KR102222964B1 - The manufacturing method of semi-inflammable interior panel and the interior panel manufactured by the method - Google Patents

Abstract

The present invention relates to a semi-non-combustible building interior material including cotton fibers, and more particularly, to obtain a cotton fiber material in the state of lump by beating and polishing the cotton fiber, and mixing it with the porous mineral granules of expanded vermiculite or perlite to form a plate material in a lump state. It relates to a method of manufacturing a semi-non-combustible building interior material by going through a molding step after forming a composition and then undergoing a dehydration process to obtain a fibrous board, impregnated with a flame retardant solution, and dried, and a semi-non-combustible building interior material by the manufacturing method.

Description

The manufacturing method of semi-inflammable interior panel and the interior panel manufactured by the method}

The present invention relates to a semi-non-combustible building interior material including natural mineral granules and cotton fibers, and is specifically eco-friendly, does not burn in the event of a fire, and does not generate toxic gases.

In addition, the present invention can produce embossing treatment and various patterns and colors on the surface of the board, and the board thickness is thin and light, so that the interior material construction is convenient.

Building interior materials are materials that both finish and decorate the inner surface of the structure that makes up the space of the building, and are often made of plate-shaped materials to form the surface, including durability, texture, and touch. It must meet the required performance, and representatively, there are wall interior materials, flooring materials, and ceiling materials.

Amid increasing awareness of fires in recent years, the need for non-combustible interior materials is on the rise. This is because conventional building interior materials are mostly made of organic compounds, so that a lot of toxic gases are discharged due to flammable substances in the event of a fire.

Generally, materials corresponding to semi-nonflammable (flame retardant grade 2) include gypsum board, magnesium board, CRC board, wood wool board, and calcium board, but these materials cannot be used as a final finishing material because the surface is not beautiful. As a surface material having different physical properties such as paper coating, HPL, deco film, PET film, etc. is selected and used by bonding, the problem of flame retardancy of the surface material arises.

Most of the surface materials are difficult to manufacture as a material having flame retardancy, and in the case of HPL, the price is considerably high because it is manufactured by impregnating a melamine resin with a pattern paper.

In general, semi-incombustible ceiling materials can be largely divided into smc ceiling materials, which are thermosetting resin ceiling materials, and ceiling materials including inorganic fibers, depending on the raw materials of manufacture. Smc ceiling materials are widely used as ceiling materials such as toilets that need waterproofing, and ceiling materials containing inorganic fibers are mineral wool products and glass wool products, and there are products containing inorganic fibers, along with gypsum. There are tex products that are combined. Mineral wool products are made of ceramic fibers made of artificial minerals, and glass wool products are made of glass raw materials such as silica sand and cullet.

In addition, there are floor interior materials and wall interior materials, and these are generally in the form of solid panels, and as a result of recent building fires, there is a growing interest in non-combustible or semi-non-combustible interior materials.

Semi-non-combustible interior materials are generally advantageous in that they are non-combustible materials because they contain inorganic fibers or minerals, but they have to be manufactured by a felt manufacturing technique, so it is difficult to diversify designs and manufacturing costs are high. Above all, there is a disadvantage that is avoided because it is not good for respiratory organs due to mineral dust generated from the interior material, and it is difficult to construct due to the heavy weight of the product and it is weak against impact.

Recently, attempts have been made on sound-absorbing panels using perlite or vermiculite, but this also has several disadvantages.

That is, Patent Document 1 discloses a panel manufacturing method using sodium silicate and expanded vermiculite. The invention disclosed in Patent Document 1 relates to a method for manufacturing a panel using sodium silicate and expanded vermiculite, and a spraying process of evenly spraying liquid soda of the same weight as the expanded vermiculite on the expanded vermiculite using a pressure sprayer, and the above-described As described above, a molding process in which the expanded vermiculite spray-coated with soda liquid silicate is injected into the mold at a thickness exceeding 0-40% of the desired thickness and press-molded to the desired thickness, and the panel molded as described above is subjected to 2000 in a microwave dryer. By providing a manufacturing method consisting of a drying process of irradiating and drying at -3000MHz, 500-1500W, the panel has uniform strength from the inside to the outside, and has relatively light weight due to the porosity of the expanded vermiculite.

In addition, Patent Document 2 discloses a method of manufacturing a non-combustible sound absorbing material that can be used as an interior material. The invention disclosed in Patent Document 2 is a first mixing step of mixing the first inorganic binder and expanded vermiculite in a ratio of 1:1 by weight, a drying step of drying the mixture after the first mixing step, and the drying step. 1 Through a second mixing step of mixing 60 to 80 parts by weight of expanded vermiculite coated with an inorganic binder and 20 to 40 parts by weight of a second inorganic binder, a molding step of compression molding the mixture through the second mixing step, and the molding step. It provides a method of manufacturing a non-combustible sound-absorbing material, characterized in that consisting of a processing step of processing the surface of the compression-molded mixture.

However, since the sound-absorbing material and panel of the invention disclosed in Patent Documents 1 and 2 are manufactured by pressing the expanded vermiculite into a mold together with an inorganic binder, there is a limit to the automation of production, so the production cost is high. In addition, since it is combined by an inorganic binder, even a small impact can be easily damaged. Therefore, if an earthquake occurs, a dangerous situation can occur due to the fall of the interior material. In addition, it is difficult to produce a variety of designs or colors due to the uneven appearance of the gemstone itself.

In addition, since the manufacturing cost of the interior panels of the prior art is high, the construction cost is high, and this causes the building owners to hesitate to replace the interior materials of the building despite the risk of a fire in the building, and as a result, it is not possible to prevent human damage caused by the fire.

1. Domestic registered patent No. 10-0895213 2. Domestic registered patent No. 10-1133931

An object of the present invention is to provide a method of manufacturing a semi-non-combustible building interior material that is resistant to flames and does not emit toxic gas as a semi-non-combustible building interior material, and a building interior material according to the manufacturing method.

In addition, the present invention aims to provide a semi-non-combustible building interior material that is remarkably inexpensive and light in manufacturing cost, convenient construction, and strong against impact in manufacturing a non-combustible building interior material.

In order to solve the above problems,

The present invention is a step of obtaining a cotton fiber material in a state of stiffness by cutting the cotton fiber material finely and then beating-polishing with water in a water tank tank in which a beater is installed;

Adding and mixing at least one of natural mineral granules having a lighter specific gravity of at least one of expanded vermiculite and perlite to the cotton fiber material in a constricted state to obtain a mixed composition in a congested state;

A plate material acquiring step of discharging the mixed composition containing water into a plate by discharging it on a mesh and then dehydrating it;

It provides a method for manufacturing a semi-non-combustible building interior material comprising a; impregnating the dehydrated plate with a flame-retardant solution and drying by a dryer.

Although only expanded vermiculite granules can be added to the cotton fiber material in the dry state, the expanded vermiculite granule can be made into a mixed composition, but at this time, the expanded vermiculite is sticky and clumps together and is not well mixed with the cotton fiber material, so preferably pearlite. , Illite, diatomaceous earth granules, it is preferable to add at least one of the addition to improve the agitation.

Preferably, the semi-non-combustible building interior material manufactured by the above manufacturing process is finally cut to an appropriate length and molded into a predetermined pattern to be completed.

In the present invention, since the interior material is manufactured using porous natural mineral granules of natural minerals such as expanded vermiculite or perlite, it is not only non-flammable, but also has flexibility because natural mineral granules are cohesively bonded by the fine fibers of cotton fibers. Since it is produced in a manner of producing nonwoven fabrics, mass production is possible, and since it is impregnated with liquid sodium silicate, it has the characteristics of increasing bonding strength and non-flammability.

The present invention can be mass-produced and the manufacturing cost is remarkably inexpensive, so it is possible to replace the interior materials of buildings that use asbestos interior materials at low cost, and because it is a flexible interior material, it is easy to install by workers during installation to ensure safety. In addition, there is an advantage that it does not fall and damage or cause personal injury when an earthquake occurs.

1 is a top view of a semi-non-combustible building interior material including cotton fibers according to the present invention
Figure 2 is a flow chart showing a method of manufacturing a semi-non-combustible building interior material including cotton fibers according to the present invention

Hereinafter, a method of manufacturing a semi-non-combustible building interior material including cotton fibers according to the present invention will be described in detail with reference to the accompanying drawings.

<Example>

(1) Acquiring a cotton fiber material in a dry state by beating (beating) grinding step (S 100)

After cutting a cotton fiber material containing a large amount of cellulose into a length of 40 mm, fill the water tank tank with a beater with 3000 kg of water, and then add 150 kg of cotton fiber material to beating and polished for 1 to 2 hours. It is the stage of obtaining ashes.

Commonly known cotton wool contains 98% cellulose, and bast fibers such as flax, hemp, ramie grass, and jute contain about 70% cellulose. do. In addition, wood, the raw material of pulp, contains about 40-50% cellulose. Therefore, it is preferable to use a cotton fiber material containing a large amount of cellulose. Preferably, cotton fibers utilize waste fibers generated as a by-product in the manufacturing process of cotton products.

Since chemical fibers are not made of cellulose, they cannot be cohesively bound to porous natural minerals such as expanded vermiculite or pearlite granules because they are not dissolved in water even by beating grinding.

Of course, it is possible to obtain cellulose from other fibers or pulp other than cotton fibers, but the manufacturing cost is not suitable and, above all, cotton fibers containing a large amount of high-quality cellulose are most preferred. The large amount of cellulose contained in the cotton fiber makes it possible to increase the effect of semi-incombustibility. In particular, cotton fiber is an eco-friendly material that is harmless to the human body as well as a low burden of raw/subsidiary material costs, and is a sustainable resource, because it is possible to utilize a large amount of waste cotton fibers that are used and discarded at industrial sites or at home.

Of course, it can be used as a raw material for bast fibers such as flax, hemp, ramie, jute, etc. containing about 70% cellulose, or wood, which is a raw material for pulp containing about 40-50% cellulose, but has a non-flammable effect. It has low drawbacks.

(2) Porous mineral granule input mixing process (S 200)

Expanded vermiculite as a porous mineral may be added to the cotton fiber material in the dark state. At this time, 50 to 70 parts by weight may be included with respect to 100 parts by weight of the cotton fiber material, and if the expanded vermiculite is included within the stated range, when it is mixed with the cotton fiber material in the state of lump, the adhesion with the cotton fiber material is excellent, and the semi-nonflammable function of the cotton fiber material Will be able to improve.

Expanded vermiculite is an inorganic material with excellent non-combustibility, good insulation, and light specific gravity, so it does not settle in the water tank and floats in water. It is naturally mixed with the beating-polished cotton fiber during the mixing process, and has excellent adhesion to the cotton fiber material. Incombustibility can be further improved. That is, the cotton fiber material penetrates into every corner of the pores of the expanded vermiculite, connects the expanded vermiculite to each other, and is integrated at the same time.

The expanded vermiculite is crushed to a particle diameter of 1-3 mm and then sintered at 1000-1200°C. When the expanded vermiculite is sintered at 1000-1200°C, the expanded vermiculite swells up to become less dense and floats in water.

Since the expanded vermiculite tends to clump together due to the sticky nature of each other, when 30 to 50 parts by weight of pearlite is properly added to this, the pearlite acts as a crosslinking function and maintains a constant spacing of the expanded vermiculite to help uniform mixing. give.

In a preferred embodiment, 90 to 110 kg of expanded vermiculite and 15 to 25 kg of pearlite are added and mixed, so that the microfibers of the cotton fiber material and the porous mineral are entangled with each other, so that they are combined as one. That is, since expanded vermiculite and pearlite are porous, they are lightweight and float in water, and the microfibers of cotton fiber material floating on the upper part of the water are inserted into the pores of the expanded vermiculite and pearlite, and at the same time, they are entangled and strongly bonded.

Although not included in the above embodiment, preferably, while adding 5 to 10 kg of illite and 3 kg of diatomaceous earth sequentially, minerals penetrate between the cotton fiber materials so that they can be integrated with the cotton fiber material.

The diatomaceous earth is a sediment produced by the lactic acid harmfulness of diatoms, which are single-celled algae, accumulating on the bottom of the sea or lake, and is mainly composed of silica (SiO ² ), which is an inorganic compound, and has various performances such as deodorization, insulation, humidity control, etc. In addition, it imparts excellent flame retardancy.

In addition, expanded graphite has a layered structure of graphite, so when an atom or small molecule is put between the layers and heat is applied, the particles are separated like an accordion and the particles expand hundreds of times. In the case of beating, if a small amount of 1~2kg of expanded graphite powder is added, it is in close contact with the pores of the cotton fiber to form a unity, so it expands in case of fire, blocks oxygen and has a self-extinguishing function, so that the flame cannot spread any more. Thus, it is possible to further improve the semi-noncombustibility of the cotton fiber. However, if an excessive amount is added, the background color is expressed in black, which can be a problem when painting.

(3) Plate material acquisition process (S 300)

The cotton fiber material in the state of being mixed with the porous mineral is discharged onto a mesh in a state containing water, and is made into a cotton fiber plate through a dehydration process.

Dehydration is performed by natural dehydration or compression rollers, or dehydration is carried out through a step-down roller process to achieve a moisture content of 20 to 30%.

(4) Flame retardant solution impregnation process and drying process (S 400)

This is a step of impregnating the dehydrated cotton fiber sheet with a flame-retardant solution and obtaining a cotton fiber sheet after drying with a hot air dryer. By impregnating the cotton fiber plate with a flame retardant solution, it binds the cotton fiber material and the porous mineral and improves non-flammability.

The dehydrated cotton fiber sheet is preferably dried at 180° C. by a hot air dryer after impregnation of the flame retardant solution, and is cut into a size of 1200 mm in width, 4.5 mm in thickness, and 2500 mm in length.

The flame retardant solution uses soluble silicate. Liquid sodium silicate is preferred from an economical point of view. However, if only sodium silicate is used as the flame retardant, the cotton fiber board absorbs moisture and tends to become moist. Therefore, in addition to the liquid sodium silicate, one or more of colloidal silica, water disperse silica, or modified silicate is selected and mixed. It is desirable.

(5) Flat 1st forming process (S 500)

The molding process that is additionally executed after the drying process is an operation of smoothing the surface of the plate material by putting a nonwoven fabric-type cotton fiber plate into a press and compressing it by applying pressure. At this time, heat and pressure are applied to dry the residual moisture and flame retardant.

The surface of the firstly molded plate is coated with water-based paint in various colors and dried.

(6) 2nd molding process

The manufacturing process can be completed with the S 500 process, but rather, the plate dried after the first molding process and the painting process is placed on a mold with the coated side facing upward, and blister pressure forming is performed. If you do it, you will be able to obtain more colorful and three-dimensional interior materials.

The color-coated plate dried as described above is pressed and molded in a mold, thereby forming a shape on the plate by the pressing, and it is seen as a two-tone color by the pressing phenomenon, thereby improving a three-dimensional effect. Preferably, the interior construction material of the present invention is about 2 to 3 mm.

<Test Example>

1) Semi-incombustible test

The test results below are based on the test results of the Disaster Prevention Test Research Institute, which is an accredited testing institution, for the product according to the above embodiment.

Test item Sample number One 2 3 standard Semi-incombustible
material Heat release rate Total calories released 2.4 3.1 6.5 8MJ/m ² or less Time exceeding 200kw/m ² (s) 0 0 0 10s or more Cracks, holes and melting through the specimen none none none There won't be gas
Hazard Mean Time to Stop Behavior in Rats 13 minutes
54 seconds 14 minutes
10 seconds 13 minutes
58 seconds More than 9 minutes

2) Asbestos content

Recently, asbestos was not detected at all as a result of the asbestos detection test of the product according to the above example regarding the harmfulness of asbestos. It is in accordance with the test results of the Korea Construction Living Environment Testing Institute, an accredited testing agency.

3) mildew resistance

In the experiment to test mold resistance for the product according to the above example, aspergillus brasiliensis ATCC9642, Penicillium funiculosum ATCC 11797, Chaetomium globosum ATCC 6205, Trichoderma virens ATCC 9545, Aureobasidium pullulans ATCC 15233 were cultured for 4 weeks, The development of hyphae was not recognized around the inoculation site of the test piece. This is also in accordance with the test results of the Korea Institute of Construction Living Environment Test, an accredited testing agency.

4) Antibacterial test

In the antibacterial test for the product according to the above example, after 24 hours, the bacteria reduction rate of E. coli and Pseudomonas aeruginosa was shown to be 99.9%. This is also in accordance with the test results of the Korea Institute of Construction Living Environment Test, an accredited testing agency.

The cotton fiber board comprising the porous mineral according to the present invention made of such a manufacturing process is provided with an eco-friendly material that is harmless to the human body, but has excellent workability as it has light and flexible properties, as well as good semi-noncombustibility, heat insulation, design, and economy. It is expected to open a new horizon for interior materials.

In the above, specific embodiments of the present invention have been described above. However, the spirit and scope of the present invention are not limited to these specific embodiments, but various modifications and variations are possible within the scope of not changing the gist of the present invention. You will understand when you grow up.

Therefore, the embodiments described above are provided to completely inform the scope of the invention to those of ordinary skill in the technical field to which the present invention belongs, and should be understood as illustrative and non-limiting in all respects, The invention is only defined by the scope of the claims.

100: Semi-incombustible building interior material according to the present invention
S 100: The process of making cotton material beating and grinding in a water tank to bring it into a pile state.
S 200: Process of mixing porous natural mineral granules
S 300: The process of obtaining a cotton fiber plate from the mixed raw material
S 400: Flame retardant solution impregnation and drying process
S 500: Forming and painting process

Claims (4)

(A) forming a cotton fiber material in a dry state by beating and grinding the cotton fiber material in a water tank tank in which a beater is installed;
(B) adding at least one of expanded vermiculite and perlite as a porous mineral granule to the cotton fiber material in a dry state and mixing so as to be integrated with the cotton fiber material to form a mixed composition in a dry state;
(C) discharging the mixed composition onto a mesh and dehydrating water to obtain a plate material;
(D) impregnating the obtained plate with a flame retardant solution further comprising at least one of colloidal silica, water-dispersed silica, and modified silicate in sodium silicate;
(E) forming and painting a pattern with a predetermined pattern;
Method for producing a semi-non-combustible building interior material comprising a
delete The method of claim 1,
In the step (b) of adding a porous mineral to a cotton fiber material in a dry state, graphite is added and mixed.
Semi-incombustible building interior material manufactured by the manufacturing method of paragraph 1 or 3

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