KR102282522B1 - Bead method insulation bead and flame―retardant insulation board - Google Patents

Abstract

The technology disclosed in the present invention can provide a flame-retardant insulation board in which two types of heat-insulating beads formed and dried by a bead method after coating a flame-retardant layer on foamed particles are fused to each other.

Description

Bead method type 2 insulation bead and flame-retardant insulation board {Bead method insulation bead and flame-retardant insulation board}

The present invention relates to a bead method type 2 insulation bead and a flame-retardant insulation board.

Various currently known foams are used in the foaming process of expanded polyurea, foamed urethane, urethane foam, expanded polyisocyanurate, expanded polystyrene, bead method expanded styrene, extrusion method expanded styrene, expanded styrofoam, expanded ethylene, expanded propylene, etc. It includes foamed products using raw materials.

These foams contain a bead method type 1 heat insulating material and a bead method type 2 heat insulating material. Here, the bead method type 1 insulation material is a white bead method foamed styrene, and it corresponds to a product with an initial thermal conductivity of 0.035 W/mK or more measured by KS M3808, KS M3809, KS L9102, and the bead method type 2 insulation material is a black bead method foamed styrene As a result, it corresponds to a product with an initial thermal conductivity measurement value of 0.034W/mK or less. Here, Type 2 insulation is classified as Grade A in the insulation grade classification according to the energy saving design standards, and Type 1 insulation with lower thermal conductivity is classified as Grade B or D, which does not reach Grade A of Type 2 insulation.

These two kinds of heat insulating material when three minutes, No.1 (30kg / m ³ or more) according to the density of the products, No. 2 (25kg / m ³ or more), No. 3 (20kg / m ³ or more), No. 4 (15kg / m ³ above), and due to the difference in density, the initial thermal conductivity is also No. 1 (0.031 W/mK or less), No. 2 (0.032 W/mK or less), No. 3 (0.033 W/mK or less), No. 4 (0.034 W/mK or less) ), there is a difference.

These two-type insulation materials are functional materials made to have improved insulation performance, excellent economy, and perfect eco-friendliness even at low densities by offsetting the effects of radiant heat as the additives impregnated inside act as infrared absorbers and reflectors compared to first-type insulation materials. In other words, it is possible to improve the thermal insulation performance compared to the existing expanded polystyrene (EPS) by the additives added during the production process, thereby satisfying the “A” grade insulation requirements according to the building energy saving design standards.

However, the commercially available two types of expanded styrene by the bead method have a disadvantage in that thermal bridges must be performed individually for thermal bridge construction. In addition, it is necessary to further improve the thermal insulation properties in consideration of the field situation in which the thickness of the insulation layer is frequently limited due to architectural reasons that occur frequently during repair work.

In addition, conventional insulation boards are usually manufactured by coating the foam particles with a flame retardant and molding the coated beads.

The flame retardancy of the flame retardant insulation board is determined by the amount of the flame retardant, and when a large amount of the flame retardant is used to increase the flame retardancy, the fusion force between the flame retardant particles is weakened, causing the board to crumble, and the thermal conductivity is increased, resulting in a decrease in the insulation property. do.

Actual products of many flame-retardant insulation boards sold on the market do not pass the standard test, so technology development related to insulation boards having flame retardancy and self-extinguishing properties that can actually protect people and properties is requested.

Patent Document 1: Republic of Korea Patent Publication No. 2016-0071080

One aspect of the present invention is to specify the structure and composition of the additive, the adhesive layer, and the flame-retardant layer to prevent the thermal bridge phenomenon and the peeling of the flame-retardant layer, and to provide a bead method with excellent thermal insulation properties while strengthening the fusion strength. aim to

In addition, one aspect of the present invention is two kinds of bead methods that can prevent thermal bridge phenomenon and improve adhesion and provide high density by increasing the particle size when molding the insulating material by increasing the degree of foaming of the expanded particles. An object of the present invention is to provide an insulating bead.

In addition, one aspect of the present invention provides a flame-retardant insulation board with improved thermal insulation, compressive strength, flexural fatigue strength, and flame retardancy and self-extinguishing properties even if the thickness of the insulation layer is limited by including the bead method type 2 insulation beads with enhanced fusion properties. aim to do

The bead method according to one aspect of the present invention is a two-type insulating bead

expanded particles containing a carbon-based material and having an average radius of t1 (mm);

an adhesive layer having a thin film thickness of t2 (mm) by coating the first adhesive to be foamed on the outer surface of the foamed particles; and

A flame retardant layer comprising a second adhesive and a flame retardant foamed on the adhesive layer and coated with a thickness t3 (mm) thicker than the t2 (mm);

The ratio of t1 and t2 + t3 is 1:0.0001 to 1:0.2,

When the average diameter of the bead method type 2 insulating beads before molding is s1 (mm), and the average diameter after drying of the bead method type 2 insulating beads is s2 (mm), s2 ≥ s1 + s1 x 0.005 characterized.

In this case, the carbon-based material may be at least one selected from expanded graphite, graphene, carbon nanofibers, and carbon black.

In addition, the content of the carbon-based material may be 1 to 15% by weight based on the content of the expanded particles.

The aforementioned carbon-based material can be obtained by mechanical shearing.

The carbon-based material may have a particle size of 0.1 to 0.8 μm, and an aspect ratio of 100:1 or more.

The carbon-based material may include expanded graphite.

In this case, the raw material for expanded styrene may have an average diameter of 0.5 to 1.5 mm and a maximum expansion ratio of 70 to 150 times.

In addition, it is preferable that the first adhesive and the second adhesive are methylenediphenyl diisocyanate.

In addition, the flame retardant may include expanded graphite.

At this time, the bead method type 2 insulating beads may have a density of 0.5 g/cm ³ or less.

Flame-retardant insulation board according to another aspect of the present invention,

A board in which two types of insulating beads are fused to each other by forming and drying the bead method after coating the foam particles with a flame retardant layer; and

A flame retardant layer with a thickness of 0.05 to 1 mm is coated on the board,

The bead method is characterized in that the two-type insulating bead contains a carbon-based material.

At this time, the bead method type 2 insulating bead,

expanded particles containing at least one carbon-based material selected from expanded graphite, graphene, carbon nanofibers and carbon black and having an average radius of t1 (mm);

an adhesive layer having a thin film thickness of t2 (mm) by coating the first adhesive to be foamed on the outer surface of the foamed particles; and

A flame retardant layer comprising a second adhesive and a flame retardant foamed on the adhesive layer and coated with a thickness t3 (mm) thicker than the t2 (mm);

The ratio of t1 and t2 + t3 is 1:0.0001 to 1:0.2,

When the average diameter of the bead method type 2 insulating beads before molding is s1 (mm), and the average diameter after drying of the bead method type 2 insulating beads is s2 (mm), s2 ≥ s1 + s1 x 0.005 can

In this case, the carbon-based material may be at least one selected from expanded graphite, graphene, carbon nanofibers, and carbon black.

The content of the carbon-based material may be 1 to 15% by weight based on the content of the expanded particles.

The aforementioned carbon-based material can be obtained by mechanical shearing.

The carbon-based material may have a particle size of 0.1 to 0.8 μm, and an aspect ratio of 100:1 or more.

The carbon-based material may include expanded graphite.

In this case, s1 may be an integer of 1 to 10.

In addition, the flame retardant and the flame retardant layer preferably include expanded graphite.

The flame-retardant insulation board may have a flexural fracture load of 15N or more and a compressive strength of 5N/cm ^{2 or} more when measured according to KS M 3808:2011.

As described above, the bead method according to an aspect of the present invention can prevent the flame-retardant layer from peeling off by improving the bonding strength between the foamed particles and the flame-retardant layer in the bead-method type 2 insulation bead and the flame-retardant insulation board. In addition, there is an effect of improving the thermal insulation by strengthening the fusion force between the expanded particles. In addition, by increasing the degree of foaming of the expanded particles, the particle size according to the strengthening of the foam is increased, and as a result, the force of colliding with each other is increased to provide a high density.

In addition, the flame-retardant insulation board according to one aspect of the present invention can reduce the heating system scale, there is an advantage of having a smaller investment cost and a smaller environmental burden.

In addition, the flame-retardant insulation board according to the embodiment of the present invention can constitute an outer wall at a minimum cost and can reduce the thickness of the wall or the base portion structurally at least.

Furthermore, even when the thickness of the insulation layer is limited due to construction reasons, which occurs frequently during maintenance work, the insulation properties are very excellent, so that even with such a limited allowable thickness, more energy saving effect than necessary can be obtained.

In addition, it is not necessary to install individual insulation to avoid thermal bridge phenomenon, and it is possible to provide a composite insulation system, providing a cool living environment in summer and warm in winter. can provide a safe environment from

In addition, the flame-retardant insulation board according to the embodiment of the present invention can constitute an outer wall at a minimum cost and can reduce the thickness of the wall or the base portion structurally at least.

1 is a view schematically showing a cross-sectional view of a bead method type 2 insulating bead according to an embodiment of the present invention.
2 is a view schematically showing an apparatus for manufacturing a type 2 insulating bead using a bead method according to an embodiment of the present invention.
3 is a conceptual diagram of a coating machine according to an embodiment of the present invention.
4 shows a photograph of a foaming raw material, a foamed material, and a coating material used while manufacturing the bead method two-type insulating bead according to an embodiment of the present invention.
5 is a photograph of a flame-retardant board manufactured by using the bead method type 2 insulation bead according to an embodiment of the present invention divided into before and after adding a flame-retardant layer.

Hereinafter, with reference to the accompanying drawings, the bead method according to an embodiment of the present invention will be described in detail the second type of insulation bead, flame-retardant insulation board, a specific manufacturing method and manufacturing apparatus as follows. The present invention may be embodied in many different forms and is not limited to the embodiments described herein.

Prior to describing the present invention in detail below, it is to be understood that the terminology used herein is for the purpose of describing specific embodiments and is not intended to limit the scope of the present invention, which is limited only by the appended claims. shall. All technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the art, unless otherwise stated.

Throughout this specification and claims, unless stated otherwise, the term comprise, comprises, comprising is meant to include the stated object, step or group of objects, and steps, and any other object. It is not used in the sense of excluding steps or groups of objects or groups of steps.

On the other hand, various embodiments of the present invention may be combined with any other embodiments unless clearly indicated to the contrary. Any feature indicated as particularly preferred or advantageous may be combined with any other feature and features indicated as preferred or advantageous.

In the drawings, the width, length, thickness, etc. of the components may be exaggerated for convenience. As a whole, it has been described from an observer's point of view when describing the drawings, and when it is said that one component is "above/below" or "above/below" another component, it is , including the case where there is another component in the middle.

The present inventors have completed the present invention based on this by confirming the technology for enhancing the fusion strength, thermal insulation and flame retardancy of the beads constituting the board.

Specifically, in the present invention, the fusion strength of the beads constituting the board is enhanced for the following reasons.

First, the structure and composition of the additive, the adhesive layer, and the flame retardant layer are mentioned. In the present invention, the adhesive layer serves to bond the foam particles and the flame-retardant layer. The reason for separately providing the adhesive layer as described above is to allow the adhesive layer to be uniformly formed over the entire surface of the foamed particles to improve bonding strength when bonding the foamed particles and the flame-retardant layer. Therefore, it is important that the adhesive layer be coated with 95% or more, preferably 98% or more of the total surface of the foamed particles. At this time, since the flame-retardant layer has relatively low adhesive strength compared to the adhesive layer, if the adhesive layer is not provided, the flame-retardant layer is peeled off and the flame-retardant effect can be reduced.

In addition, in order to help prevent such peeling, it is preferable that the flame-retardant layer includes a urethane foaming adhesive while basically having the function of a flame retardant. By the additionally included adhesive, as well as peeling off the flame retardant layer, it is possible to reinforce the fusion strength and flame retardant strengthening effect between the beads.

When the flame-retardant insulation board of the present invention is broken (in the case of breaking the board rather than cutting it with a tool), it can be seen that the two-bead method of insulating beads sticking together with enhanced fusion force are split. On the other hand, in the prior art, since the bonding force between the bead method type 2 insulation beads is weak, if they break in the same way, it can be confirmed that the bead method type 2 insulation beads are pulled out while maintaining the bead shape on either side of the fracture surface without being split. there is.

In consideration of compatibility with the flame retardant component used in the present invention to provide the above-described effect, it is appropriate to include a carbon-based material such as expanded graphite as an additive included in expanded styrene.

Second, it is due to increasing the degree of foaming of the foamed particles. As the foaming of the foamed particles is strengthened, the particle size increases, and the force that the foamed particles collide with each other increases to achieve a high density, thereby forming a tight board with each other and preventing thermal crosslinking.

Accordingly, in the embodiment of the present invention, foaming properties are strengthened as a whole through foaming, aging, coating, molding, and drying processes of the expanded particles. At this time, in order to maximize fusion properties, thermal insulation properties and flame retardancy, the size of the expanded particles should be uniformly made. To this end, in various aspects of the present invention, in order to keep the size of the expanded particles constant, various means are provided for preventing the size of the expanded particles from changing according to the temperature gradient during the process.

In addition, the foaming may further increase under the influence of the foaming adhesive included in the adhesive layer and the flame-retardant layer as well as increasing the foaming degree of the foamed particles themselves. That is, after coating, the particle size before molding (hereinafter, also referred to as s1) increases to the particle size after manufacturing the board (hereinafter also referred to as s2). In this case, it is preferable that s1 and s2 have a relationship of s2 ≥ s1 + s1 x 0.005.

<First aspect>

A first aspect of the present invention relates to a flame-retardant insulation board in which the bead method type 2 insulation bead and the bead method type 2 insulation bead are molded. Here, the bead method type 2 insulation bead relates to a type 2 type insulation bead method having a structure formed by coating a flame retardant through an adhesive layer on the outer surface of the foamed particles formed by foaming the bead method type 2 expanded styrene raw material.

The bead method type 2 insulating bead is made by spreading the foamed particles in a less-stretched form by drying the expanded particles formed by foaming the bead method type 2 expanded styrene raw material under an appropriate temperature gradient to form a more resilient form. The method of drying under the corresponding temperature gradient will be described in detail in the manufacturing apparatus of the second aspect to be described later.

The bead-method type 2 expanded styrene raw material has an average diameter of 0.5 to 1.5 mm, and a maximum expansion ratio of 70 to 150 times, or 75 to 110 times is preferable for use in the present invention, but is not limited thereto.

Referring to FIG. 1 schematically showing a cross-sectional view of a spherical bead as an embodiment of the bead method type 2 insulating bead, these expanded particles correspond to the innermost core indicated by reference numeral 11.

In this case, the expanded particles 11 may be various, such as a spherical shape, a columnar shape, or a rugby ball shape.

Since the foaming particles 11 expand the foaming agent in the softened raw material by applying heat to perform foaming, it is not possible to obtain foamed particles in a sufficiently resilient state with one-time foaming. As shown in FIG. 1, it can be made into a shape close to a tangy spherical shape by spreading the foamed particles in an unstretched form.

The bead method according to an embodiment of the present invention may be provided using the above-described foamed particles. That is, an adhesive layer containing a carbon-based material and formed of a thin film thickness of t2 by coating the first adhesive on the outer surface of the foamed particles having an average radius of t1 (mm) (corresponding to reference numeral 12 in FIG. 1); and a flame retardant layer (corresponding to reference numeral 13 in FIG. 1 ) comprising the second adhesive and a flame retardant on the adhesive layer 12 and coated with a thickness t3 thicker than t2.

In this case, the carbon-based material may be at least one selected from expanded graphite, graphene, carbon nanofibers, and carbon black.

In addition, the content of the carbon-based material may be 1 to 15% by weight, or 2 to 8% by weight based on the content of the expanded particles.

The aforementioned carbon-based material can be obtained by mechanical shearing.

The carbon-based material may have a particle size of 0.1 to 0.8 μm, and an aspect ratio of 100:1 or more.

The carbon-based material preferably includes expanded graphite.

Here, the carbon-based material may be expanded graphite, but is not limited thereto.

The expanded graphite preferably has an aspect ratio of 100:1 or more to provide expanded dispersibility.

The expanded graphite is obtained by mechanical shearing of graphite, and it is preferable to use a particle size of 0.1 to 0.8 μm to provide expanded dispersibility.

The content of the carbon-based material is preferably 1 to 15% by weight, or 2 to 8% by weight based on the content of the expanded particles, as it can provide improved adhesion, flame retardancy and heat insulation.

Here, when the radius of the expanded particles is t1, the thickness ratio of the layers is 1:0.0001 to 1:0.2, 1:0.001 to 1:0.2, 1:0.01 to 1:0.2, for example, the ratio of t1 and t2+t3; 1:0.0001 to 1:0.02, or 1:0.0001 to 1:0.002. Within this range, it is possible to provide enhanced fusion strength, flame retardancy, and prevention of peeling of the flame-retardant layer.

The first adhesive and the second adhesive may use the same or different urethane-based adhesives, and in particular, it is more preferable to use a urethane foaming adhesive to provide additional foaming of the expanded particles when sufficient heat is given. Examples of the urethane foam adhesive may include monomeric diisocyanate, and specific examples thereof include methylene diphenyl diisocyanate (MDI) material.

The methylenediphenyldiisocyanate is a material obtained by treating phosgene (COCl2) on diphenylmethanediamine produced by condensation of aniline and formaldehyde. Considering storage and ease of use, polymeric MDI (polymeric MDI), Various types of MDI such as modified MDI), monomeric MDI (monomeric MDI), and pure MDI (prepolymer) are manufactured. In the present invention, all of these various types of MDI can be used, and the type is not particularly limited.

This methylenediphenyl diisocyanate is relatively small compared to other hydrophobic resin components with a molecular weight and is easily dispersed, and the isocyanate group (-NCO) contained in the molecular structure reacts with a compound having active hydrogen to generate a urethane bond and a urea bond As can be done, the mechanical properties of the flame-retardant expanded styrene particles can be improved by removing moisture in the steam and increasing the crosslinking density of the hydrophobic resin to improve adhesion.

The urethane foam adhesive may be used by including thermo-expandable microspheres in an amount of 10% by weight or less based on the adhesive content. The thermally expandable microsphere corresponds to a material suitable for performing additional foaming in the coating step, particularly the molding step, which will be described later with compatibility with the urethane foam adhesive.

These thermally expansible microspheres have the form of a capsule having a hollow and a shell, and contain a liquid having a boiling point below the softening temperature of the shell in the hollow for foaming. The liquid may be a hydrocarbon, more preferably a hydrocarbon having a boiling point of less than 60° C. at atmospheric pressure. In one example the preferred foaming liquid therein is isobutane.

On the other hand, the acryl-based copolymer constitutes the shell, and is in the form of a powder at room temperature, but when exposed to high temperature, the capsule is expanded by vaporization of the liquefied hydrocarbon in the hollow and can be applied as a foaming agent. On the other hand, unlike general chemical blowing agents, the gas is not exposed to the surface.

That is, in the present invention, the adhesive layer serves to bond the foam particles and the flame-retardant layer. By separately providing the adhesive layer in this way, the adhesive layer is uniformly formed over the entire surface of the foamed particles, thereby improving bonding strength when bonding the foamed particles and the flame-retardant layer. At this time, since the flame-retardant layer has relatively low adhesive strength compared to the adhesive layer, if the adhesive layer is not provided, the flame-retardant layer is peeled off and the flame-retardant effect can be reduced.

The flame retardant is, for example, expanded graphite, aluminum powder, Al(OH) ₃ , Mg(OH), Al ₂ O ₃ , a flame retardant filler comprising at least one selected from the group consisting of iron, zinc, copper and alloys thereof. include

The flame retardant is preferably used in a liquid form using water or an organic solvent in consideration of aspects such as workability and uniformity of the coating film.

In addition, the flame retardant preferably includes a thermoplastic resin such as vinyl acetate resin, polyvinyl acetate resin (PVA), acrylic resin, ethylene vinyl acetate resin (EVA), which functions as a binder.

The expanded graphite is preferably contained in an amount of 20 to 40 parts by weight with respect to 100 parts by weight of the thermoplastic resin because it can suppress cracks and the like with sufficient flame retardant effect.

Expanded graphite used in the present invention is a material that imparts flame retardancy, and water and oxide compounds contained in heat generate gas, and as a result, scale-like graphite expands to form a stable layer against heat or chemicals. Accordingly, it exhibits a flame retardant effect in a solid-state char method.

Since the expanded graphite is a flame retardant that forms a halogen-free solid state, it is environmentally preferable because it can suppress flammability to a low level, and it is possible to simultaneously solve the problem of separation and flame retardancy, which is a major problem of inorganic materials.

The expanded graphite used in the present invention includes an epoxy-containing silane having a weight average molecular weight of 100 to 400 g/mol to inhibit aggregation with each other; phenyl group-containing silane; vinyl group-containing silanes such as vinyltrichlorosilane and vinyltrimethoxysilane; N-2(aminoethyl)-3-aminopropylmethyldimethoxysilane, N-2(aminoethyl)3-aminopropyltrimethoxysilane, N-2(aminoethyl)3-aminopropyltriethoxysilane, 3 -Aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, 3-triethoxysilane-N-(1,3-dimethylbutylidene)propylamine, N-phenyl-3-aminopropyltrimethoxy amine group-containing silanes such as silane; and expanded graphite coated with a silane compound selected from the group consisting of mixtures thereof. The amount of the silane compound used may be included in the range of 0.01 to 20 parts by weight based on 100 parts by weight of the expanded graphite, but is not limited thereto.

The expanded graphite preferably uses fine particles of 80 to 240 mesh in terms of dispersibility.

On the other hand, Al(OH) ₃ , Mg(OH), Al ₂ O ₃ improves flame retardancy as a flow improver, and in particular, as the reaction is initiated at around 180° C., the compound is decomposed to produce water, thereby extinguishing the fire do In particular, Al(OH) ₃ has a rich number of structures among inorganic flame retardants, and thus has excellent flame retardant effect as well as acid resistance and alkali resistance, and is advantageous in terms of cost. The average particle diameter of Al(OH) ₃ is preferably 1 to 10 µm, or 2 to 4 µm, in terms of workability and dispersibility.

In addition, aluminum powder, iron, zinc, copper, etc. may serve to increase the softening point of Styrofoam particles having low softening properties and suppress the generation of smoke during combustion.

Among them, flame-retardant fillers such as expanded graphite, Al(OH) ₃ , and aluminum powder may provide an effect of increasing thermal insulation. Therefore, it is preferable that the flame retardant filler is included in an amount of 25 to 100 parts by weight based on 100 parts by weight of the thermoplastic resin, and the solvent is included in an amount of 20 to 200 parts by weight if necessary.

It may further include components usable as a flame retardant, such as boric acid and sodium silicate, within the range that does not inhibit the effects of the present invention. If necessary, it may further include a material capable of promoting fusion between the expanded particles when molding the expanded particles later, and stearic acid, stearic acid triglyceride, hydroxystearic acid triglyceride, stearic acid sorbitan ester, etc. can be heard These fusion accelerators may be used within a content range that does not adversely affect the effects disclosed in the present invention.

The second adhesive included in the flame retardant layer may be, for example, 10% by weight or less, or 0.1 to 5% by weight based on the amount of the flame retardant used.

That is, in the present invention, the flame-retardant layer basically has the function of a flame retardant and additionally includes a foaming adhesive. Thus, by the additionally included adhesive, it is possible to reinforce the effect of strengthening the adhesion strength between the beads as well as peeling the flame retardant layer.

When the board manufactured with the beads is broken, it can be confirmed that the two-type insulating beads of the bead method that are stuck together with enhanced fusion force are split and broken. On the other hand, in the prior art, since the bonding force between the two-type insulation beads of the bead method is weak, when they break in the same way, it can be confirmed that the bead method-type insulation beads are not split and are pulled out while maintaining the bead shape on either side of both cut surfaces. .

The bead method of type 2 insulating beads may have a density of 0.5 g/cm ³ or less, 0.01 to 0.5 g/cm ³ or 0.05 to 0.2 g/cm ³ . The density may vary depending on the amount of the foaming agent or the ease of foaming, and the apparent density may vary depending on the foamed shape due to the internal pore structure.

The bead method type 2 insulating beads may have an average diameter (width of a cross-section) of 1 to 10 mm, or 2 to 5 mm, and in the case of the above specifications, it is possible to provide adequate thermal insulation.

The flame-retardant insulation board according to an embodiment of the present invention comprises: a board in which two types of insulation beads are fused to each other by forming and drying the bead method after coating the foamed particles with a flame-retardant layer; and a flame retardant layer having a thickness of 0.05 to 1 mm is coated on the board, and the bead method may contain a carbon-based material.

In this case, the two-type insulating beads of the bead method include expanded graphite, graphene, carbon nanofibers, and expanded particles containing at least one carbon-based material selected from carbon black and having an average radius of t1 (mm); an adhesive layer formed by coating a first urethane foaming adhesive on the outer surface of the foamed particles to have a thin film thickness of t2; and a flame retardant layer comprising the second urethane foam adhesive and a flame retardant on the adhesive layer and coated with a thickness t3 thicker than t2; The ratio may be 1:0.0001 to 1:0.2.

Accordingly, in the embodiment of the present invention, the entire foaming process goes through aging, coating, molding, and drying processes, but in particular, the particle size after coating and before molding (hereinafter also referred to as s1) increases to the particle size after manufacturing the board (hereinafter also referred to as s2). In this case, it is preferable that s1 and s2 have a relationship of s2 ≥ s1 + s1 x 0.005.

In addition, the foaming may further increase under the influence of the foaming adhesive included in the adhesive layer and the flame-retardant layer as well as increasing the foaming degree of the foamed particles themselves.

The board may have a flexural fracture load of 15N or more measured according to KS M 3808:2011 standard, and a compressive strength measured according to KS M 3808:2011 standard may be ^{5N/cm 2 or more.}

<Second aspect>

A second aspect of the present invention relates to an apparatus for manufacturing a type 2 insulating bead by a bead method and an apparatus for manufacturing a board molded by fusing these bead method type 2 insulating beads.

The dryer applied to the drying of the expanded particles in the present invention can be performed using the dryer 120 shown in FIG. 2 is a view schematically showing an apparatus for molding a flame-retardant insulation board using a bead method type 2 insulation bead according to an embodiment of the present invention.

Hereinafter, referring to FIG. 2, FIG. 2 shows a foaming machine 110 for foaming expanded styrene raw material containing a carbon-based material, a dryer 120 for drying the expanded particles delivered from the foaming machine 110, and As an apparatus for manufacturing two types of insulating beads using a bead method including a coating machine 130 for coating the foam particles delivered from the dryer 120, EPS raw materials are put into the hopper of the extrusion cylinder, and the foamer 110 is fed . The foaming machine 110 may use a foaming machine of various foaming molding types, for example, a pre-expander type foaming machine may be used.

The foam particles delivered from the foaming machine 110 are dried in the dryer 120 . The dryer 120 is dried by flowing the expanded particles 11 inside the drying body 121 by hot air. Considering this drying efficiency, the drying body 121 is, for example, a fluidized-bed dryer. It is preferable to use

In consideration of the effect on the foamed particles during rotational drying due to the difference in temperature gradient on the top and bottom surfaces of the drying body 121, a vent is provided on the bottom of the drying body 121 and hot air is blown into the drying body 121. It is preferable to provide a heating means 122 for heating the bottom surface of the.

At this time, it is preferable to provide an external air blocking means on the upper surface of the drying body 121 to adjust the internal temperature gradient of the drying body 121, particularly the internal temperature gradient between the upper and lower sides.

In the absence of an external air blocking means, especially in winter, when cold air directly touches the upper surface of the drying body, the temperature gradient of the upper surface of the drying main body and the lower surface to which the hot air is supplied becomes severe, so that the uniformity of the foamed particles during drying is deteriorated.

This outdoor air blocking means may be provided in various ways to prevent the outside air from affecting the inside of the drying body.

As shown in Figure 2, in an embodiment, the outdoor air blocking means may be composed of a housing (housing, 123) and an air stack (air stack, 124). The housing 123 is provided on the upper surface of the drying body to provide a space for accommodating air therein, and the air stack 124 is provided on the upper portion of the housing.

The air stack exhausts air to the outside when the temperature inside the housing is high, but prevents cold outside air from entering the inside. The outdoor air blocking means may further include an air conditioning unit 125 on the side. The air conditioning unit 125 may appropriately adjust the amount of air introduced therein. The air conditioning unit may be provided by installing a bellows-type entrance on the side of the housing.

Although not shown in FIG. 2 for a brief description, it is preferable that the above-described foaming machine 110 and dryer 120 are provided repeatedly to maximize the foaming and drying effect. For example, in the manufacturing apparatus of the present invention, the foaming machine 110, the dryer 120, the foaming machine (not shown), and the dryer (not shown) may be alternately provided with a foaming machine and a dryer in the order. As a specific example, the manufacturing apparatus of the present invention foams in the order of the foaming machine 110 , the dryer 120 , the aging machine 130 , the foaming machine (not shown), the dryer (not shown), and the aging machine (not shown). It may be that the tile dryer and the aging machine are alternately provided.

The delivery of the expanded particles from the dryer 120 to the foaming machine (corresponding to the additional foaming machine not shown) may use various methods known in the art, for example, a screw method may be used.

The foam particles delivered from the dryer (not shown) are aged in the aging machine 130 while high-pressure spraying water to control humidity and prevent static electricity. The foam particles transferred from the aging stage are coated with an adhesive and a flame retardant through the coating machine 140 .

In an embodiment of the present invention, the coating machine 140 includes a stirring tank 141 , a drying tank 143 , a transfer tank 145 , and a temperature gradient control means 150 . 3 shows a conceptual diagram of the coating machine.

In the stirring tank, a first adhesive and a flame retardant are injected into the foamed particles to coat the foamed particles to prepare two kinds of insulating beads by the bead method. The stirring tank is provided with an inlet for injecting the adhesive and the flame retardant that are supplied simultaneously or sequentially through the adhesive pre-added tank 142 or the flame retardant post-added tank 144 .

The flame retardant post-addition tank 144 may include a mixing tank and a separate adhesive supply tank 146 for receiving them before use and supplying them to the stirring tank 140 in a well-mixed state.

The drying tank 143 receives and dries the coated bead method type 2 insulating beads from the stirring tank. In the drying tank, the temperature of the bead method type 2 insulating bead is reduced to less than 50° C. and agitated for 100 to 500 seconds.

The transfer tank 145 is dried while transferring the bead method type 2 insulating beads dried in the drying tank 143 . At this time, it is dried while being transferred over 100 to 300 seconds while maintaining less than 50°C.

The temperature gradient control means 150 is adjusted so that there is no temperature gradient in the external space where the coating machine is installed. In order to uniformly coat the bead method type 2 insulating beads, it is necessary to control the temperature inside the coating machine.

That is, it is necessary to eliminate the temperature gradient inside the coater to realize higher flame retardancy, heat insulation, and fusion properties, and for this purpose, it is necessary to control the temperature around the coater, not inside the coater.

In the present invention, since foaming of the bead method type 2 insulating beads proceeds while going through the coating machine 140, when a temperature gradient occurs inside the coating machine, the foaming of the beads becomes non-uniform. To this end, a fine temperature gradient control means 150 is required to maintain the area where the wall surface of the coating machine is in contact with the outside air at a temperature similar to that of the inside of the coating machine.

The temperature gradient control means 150 includes a measurement unit 151 , a control unit 153 , and a heating device 155 . That is, a measuring unit capable of measuring the outside temperature is installed in the space around the coating machine to sense it, and if a constant temperature cannot be maintained, the control unit operates the heating device to maintain the temperature.

On the other hand, the stirring tank 140 may be rotated up and down based on the central axis in the horizontal direction, but is not limited thereto, and various coating methods of coating while stirring may be used.

The two kinds of bead method heat insulating beads transferred from the coating machine 140 are dried in the dryer 150 . The dryer 150 used here may include only the drying main body 121 among the dryer 120 presented above, and if necessary, as in the dryer 120, the outside air blocking means 123, 124, 125, or the bottom surface of the drying body 121 on the upper part. The heating means 122 may be included.

The foamed particles delivered from the dryer 150 provide aging and humidity control, anti-static properties, and the like using the aging machine 160 . In this case, the usable aging unit 160 may use, for example, a multi-stage aging silo.

The two-bead method heat insulating beads delivered from the aging machine 160 may be introduced into the board forming machine 170, steam treated under vapor pressure, and then discharged by vacuum cooling. The board molding machine 170 may be a block molding machine or a mold molding machine, and it is preferable that these molding machines are performed under a heating chamber to efficiently provide additional foaming by an adhesive or the like.

<Third aspect>

A third aspect of the present invention relates to a method for manufacturing a bead method type 2 insulating bead. These bead method two-type insulating beads are manufactured by foaming a foamed styrene raw material containing a carbon-based material, coating an adhesive on the outer surface to make a flame retardant binding site, and then attaching a flame retardant.

Specifically, the manufacturing method includes steps 1-1, 1-2, 1-3, 1-4, and steps 1-5 to 1-8. The name of each stage is a name given to distinguish each stage from other stages, and does not include all technical meanings of each stage.

Step 1-1 is a step of foaming the expanded styrene raw material in a foaming machine.

The foamed styrene raw material used in the present invention may contain, for example, a carbon-based material and have an average diameter of 0.5 to 1.5 mm.

The foaming may be performed under conditions of, for example, 80° C. or higher, vapor pressure 0.5 kg/cm or less, or 0.1 to 0.2 kg/cm, steam 120 seconds or less, or 100 to 120 seconds conditions.

Step 1-2 controls the temperature gradient between the central temperature inside the drying body and the upper temperature inside the drying body by blocking the upper outside air of the drying body while drying the expanded particles delivered in the foaming step in the drying body. At the same time, it is a step of heating the bottom surface of the drying body by blowing hot air from the lower part of the drying body.

At this time, it is preferable that the temperature of the drying body is dried with hot air at 30° C. or higher, and by performing foaming and drying in this way, the foam can be foamed at a foaming ratio of 70 to 90 times based on the raw material of foamed styrene.

In step 1-3, the expanded particles that have passed through the dried body are aged at a temperature of 40° C. or less for 3 to 12 hours. It is preferable to proceed in a multi-step silo method in consideration of the aging efficiency, and it is more preferable to control the humidity by intermittently spraying water at a high pressure.

In Steps 1-4, the aged raw material is put into a secondary foaming machine (using the aforementioned foaming machine or a separate foaming machine may be used) in a screw method to perform additional foaming, and then dried. At this time, the additional foaming condition is performed at 80~90℃ to further advance the foaming less performed in the previous foaming, and then use the same dry body as described above (with the method of blocking the upper external air and blowing hot air from the lower part) Alternatively, it is preferable to dry with hot air while maintaining a drying room temperature of 30° C. or higher using a separate drying body.

By repeating foaming and drying in this way, it is possible to foam up to about 100 to 130 times the expansion ratio based on the first used foamed styrene raw material.

Steps 1-5 are aged for 3 to 12 hours at 0 ~ 40 ℃ the expanded particles passed through the additional drying body. It is preferable to proceed in a multi-step silo method in consideration of aging efficiency, and it is more preferable to control humidity and prevent static air by intermittently spraying water at high pressure.

Steps 1-6 are the steps of applying a urethane foam adhesive to the outer surface of the obtained foamed particles.

Using the urethane foam adhesive within the range of 3 to 20 parts by weight, 3 to 10 parts by weight, or 4 to 8 parts by weight of the urethane foam adhesive based on 100 parts by weight of the foamed particles is a coating that will be described later while making a place for the flame retardant to bind. It is preferable because it can cause additional foaming in the step or molding step.

If necessary, thermally expandable microspheres may be included in the urethane foam adhesive in an amount of 10% by weight or less based on the adhesive. The thermally expandable microsphere corresponds to a material suitable for performing additional foaming in the coating step, particularly the molding step, which will be described later with compatibility with the urethane foam adhesive.

These thermally expansible microspheres have the form of a capsule having a hollow and a shell, and contain a liquid having a boiling point below the softening temperature of the shell in the hollow for foaming. The liquid may be a hydrocarbon, more preferably a hydrocarbon having a boiling point of less than 60° C. at atmospheric pressure. In one example the preferred foaming liquid therein is isobutane.

On the other hand, the acryl-based copolymer constitutes the shell, and is in the form of a powder at room temperature, but when exposed to high temperature, the capsule is expanded by vaporization of the liquefied hydrocarbon in the hollow and can be applied as a foaming agent. On the other hand, unlike general chemical blowing agents, the gas is not exposed to the surface.

Step 1-7 is a step of applying a flame retardant containing expanded graphite after the adhesive application step.

The flame retardant containing the expanded graphite may include the various materials disclosed in the above-mentioned <first aspect>, for example, it is preferable to include an acrylic adhesive resin such as a flame retardant filler containing expanded graphite, polysol, PVA-based, etc. do.

The flame retardant is stored in a separate storage tank until sprayed, mixed before use, and mixed well using a homogenizer or evenly stirred before spraying. At the same time, it is more preferable to form the flame-retardant layer 13 with a uniform thickness.

In addition, from the viewpoint of forming the flame-retardant layer 13 with a uniform thickness, it is preferable to perform spraying in a manner that enables instantaneous even application, such as a nozzle or a syringe.

The flame retardant may be used within the range of 50 to 250 parts by weight, 100 to 200 parts by weight, or 100 to 150 parts by weight based on 100 parts by weight of the expanded particles, and the expanded particles 11 do not directly contact with external gas within this range. It is preferable that the flame-retardant layer 13 can be formed to a thickness that is not high enough.

In addition, based on the amount of the flame retardant used, the second adhesive may be included in an amount of 10% by weight or less, or 0.1 to 5% by weight, thereby improving bonding strength during bonding of the foamed particles and the flame retardant layer. The second adhesive used at this time may use the above-described urethane-based foaming adhesive, and may include thermally expansible microspheres if necessary.

Steps 1-6 and 1-7 may be performed simultaneously or sequentially as needed.

The application in these steps is carried out with stirring at 40-60° C., or 45-55° C. for 100-300 seconds, 150-250 seconds, or 150-200 seconds, followed by 200 seconds at 30-50° C., or 35-45° C. More preferably, while stirring for 200 to 300 seconds, or 200 to 250 seconds, the coated material is dried and then transferred at 30 to 50 ° C., or 35 to 45 ° C. for an additional 100 to 300 seconds, preferably 150 to 250 seconds. Further drying is preferred.

If necessary, a step of aging at 40° C. or lower for 2 to 5 hours may be added as steps 1-8.

<Fourth aspect>

A fourth aspect of the present invention relates to a method for manufacturing a flame-retardant insulation board using the manufactured bead method type 2 insulation beads.

Specifically, the method for manufacturing a flame retardant insulation board includes a step 2-1, a step 2-2, a step 2-3, a step 2-4, a step 2-5 to a step 2-10. The name of each stage is a name given to distinguish each stage from other stages, and does not include all technical meanings of each stage.

Step 2-1 is a step of foaming the expanded styrene raw material containing the carbon-based material.

In the present invention, the foaming may be performed under the conditions of, for example, a foaming temperature of 90° C. or higher, a vapor pressure of 0.5 kg/cm or less, or 0.1 to 0.2 kg/cm, steam 120 seconds or less, or 100 to 120 seconds, but is limited thereto no.

Step 2-2 controls the temperature gradient between the central temperature inside the drying body and the upper temperature inside the drying body by blocking the upper outside air of the drying body while drying the expanded particles delivered in the foaming step in the drying body. At the same time, it is a step of heating the bottom surface of the drying body by blowing hot air from the lower part of the drying body.

At this time, the temperature of the drying body is preferably hot air dried at 30° C. or higher, and by performing foaming and drying in this way, the foamed styrene raw material can be foamed at a foaming ratio of 70 to 90 times.

In step 2-3, the expanded particles that have passed through the dried body are aged at a temperature of 40° C. or less for 3 to 12 hours. It is preferable to proceed in a multi-step silo method in consideration of the aging efficiency, and it is more preferable to control the humidity by intermittently spraying water at a high pressure.

In step 2-4, the aged raw material is put into a secondary foaming machine (using the aforementioned foaming machine or a separate foaming machine) in a screw method to perform additional foaming, and then dried. At this time, the additional foaming condition is performed at 80~90℃ to further advance the foaming less performed in the previous foaming, and then use the same dry body as described above (with the method of blocking the upper external air and blowing hot air from the lower part) Alternatively, it is preferable to dry with hot air while maintaining a drying room temperature of 30° C. or higher using a separate drying body.

By repeating foaming and drying in this way, the expanded styrene raw material can be foamed at an expansion ratio of 100 to 130 times.

In step 2-5, the expanded particles that have passed through the additional drying body are aged at 0 to 40° C. for 3 to 12 hours. It is preferable to proceed in a multi-step silo method in consideration of aging efficiency, and it is more preferable to control humidity and prevent static air by intermittently spraying water at high pressure.

Step 2-6 is a step of applying a urethane foam adhesive to the outer surface of the obtained foam particles.

Using the urethane foam adhesive within the range of 3 to 20 parts by weight, 3 to 10 parts by weight, or 4 to 8 parts by weight of the urethane foam adhesive based on 100 parts by weight of the foamed particles is a coating that will be described later while making a place for the flame retardant to bind. It is preferable because it can cause additional foaming in the step or molding step.

If necessary, thermally expandable microspheres may be included in the urethane foam adhesive in an amount of 10% by weight or less based on the adhesive. The thermally expandable microsphere corresponds to a material suitable for performing additional foaming in the coating step, particularly the molding step, which will be described later with compatibility with the urethane foam adhesive.

These thermally expansible microspheres have the form of a capsule having a hollow and a shell, and contain a liquid having a boiling point below the softening temperature of the shell in the hollow for foaming. The liquid may be a hydrocarbon, more preferably a hydrocarbon having a boiling point of less than 60° C. at atmospheric pressure. In one example the preferred foaming liquid therein is isobutane.

On the other hand, the acryl-based copolymer constitutes the shell, and is in the form of a powder at room temperature, but when exposed to high temperature, the capsule is expanded by vaporization of the liquefied hydrocarbon in the hollow and can be applied as a foaming agent. On the other hand, unlike general chemical blowing agents, the gas is not exposed to the surface. These thermally expansible microspheres are marketed under the product name Expancel 980 DU 120 by Akzo Nobel.

Step 2-7 is a step of spraying a flame retardant by evenly mixing a flame retardant containing expanded graphite after the adhesive application step.

The flame retardant containing the expanded graphite may include various related materials described in the first aspect described above, for example, it is preferable to include an acrylic adhesive resin such as a flame retardant filler containing expanded graphite, polysol, and PVA based. .

These materials are stored in a separate storage tank until the flame retardant is sprayed, and then mixed before use and mixed well using a homogenizer or evenly stirred and then sprayed. It is preferable that the flame-retardant layer 13 can be uniformly formed on the entire surface with a thickness.

In addition, from the viewpoint of forming the flame-retardant layer 13 with a uniform thickness, it is preferable to perform spraying in a manner that enables instantaneous and even application such as a nozzle or a syringe.

The flame retardant may be used within the range of 50 to 250 parts by weight, 100 to 200 parts by weight, or 100 to 150 parts by weight based on 100 parts by weight of the expanded particles, and the expanded particles 11 do not directly contact with external gas within this range. It is preferable that the flame-retardant layer 13 can be formed to a thickness that is not high enough.

In addition, by including the adhesive in the range of 10% by weight or less, or 0.1 to 5% by weight based on the amount of the flame retardant used, bonding strength between the foamed particles and the flame retardant layer can be improved. The adhesive used at this time may use the above-mentioned urethane-based foam adhesive, and may include thermally expansible microspheres if necessary.

Steps 2-6 and 2-7 may be performed simultaneously or sequentially as needed.

The application in these steps is carried out with stirring at 40-60° C., or 45-55° C. for 100-300 seconds, 150-250 seconds, or 150-200 seconds, followed by 200 seconds at 30-50° C., or 35-45° C. More preferably, while stirring for 200 to 300 seconds, or 200 to 250 seconds, the coated material is dried and then transferred at 30 to 50 ° C., or 35 to 45 ° C. for an additional 100 to 300 seconds, preferably 150 to 250 seconds. Further drying is preferred.

If necessary, a step of aging at 40° C. or lower for 2 to 5 hours may be added as step 2-8.

As the 2-9 step, after the flame-retardant aging step, the bead method type 2 insulation beads are immediately put into the board molding or stored and stored until molding. The board molding used here is, for example, vacuum filling of raw materials, and then, for example, vapor pressure of 1 to 5 kg/cm, or 1 to 3 kg/cm, primary steam 10 to 20 seconds or 10 to 15 seconds, secondary steam 1 to 10 seconds, or 1 to 5 seconds, vacuum cooling 40 to 50 seconds after the process can be carried out by discharging, and may be block molding or mold molding if necessary.

Then, as a step 2-10, a flame-retardant layer is coated on the molded insulation board. At this time, it is preferable that the flame retardant layer is formed to a thickness of 0.05 to 1 mm, a thickness of 0.1 to 0.5 mm, or a thickness of 0.1 to 0.3 mm using a flame retardant containing expanded graphite can provide an optimal flame retardant and heat insulation effect.

As described above, the present invention provides a technology for strengthening the fusion strength of the beads constituting the board. Specifically, the fusion strength of the beads constituting the board in the present invention is the structure and composition of the additive, the adhesive layer and the flame retardant layer. is reinforced by That is, in the present invention, the adhesive layer serves to bond the foam particles and the flame retardant layer. The reason for separately providing the adhesive layer as described above is to allow the adhesive layer to be uniformly formed over the entire surface of the foamed particles to improve bonding strength when bonding the foamed particles and the flame-retardant layer. At this time, since the flame-retardant layer has relatively low adhesive strength compared to the adhesive layer, if the adhesive layer is not provided, the flame-retardant layer is peeled off and the flame-retardant effect can be reduced.

In addition, in order to help prevent such peeling, the flame retardant layer basically has the function of a flame retardant and additionally includes an adhesive. Thus, by the additionally included adhesive, it is possible to reinforce the effect of strengthening the adhesion strength between the beads as well as peeling the flame retardant layer. For reference, if the board is cut by hand, it can be seen that the two-type insulating beads of the bead method that are stuck together with enhanced fusion force are split and cut. On the other hand, in the prior art, since the bonding force between the bead method type 2 insulation beads is weak, when cutting by hand likewise, it is confirmed that the bead method type 2 insulation beads are pulled out while maintaining the bead shape on either side of the cut surface without being split. can

In addition, by increasing the degree of foaming of the expanded particles, the fusion strength is strengthened. As the foaming of the expanded particles is strengthened, the particle size is increased, and the force of colliding with each other is increased to achieve a high density.

In addition, it is appropriate to include a carbon-based material as an additive included in the expanded styrene in consideration of compatibility with the flame retardant component used in the present invention to provide the above-described effect.

Therefore, in the embodiment of the present invention, the entire foaming process goes through aging, coating, molding, and drying processes, but in particular, the particle size after coating and before molding (hereinafter also referred to as s1) increases to the particle size after manufacturing the board (hereinafter also referred to as s2). In this case, it is preferable that s1 and s2 have a relationship of s2 ≥ s1 + s1 x 0.005.

In addition, the foaming may further increase under the influence of the foaming adhesive included in the adhesive layer and the flame-retardant layer as well as increasing the foaming degree of the foamed particles themselves.

In fact, as a result of testing the bending fatigue strength of the board molded according to the embodiment of the present invention through FIG. 5 , it can be confirmed that the board is bent only bent and not cut even when folded. In addition, through FIG. 6 , it can be seen that the results of the quasi-noncombustibility test in the board molded according to the embodiment of the present invention are superior to the results of the quasi-noncombustibility test in the commercially available board.

The flame-retardant insulation board manufactured with the bead method type 2 insulation beads provided in this way is an external wall insulation (composite insulation) system, impact sound insulation, top floor insulation, sloped roof insulation, basement insulation, flat roof insulation, and prefabricated insulation (shultering stones) type. It can be applied to all architectural uses including products.

Hereinafter, embodiments of the present invention will be described in more detail. The following examples are intended to illustrate the present invention, and are not intended to limit the present invention thereto.

<Example>

The following materials were prepared for the production of two types of insulating beads by the bead method of Examples.

EPS containing carbon-based materials: Kumho Petrochemical, 50 kg of expanded polystyrene with a particle size of 0.1-0.8 um and an aspect ratio of 100:1 or more

Adhesive 1: 3kg MDI

Adhesive 2: Akzo Nobel Product Name Expancel 980 DU 120 0.3 kg

Flame retardant: 55 kg of homogenizer mixture of expanded graphite, polysol, and PVA-based resin

<Example 1>

Preparation of two-type insulating beads by bead method

2, the EPS raw material containing the carbon-based material is filled in the foaming machine 110, and the EPS raw material is preliminarily prepared under the conditions of a temperature of 90° C. or higher, a vapor pressure of 0.1 to 0.2 kg/cm, and steam for 100 seconds. expanded foam.

Then, the particles pre-foamed in the foamer 110 were delivered to the inside of the drying body 121 of the dryer 120 . At this time, as shown in FIG. 2 , in the dryer 120 , temperature control boxes 123 , 124 , 125 are attached to the upper portion of the drying body 121 as an external air blocking means, and heating means 122 for blowing hot air through a ventilator on the bottom surface. This structure was used.

Through the structure of the dryer 120, the internal temperature of the drying body 121 was uniformly controlled to 30° C. or higher, and hot air drying was performed.

The expansion ratio of the thus obtained expanded particles was 75 times.

Then, while aging the foamed particles delivered from the dryer 120 at 40° C. or less for 3 to 12 hours in the multi-stage silo aging machine 130, water was sprayed at high pressure to control the humidity.

The raw material delivered from the aging machine 130 was put into a secondary foaming machine (not shown) in a screw method, and foamed while maintaining 80 to 90°C.

Then, the expanded particles from the secondary foaming machine (not shown) were delivered to the inside of the drying body (not shown) of the additional dryer. The dryer used at this time also has a temperature control box attached as an outside air blocking space (not shown) on the upper part of the drying body (not shown) in the same manner as described above, and a heating means for blowing hot air through a ventilator on the bottom is provided. was used.

Hot air drying was performed while uniformly controlling the internal temperature of the drying body to 30°C or higher in the dryer. The expansion ratio of the thus obtained expanded particles was 110 times.

Then, while aging the expanded particles delivered from the additional dryer at a temperature of 0 to 40° C. for 3 to 12 hours in a multi-stage silo aging machine (not shown), water was sprayed at a high pressure to control humidity and prevent static electricity.

Next, an adhesive and a flame retardant were sequentially coated on the aged foamed particles (corresponding to reference numeral 11 in FIG. 1 ) by stirring at 50° C. for 180 seconds using a coating machine 140 .

That is, the adhesive 1 was pre-added from the pre-tip tank 142 through the inlet provided as the upper inlet of the coater 140 to form the adhesive layer 12, and then the material was mixed from the raw material storage tank 144 containing the expanded graphite. Then, a mixture of the adhesive 2 supplied from the adhesive 2 storage tank 146 was mixed with the flame-retardant solution mixed evenly by stirring, and the mixture was injected into the coating machine 140 and added to form the flame-retardant layer 13 .

The coated particles were dried by stirring at 40° C. for 230 seconds, and then further dried while transported at 40° C. for about 200 seconds to form an adhesive layer 12 surrounding the expanded particles 11 thinly as shown in FIG. 1 . , a bead method having a structure in which a flame-retardant layer 13 surrounding the foamed particles 11 and the adhesive layer 12 is formed as a whole was obtained.

At this time, the temperature of the external space in which the device is installed was adjusted in order to reduce the internal temperature gradient of the devices in which the bead method type 2 insulating beads were manufactured by using the temperature gradient control means. That is, the measuring unit 151 capable of measuring the outside temperature is installed in the space around the coating machine and sensed, and when the constant temperature cannot be maintained, the control unit 153 operates the heating device 155 to maintain the temperature.

Then, while passing through the multi-stage SilO aging machine 150, it was further aged at 40° C. or lower for 2 to 5 hours to obtain a bead method type 2 insulating beads (10).

At this time, it was confirmed that the radius (t1) of the foam particles 11, the thickness (t2) of the adhesive layer 12, and the thickness (t3) of the flame-retardant layer 13 were t1: t2+t3 = 1:0.2.

4 shows photographs of raw materials, foams, and coatings used while preparing two types of insulating beads by the bead method.

<Example 2>

Manufacture of flame retardant insulation board

With reference to the apparatus of Figures 2 and 3, the bead method 2 type insulating bead 10 prepared in Example 2 is vacuum filled in a mold forming machine 170, and the vapor pressure is 2 kg/cm, the first steam 12 seconds, the second After steam 2.5 sec and vacuum cooling 40-50 sec process, it was discharged to produce boards with a thickness of 50 mm and 120 mm, respectively.

The manufactured boards were dried for 2 hours at 40-50° C. in the primary drying room, then transferred to the secondary drying room, aged at 20° C. or higher for 24 hours or more, and then cut.

Then, a flame retardant containing expanded graphite was applied to one side of the board made to a thickness of 0.2 mm, and then dried and stored.

It was also confirmed that the relationship of s2 ≥ s1 + s1 x 0.005 was satisfied when the average diameter of the bead method type 2 insulating beads before molding was s1 and the average diameter of the bead method type 2 insulating beads after the board was manufactured as s2. .

In FIG. 5, a photograph of the flame-retardant board prepared using the bead method type 2 insulating beads obtained in Example 1 is divided into before and after addition of the flame-retardant layer.

Experimental Example 1

Four types of boards of Example 2 were prepared for each density, and flame retardant insulation boards sold on the market were also prepared for each density, and then the physical properties of thermal conductivity, bending strength, compressive strength, and absorption measured by KS M 3808 method were measured and combustibility ( self-extinguishing test) was performed and the flame was extinguished within 3 seconds, and if there was no residue and did not burn beyond the combustion limit line, it was shown in Table 1 below as PASS, and as FAIL otherwise.

Styrofoam Density (kg/m ² ) thermal conductivity
(w/mK) bending strength
(n/cm ² ) compressive strength
(n/cm ² ) absorption
(g/100cm) combustibility Example 2
(No. 1) 30 or more 0.031 or less over 35 16 or more 1 or less PASS Example 2
(No. 2) 25 or more 0.032 or less 30 or more 12 or more 1 or less PASS Example 2
(No. 3) 20 or more 0.033 or less 22 or more 8 or more 1 or less PASS Example 2
(No. 4) 15 or more 0.034 or less 15 or more 5 or more 1.5 or less PASS

In addition, for all items 1 to 4 of the board of Example 2, the dimensional tolerances for each thickness in consideration of heat insulation properties and fusion properties are shown in Table 2 below.

Thickness (mm) Thickness tolerance (mm) Length x Width (in mm) Length and width tolerances (in mm) 20 ±2 900 x 600
1200 x 600
2400 x 900
2400 x 1200 Less than 1000 ± 3
Less than 1000 ± 4
Less than 2000 ± 5 30 ±2 40 ±2 50 ±2 75 ±3 100 ±3

In addition, the effect of saving raw materials when the flame-retardant insulation board of Example 2 and the commercially available product were constructed with the same thickness was examined, and is shown in Table 3 below.

thermal conductivity
(W/mk) Flame-retardant insulation board of Example 2 board of commercial products type of insulation board Density (kg/m ³ ) foam drainage foam drainage Density (kg/m ³ ) type of insulation board 0.031 No. 1 30 33 times 50% cost reduction 0.032 No. 2 25 44 times 0.033 No. 3 20 50 times 0.034 No. 4 15 60 times 33 times 30 No. 1

As shown in Tables 1 to 3, the flame-retardant insulation board according to the embodiment of the present invention has significantly improved thermal conductivity and cost reduction ability when constructing the same thickness compared to existing commercially available products, and it is confirmed that the dimensional tolerance for each thickness is also improved. can

In addition, as a result of converting carbon dioxide emissions, what was 4.9 tons when the insulation was not used was reduced to 1.7 tons when using the above-mentioned commercial insulation material, and 0.7 tons when using the flame-retardant insulation board according to the embodiment of the present invention. calculated to be visible.

Experimental Example 2

For each of the board of Example 2 and the commercially available flame-retardant insulation board, the thermal conductivity, bending strength, compressive strength, and water absorption measured by the KS M 3808 method for each density were measured and shown in Table 1 below.

As a result of checking the fusion strength between the beads in the board by manually cutting the cross-section of each of the board of Example 2 and the commercially available flame-retardant insulation board, the bead method 2 type insulation bead in the board molded according to Example 2 of the present invention In the case of these, it was confirmed that the beads were split at break as a result of strong fusion. That is, even when the board is broken, the breakage is not made between the beads because the bonding force between the beads is strong, but the beads themselves break, and the ratio of the bead breakage reaches 70% to 95%, 80% to 90%.

On the other hand, in the commercially available board, it was confirmed that the beads were located on either side of the cut surface while maintaining a spherical shape when fractured as a result of weakly fusion of the bead method type 2 insulating beads.

Experimental Example 3

As a result of manufacturing the board of Example 2 and the commercially available flame-retardant insulation board and measuring the flexural fatigue strength, the commercially available board is broken, whereas the board molded according to Example 2 of the present invention is only bent and cut I was able to see results that didn't work. It is inferred that this is the result of improved density and adhesion according to the technique of the present invention.

Experimental Example 4

As a result of confirming the self-extinguishing property as a flame retardant performance with the board of Example 2 and the commercially available flame-retardant insulation board, it was confirmed that the board of Example 2 showed improved self-extinguishing properties than the commercially available flame-retardant insulation board. This is inferred to be the result that the density and adhesion are improved according to the technique of the present invention, and further, the flame-retardant layer is well formed to a thickness such that the foamed particles do not contact the external gas.

In particular, the board molded according to Example 2 of the present invention is less than the standard value in all of the combustion performance test-heat release rate (cone calorimetric method), smoke generation rate (dynamic measurement), and mass reduction rate measured under KS F ISO 5660-1:2015 was able to confirm satisfactory results.

For reference, even though flame retardant insulation boards sold in the market are products with performance certification, combustion performance tests measured under KS F ISO 5660-1:2015 - heat release rate (cone calorimetric method), smoke generation rate (dynamic measurement), mass reduction rate It was confirmed that all criteria were not satisfied in all cases.

Experimental Example 5

The compressive strength of the board of Example 2 was measured by requesting the Korea Institute of Construction and Living Environment. As a result of measurement according to KS M 3808:2011, it was confirmed that the board molded according to Example 2 had a compressive strength of 6N/cm ² and a flexural fatigue strength of 20N or more.

Experimental Example 6

The board manufactured in Example 2 was applied on-site as an insulating material to the outer wall of the building, and then removed after 6 months to measure the fusion strength and quasi-noncombustibility. It was confirmed that there was no thermal bridge and the insulation performance was improved by 20-30%.

Through the above embodiment, the reason why the welding force of the inventive board described above, that is additive with the composition of the adhesive layer and the flame-retardant layer and the structure specific and enhanced on the basis of that road and insulation degree higher foaming of the expanded particles that could check

For reference, the flame-retardant insulation board according to the embodiment of the present invention is an eco-friendly insulation material that obtained the CE certification mart, which is the first European certification in Korea, where CE certification means that it can be freely sold and used within the European Union and European Free Trade Area. It corresponds to certification that indicates to consumers that safety standards and quality levels are satisfied.

Features, structures, effects, etc. exemplified in each of the above-described embodiments may be combined or modified for other embodiments by those of ordinary skill in the art to which the embodiments belong. Accordingly, the contents related to such combinations and modifications should be interpreted as being included in the scope of the present invention.

10 Bead Method 2 Type Insulation Bead
11 Expanded Particles Containing Carbon-Based Materials
12 adhesive layer
13 flame retardant layer
100 manufacturing equipment
110 blower
120 dryer
130, 160 ripening period
140 coating machine
150 Temperature gradient control means

Claims (15)

As an insulation bead for manufacturing an insulation board by molding and drying, and fusion to each other,
Expanded particles having a particle size of 0.1 to 0.8 ㎛, containing 1 to 15% by weight of expanded graphite having an aspect ratio of 100:1 or more, and having an average radius of t1 (mm);
an adhesive layer having a thin film thickness of t2 (mm) by coating the first adhesive to be foamed on the outer surface of the foamed particles; and
A flame retardant layer comprising a second adhesive foamed on the adhesive layer and a flame retardant comprising expanded graphite of 80 to 240 mesh and coated with a thickness t3 (mm) thicker than the t2 (mm);
The ratio of t1 and t2 + t3 is 1:0.0001 to 1:0.2,
When the average diameter of the insulating beads is s1 (mm) and the average diameter in the insulating board manufactured by fusion of the insulating beads to each other is s2 (mm), s2 ≥ s1 + s1 x 0.005. delete delete delete delete delete According to claim 1,
The raw material of the expanded particles is expanded styrene, an average diameter of 0.5 to 1.5 mm, and a thermal insulation bead having a maximum expansion ratio of 70 to 150 times. 8. The method of claim 7,
The first adhesive and the second adhesive are methylene diphenyl diisocyanate heat insulating beads. 9. The method of claim 8,
The insulating bead is an insulating bead having a density of 0.5 g/cm ³ or less. delete A board formed by coating foam particles, then molding and drying the insulating beads to be fused to each other,
The insulation bead,
expanded particles containing expanded graphite having a particle size of 0.1 to 0.8 μm and having an average radius of t1 (mm); and
an adhesive layer having a thin film thickness of t2 (mm) by coating the first adhesive to be foamed on the outer surface of the foamed particles; and
A flame retardant layer comprising a second adhesive foamed on the adhesive layer and a flame retardant comprising expanded graphite of 80 to 240 mesh and coated with a thickness t3 (mm) thicker than the t2 (mm);
The ratio of t1 and t2 + t3 is 1:0.0001 to 1:0.2,
When the average diameter of the insulating beads is s1 (mm), and the average diameter in the board manufactured by fusion of the insulating beads to each other is s2 (mm), s2 ≥ s1 + s1 x 0.005 flame-retardant insulation board . 12. The method of claim 11,
The flame-retardant insulation board has a flexural fracture load of 15N or more and a compressive strength of 5N/cm ² or more when measured according to KS M 3808:2011. delete delete delete

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