weight may be further included, and in this case, the weight ratio of the PE-based thermoplastic resin and EPDM and / or EPM is preferably 8: 2.

The composition for manufacturing an aluminum composite panel core material according to the present invention described above is first manufactured with a pellet-shaped master batch chip prior to being formed into a sheet-like core material, and then reprocessed into a sheet-shaped core material.

That is, while the conventional plastic composition for manufacturing the aluminum composite panel core material is directly put into the sheet-shaped core material manufacturing equipment line shown in Figure 3, in the present invention, the aluminum composite panel core using the novel equipment line shown in FIG. Pellet-shaped master batch chips are prepared from the remanufacturing composition, and then sheet-shaped core materials are used.

Process for producing a master batch chip in pellet form according to the invention, (a) 14 to 16% by weight polyethylene (PE) -based thermoplastic resin; 75 to 77% by weight of inorganic flame retardant; 2-3% by weight of organic flame retardant; 1-2 wt% of a compatibilizer; 1 to 2 weight percent of internal lubricant; 0.2 to 0.3 weight percent antioxidant; 1-2 wt% of a mixture comprising talc and calcium carbonate in a weight ratio of 1: 1; 0.5-1 weight percent polyethylene wax; And 0.05 to 0.1 wt% of acrylic carbide fibers; (b) kneading the mixture mixed in step (a); And (c) extruding the kneaded mixture in step (b) to produce a master batch chip in pellet form (FIG. 1).

A more specific example of a process for manufacturing the master batch chip of the pellet form will be described with reference to FIG. 4 as follows.

First, POE grafted with LDPE and MAH of MI 3.0 or higher, metal oxide gel coated with stearic acid of 5000 mesh or more, internal lubricants and antioxidants, talc and non-combustible fibers for extruding, metal oxide and PE mixed addition PE WAX and the like are mixed in the super mixer 201 for a predetermined time.

Subsequently, the semi-combustible resin is produced by stirring the mixed material while maintaining the pressurized kneader 202 at about 150 ° C. for 30 minutes or more. At this time, POE is used to reinforce flexibility while maintaining quasi-incombustibility, but when necessary, it is added and stirred when pressurizing EPDM or EPM.

Then, the semi-combustible resin kneaded in the pressurized kneader is extruded into pellets in the compound pellet extruder 203 and cut to obtain a semi-flammable pellet-shaped master batch chip.

After preparing the master batch chip in pellet form as described above, (d) extruding the master batch chip in pellet form to produce a sheet core material and (e) in the sheet form Further performing the step of adhering the surface reinforcement made of aluminum on both sides of the core material, it is possible to finally produce an aluminum composite panel comprising a core material made of the composition (Fig. 2).

An example of an aluminum composite panel manufacturing process using the equipment shown in FIG. 4 will be described below.

First, using compounded semi-non-combustible plastic pellets prepared according to the method of manufacturing a master batch chip in pellet form, utilizing a twin screw extruder 204 of LD 32 and a T-die 205 with an improved flow path, Extrude sheets of area.

The width of the product is about 1250mm, the length is 2440mm, the standard, but the length is not limited, the thickness can be manufactured molding up to 2 ~ 5mm.

In this way, after the sheet is manufactured, the multilayer blow molded adhesive film supplied from the adhesive film feeding roll 207 uses at least 50 to 100 microplastic films in the form of a semi-non-flammable plastic sheet and is provided from an aluminum uncoiler on top thereof. Adhesively molded with upper and lower aluminum sheet, semi-non-flammable plastic adhesive surface is non-polar PE resin, and aluminum coil type sheet uses MAH grafted resin double blow molded film to facilitate adhesion and install heating zone. For complete uniform adhesion to the aluminum coil, it is pre-bonded to the aluminum, and the aluminum is wound by using an uncoiler 208 to be wound in the form of a coil.

T-die 205 temperature is maintained at about 190 ~ 210 ℃ or more. In particular, the inside of the T-die is V-shaped to minimize the resistance during extrusion.

In addition, the adhesive method proceeds to a pre-adhesive method in which the sheet, the adhesive film, and the aluminum are simultaneously introduced into the middle of the chrome plated upper and lower polishing rolls 209 using the temperature after the self-extrusion of the semi-non-combustible sheet, and the sheet is preempted It enables more perfect adhesion than the post-adhesion method that uses dry oven and various rollers.

The semi-combustible aluminum composite panel, which is press-bonded and bonded, is cut and stacked via a line of cooling chamber 210 of the cooling line and a rear tension roll (take-up roll 213, pinch roll 214) for adjusting the surface of the panel. 215) is manufactured and molded in the step.

Hereinafter, the present invention will be described in more detail with reference to preferred embodiments. The examples presented are only specific illustrations of the invention and are not intended to limit the scope of the invention.

<Example>

LDPE with MI 3.0 or more 15kg, 2kg POE grafted with MAH, 70kg magnesium hydroxide (Mg (OH) ₂ ), 1.5kg stearin-based internal lubricant, 0.2kg antioxidant, 3kg calcium carbonate (CaCo ₃ ), talc (talc) 3kg , 0.05kg acrylic carbide, 1kg PE wax, 2kg EPM was added to the super mixer and mixed for a certain time.

Subsequently, the mixed material is stirred while maintaining the pressurized kneader at about 150 ° C. for 1 hour to prepare a semi-incombustible resin, and the non-combustible resin kneaded in the pressurized kneader is extruded in a pellet form in a compound pellet extruder and then cut into semi-combustible resins. Pellet-type master batch chips were obtained.

Then, the pellet-type master batch chip was used to prepare a semi-combustible core material in the form of a sheet using a twin screw extruder of LD 32 and an improved T-die.

Flame retardant test results and various physical properties of the aluminum composite panel core material manufactured as described above are as follows.

Although the embodiments of the present invention have been described above with reference to the accompanying drawings, those skilled in the art to which the present invention belongs may be embodied in other specific forms without changing the technical spirit or essential features of the present invention. You will understand that. Therefore, it should be understood that the embodiments described above are exemplary in all respects and not restrictive.

101: extruder 102: T-die
103: adhesive film feed roll 104: aluminum uncoiler
105: polishing roll 106: cooling chamber
107: protective film feed roll 108: cutting machine
109: take-up roll 110: pinch roll
111: rival `201: super mixer
202: pressure kneader `203: compound pellet extruder
204: twin screw extruder 205: T-die
206: adhesive film heater 207: adhesive film feed roll
208: aluminum uncoiler 209: polishing roll
210: cooling chamber 211: protective film feed roll
212: cutting machine 213: take-up roll
214: pinch roll 215: the upper portion

Claims (11)

14 to 16% by weight polyethylene (PE) -based thermoplastic resin;
75 to 77% by weight of inorganic flame retardant;
2-3% by weight of organic flame retardant;
1-2 wt% of a compatibilizer;
1 to 2 weight percent of internal lubricant;
0.2 to 0.3 weight percent antioxidant;
1-2 wt% of a mixture comprising talc and calcium carbonate in a weight ratio of 1: 1;
0.5-1 weight percent polyethylene wax;
0.05-0.1 wt% of acrylic carbide fiber; And
Ethylene / propylene copolymer (EPM) 1 to 2% by weight; Aluminum composite panel core material manufacturing composition comprising a. The method of claim 1,
The polyethylene (PE) -based thermoplastic resin is a composition for producing an aluminum composite panel core material, characterized in that the low density polyethylene (LDPE) having a melt index (MI) 3 or more. The method of claim 1,
The inorganic flame retardant is magnesium hydroxide (Mg (OH) ₂ ) having a particle size of 5000 mesh or more composition for producing a composite aluminum core panel material. The method of claim 3,
The composition of the aluminum composite panel core material, characterized in that the surface of the magnesium hydroxide particles coated with sodium stearate. The method of claim 1,
The organic flame retardant is a composition for producing an aluminum composite panel core material, characterized in that the melamine phosphate-based flame retardant. The method of claim 1,
The compatibilizer is a composition for producing an aluminum composite panel core material, characterized in that the MAH-g-POE graft polymerized maleic anhydride (MAH) in a polyolefin elastomer (POE). The method of claim 6,
The polyolefin elastomer (POE) is a composition for producing an aluminum composite panel core material, characterized in that ethylene-1-octene copolymer (ethylene-1-octene copolymer). The method of claim 1,
The internal lubricant is calcium stearate (calcium stearate) or sodium stearate (sodium stearate) composition for producing an aluminum composite panel core material. delete (a) 14 to 16% by weight of polyethylene (PE) -based thermoplastic resin; 75 to 77% by weight of inorganic flame retardant; 2-3% by weight of organic flame retardant; 1-2 wt% of a compatibilizer; 1 to 2 weight percent of internal lubricant; 0.2 to 0.3 weight percent antioxidant; 1-2 wt% of a mixture comprising talc and calcium carbonate in a weight ratio of 1: 1; 0.5-1 weight percent polyethylene wax; 0.05-0.1 wt% of acrylic carbide fiber; And 1 to 2 wt% of an ethylene / propylene copolymer (EPM);
(b) kneading the mixture mixed in step (a); And
(C) a method for producing a master batch chip for aluminum composite panel core material comprising the step of producing a pellet-shaped master batch chip by extruding the mixture kneaded in step (b). According to the manufacturing method of claim 10 to produce a pellet master batch chip,
(d) extruding the master batch chips in pellet form to produce sheet-shaped core materials; And
(e) adhering a surface reinforcing material made of aluminum to both surfaces of the core material in the form of a sheet.

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