KR102440719B1 - Fireproof composite panel comprising high heat-resistant fiber and phenolic resin and manufacturing method thereof - Google Patents

Abstract

The present invention relates to a fire resistant composite panel comprising high heat resistant fiber and phenolic resin and a method for manufacturing the same. This is about a significant improvement.

Description

Fireproof composite panel comprising high heat-resistant fiber and phenolic resin and manufacturing method thereof

The present invention relates to a fire resistant composite panel comprising high heat resistant fibers and a phenolic resin and a method for manufacturing the same, and more particularly, to providing a fire resistant composite panel with improved heat resistance and heat insulation by using a phenolic resin and high heat resistant fiber. will be.

The present invention relates to a composite panel used as an interior material and a partition material for buildings, ships, aircraft, railway vehicles, and the like, and more particularly, to a composite sandwich panel.

The conventional panel mainly consists of a form in which a metal sheet is adhered to the surface of a core cured with a thermosetting resin such as urethane foam or styrene foam without a reinforcing material. This type of panel has been developed focusing on light weight for the purpose of promoting work convenience, but there is a weakness in that it does not guarantee safety against fire. As another type of panel, building panels in which glass fiber fabric coated with acrylic resin is reinforced on the surface of a substrate made of unsaturated polyester resin and sand are also available on the market, but these panels produce toxic gas, combustibility and It has high flame propagation and can increase the number of casualties.

As another type of panel, a material such as a gypsum board panel has excellent thermal insulation properties and low ignition and toxic gas generation in case of fire, but has disadvantages in that it is high in weight and weak against impact.

Under this background, the present inventors have made diligent efforts to solve the problems of the panels that have been used in the prior art. As a result, the water absorption rate, destruction, By confirming that it is possible to obtain a fire resistant composite panel with improved tensile strength, heat resistance and thermal insulation properties while meeting the physical property criteria of standard evaluation items such as strength, fracture parameter, abrasion resistance, temperature change resistance, stain resistance, and elastic limit value The present invention was completed.

Korean Patent Publication No. 10-2009-0067285 (published on: June 25, 2009)

One object of the present invention is to provide a method for manufacturing a fire resistant composite panel that is applicable to various fields with improved tensile strength, heat resistance and thermal insulation properties.

In the method for manufacturing a fire resistant composite panel of the present invention, a plurality of first high heat resistant fiber sheets coated with a compounding resin composition are laminated, or a second high heat resistant fiber sheet of a different type from the first high heat resistant fiber sheet is mixed with the compounded resin. Preparing a prepreg by laminating the composition with the first high heat-resistant fiber sheet coated; and laminating the prepreg and curing the prepreg through pressure heating.

Another object of the present invention is to provide a fire resistant composite panel with improved tensile strength, heat resistance and thermal insulation properties manufactured by the method for manufacturing a fire resistant composite panel according to the present invention.

This will be described in detail as follows. Meanwhile, each description and embodiment disclosed in the present invention may be applied to each other description and embodiment. That is, all combinations of the various elements disclosed herein fall within the scope of the present invention. In addition, it cannot be considered that the scope of the present invention is limited by the specific descriptions described below.

A first aspect according to the present invention for achieving the object of the present invention described above,

Preparing a blended resin composition comprising a phenol resin;

coating the first high heat resistant fiber sheet by applying the blended resin composition;

A plurality of first high heat resistant fiber sheets coated with the compounded resin composition are laminated, or a second high heat resistant fiber sheet of the same type or a different type from the first high heat resistant fiber sheet is coated with the compounded resin composition. manufacturing a prepreg by laminating with a high heat-resistant fiber sheet; and

After laminating the prepreg, it provides a method of manufacturing a fire resistant composite panel comprising the step of curing through pressure heating.

A second aspect of the present invention for achieving the above object provides a fire resistant composite panel manufactured by the manufacturing method of the first aspect described above.

According to the above-described aspect of the present invention, it is possible to manufacture a fire resistant composite panel having excellent tensile strength, heat resistance, and thermal insulation properties.

Hereinafter, the present invention will be described in more detail.

As used herein, the term "resin" is an amorphous solid or semi-solid composed of organic compounds and derivatives thereof, and is divided into natural resins and synthetic resins. Specifically, natural resins mainly refer to rubbers naturally produced in plants, and synthetic resins are synthetic polymers other than those used as fibers and rubbers, and are broadly divided into thermoplastic resins and thermosetting resins.

As used herein, the term "high heat resistant fiber" is a fiber that neither burns nor melts at high heat. As an organic polyamide-based synthetic fiber, it can withstand high heat of about 250°C without burning for a long time, and is distinguished from non-combustible fibers such as glass fiber and carbon-based fiber.

The high heat resistance fiber is aramid (Aramid), glass fiber stitch mat (Stitch mat), glass fiber fabric (Glass fabric), glass fiber continuous mat (Continuous Mat) and glass fiber nonwoven fabric (Glass paper) A group consisting of a combination thereof It may include one or more selected from, but is not limited thereto.

The aramid may be meta-aramid or a mixture of meta-aramid and para-aramid, but is not limited thereto.

As used herein, the term "high heat resistant fiber sheet" refers to a sheet woven in various patterns using high heat resistant fiber.

In the present invention, the high heat resistance fiber sheet may be a silane-treated glass fiber or a silane-treated phenol-type glass fiber, but is not limited thereto.

In the present invention, the high heat resistance fiber sheet may be a twill weave, a main weave, a plain weave, or a combination thereof.

As used herein, the term “prepreg” refers to a composite intermediate stage material in which a liquid synthetic resin such as an epoxy resin is infiltrated into a fiber reinforcement such as carbon fiber or glass fiber. Specifically, it is possible to obtain a molded article with excellent mechanical and thermal properties by applying appropriate heat and pressure to the prepreg.

Specifically, the prepreg may include one or more glass fibers selected from the group consisting of regular glass fibers, plain weave glass fibers, and twill glass fibers. More specifically, the prepreg may be to improve the tensile strength of the fire resistant composite panel by including the glass fibers.

The blended resin composition may include a resol-type phenolic resin, a novolak-type phenolic resin, aluminum hydroxide, a coupling agent, and calcium carbonate, but is not limited thereto.

As used herein, the term "phenolic resin" means that it has excellent heat resistance and combustion resistance as a rainy season material. Specifically, it may be produced by reaction of phenols and aldehydes.

As used herein, the term “resol-type phenolic resin” refers to a phenolic resin produced by reacting phenols and aldehydes using a base catalyst.

In the present invention, the resol-type phenolic resin included in the blended resin composition may have a nonvolatile content of 60 to 90% by weight, more preferably 75 to 85% by weight, but is not limited thereto.

The resol-type phenolic resin should be a viscous liquid due to the characteristics of the coating method, but it is preferable that a non-volatile component is present in order to meet favorable conditions for molding in the manufacturing process. When the non-volatile content is less than 60% by weight, the viscosity is lowered to deteriorate the moldability, and when it exceeds 90% by weight, the viscosity is increased, which may interfere with the moldability.

The resol-type phenolic resin may be a phenolic resin having an average molecular weight (weight average molecular weight) of 300 to 1700, preferably 500 to 1500, but is not limited thereto.

When the average molecular weight of the resol-type phenolic resin is less than 300, it may be difficult to form a suitable coating or coating layer on the sheet in the coating process due to the low viscosity of the resin and flowability. It may be difficult to ensure proper fluidity of In addition, when the average molecular weight of the resol-type phenolic resin is less than 300 or more than 1700, heat resistance (heat resistance) deterioration and strength reduction may occur.

As used herein, the term "novolak-type phenolic resin" means that it is formed by using an acid catalyst in a phenol resin produced by the reaction of phenols and aldehydes.

In the present invention, the novolak-type phenolic resin included in the blended resin composition may be a phenolic resin having an average molecular weight (weight average molecular weight) of 2,000 to 10,000, preferably 3,000 to 7,000, but is not limited thereto.

When the average molecular weight of the novolak-type phenolic resin is less than 2,000, it may be difficult to form a suitable coating or coating layer on the sheet in the coating process due to flowability due to the low viscosity of the resin. It may be difficult to ensure proper fluidity of the resin composition, and accordingly, it may be difficult to prepare a sheet coated with the compounded resin composition. In addition, when the average molecular weight of the novolac-type phenolic resin is less than 2,000 or more than 10,000, the bonding strength with the high heat-resistant fiber is lowered, which may adversely affect physical properties such as tensile strength.

In the present invention, the aluminum hydroxide included in the compounding resin composition may have a particle size of 4 to 15 μm, but is not limited thereto. If the particle size of the aluminum hydroxide is less than 4㎛, moldability may be difficult due to increase in the viscosity of the resin after compounding, and if it exceeds 15㎛, damage to the high heat-resistant fiber during molding and problems with resin mixing may occur.

In the present invention, the coupling agent may include an aqueous epoxy resin or a urethane resin, but is not limited thereto.

In the present invention, the calcium carbonate included in the blended resin composition may have a particle size of 1 to 50 μm, but is not limited thereto.

If the particle size of the calcium carbonate is less than 1 μm, the reaction may occur too quickly during the mixing process, resulting in a risk of explosion, etc., and if it exceeds 50 μm, problems such as precipitation due to residue may occur.

In the blended resin composition according to the present invention, the resol-type phenolic resin is 60 to 94% by weight, specifically 50 to 80% by weight, the novolak-type phenolic resin is 0.1 to 10% by weight, specifically 2 to 5% by weight, 5 to 30 wt% of aluminum hydroxide, specifically 10 to 20 wt%, 0.1 to 3 wt% of the coupling agent, 1 to 2 wt%, and 0.1 to 10 wt%, specifically 3 to 7 wt%, of calcium carbonate may be, but is not limited thereto.

When the content of the resol-type phenolic resin is less than 60% by weight or exceeds 94% by weight, heat resistance (flame retardancy) and strength may decrease.

When the content of the novolak-type phenolic resin is less than 0.1% by weight or exceeds 10% by weight, the bonding strength with the high heat-resistant fiber is lowered, and physical properties such as tensile strength may decrease.

When the content of aluminum hydroxide is less than 5% by weight or more than 30% by weight, the strength of physical properties may be lowered.

When the content of the coupling agent is less than 0.1% by weight, a problem of insufficient bonding between the fiber and the resin may occur, and when the content of the coupling agent exceeds 3% by weight, it may be meaningless for bonding between the fiber and the resin.

The content of calcium carbonate may be 0.1 wt% to 10 wt%. If it is less than 0.1% by weight, the uniformity of the surface may be deteriorated when coating the blended resin composition, and if it is more than 10% by weight, it may cause defects during the molding process due to a decrease in the strength of the fire resistant composite panel and an increase in the resin viscosity. .

If necessary, each content of the resol-type phenolic resin, novolak-type phenolic resin, aluminum hydroxide, coupling agent, and calcium carbonate can suggest a content range through heat release and gas hazard investigation, and the refractory composite of the present invention It may be presented in consideration of the physical properties of the panel.

In the method for manufacturing a fire resistant composite panel according to the present invention, the step of preparing the blended resin composition including the phenolic resin may be performed at 10° C. to 150° C. for 1 minute to 120 minutes, but is not limited thereto.

In the method for manufacturing a fire resistant composite panel according to the present invention, the coating step may be performed at a resin composition discharge rate of 10 kg/hr to 50 kg/hr, and at 100° C. to 170° C. conditions, but is not limited thereto.

In the method for manufacturing a fire resistant composite panel according to the present invention, the step of preparing the prepreg may be performed at 10° C. to 150° C. for 1 minute to 120 minutes, but is not limited thereto.

In the method for manufacturing a fire resistant composite panel according to the present invention, the curing step may be performed at a pressure of 1 to 50 MPa and a temperature of 130 to 180° C., but is not limited thereto. When the pressure in the curing step is less than 1 MPa or exceeds 50 MPa, the tensile strength may be lowered, and when the temperature is less than 130 ° C. and more than 180 ° C., gas is generated and molding may be difficult. The pressure and temperature may appropriately change the temperature conditions according to the number and state of the prepreg stacked.

In the fire resistant composite panel according to the present invention, the high heat-resistance fiber sheet can be manufactured by laminating a plurality of main weave fiber sheets and plain weave fiber sheets alone or by combining them.

As an example, the fire resistant composite panel according to the present invention stacks a plurality of twill fiber sheets, stacks a plurality of main weave fiber sheets, or a plurality of plain weave fiber sheets according to the required specifications such as thickness, strength, and fire resistance of the final product. Alternatively, a plurality of twill fiber sheets, a plurality of main weave fiber sheets, and a plurality of plain weave fiber sheets may be alternately laminated, or may be manufactured by laminating in a combination in a predetermined order. In the case of including the main weave fiber sheet compared to the case in which the main weave fiber sheet is not included, advantageous effects can be obtained in particular in terms of tensile strength, heat resistance, and thermal insulation properties, so for example, a main weave fiber sheet and a plain weave fiber sheet are provided. It may be desirable to laminate in a repeated pattern of weave, plain weave, plain weave, or pole type.

The manufacturing method of the fire resistant composite panel according to the present invention may be implemented by a horizontal coating method or a vertical coating method, but is not limited thereto.

Specifically, the coating method of the present invention may be selected from a vertical coating method or a horizontal coating method according to the viscosity of the resin and the state of the high heat-resistant fiber.

In one embodiment,

According to the present invention, the fire resistant composite panel can be manufactured by a horizontal coating method, a first unwinder capable of fixing and mounting a first high heat resistant fiber sheet, and a high heat resistant fiber mounted on the first unwinder. a first driving unit for moving the coating unit;

a coating unit for coating by applying the blended resin composition to the high heat-resistant fiber;

a drying unit for drying the first high heat resistant fiber sheet coated with the blended resin composition through the coating unit;

a second unwinder capable of fixing and mounting a second high heat resistant fiber sheet of the same type or a different type as the first high heat resistant fiber sheet;

a second driving unit for laminating the first high heat resistant fiber sheet transferred through the drying unit and the second high heat resistant fiber sheet transferred from the second unwinder to the first rewinder;

A first rewinder for constantly winding high heat-resistant fibers laminated only with the first high heat-resistant fiber sheet, or laminated with a first high heat-resistant fiber sheet and a second high heat-resistant fiber sheet; may be performed in a horizontal coating device comprising a However, the present invention is not limited thereto.

The horizontal coating device may be capable of controlling the resin in the comma coater of the coating unit, controlling the temperature of the drip tray for storing the resin, and having a plurality of second driving units performing a lamination function.

In one embodiment, the fire resistant composite panel according to the present invention may be manufactured by a vertical coating method, and may include: a third unwinder capable of fixing and mounting the first high heat resistant fiber sheet;

an impregnation unit for impregnating the first high heat-resistant fiber sheet transferred from the third unwinder into the blended resin composition;

a coating unit provided with double-sided rollers or double-sided knives for controlling the resin content of the first high heat-resistant fiber sheet impregnated in the impregnation unit;

a drying unit for drying the first high heat-resistant fiber sheet coated with the blended resin composition through the impregnating unit and the coating unit;

A third rewinder for constantly winding the first high heat-resistant fiber sheet dried in the drying unit; may be performed in a vertical coating device including, but is not limited thereto.

The vertical coating method is easy to change to the equipment of the impregnation part, for example, a double-sided knife or a double-sided roller, depending on the type, viscosity, etc. of the resin used during coating, and due to the long chamber length, it is easy to control the drying time in the drying part. can be advantageous

In addition, in the vertical coating method, the resin can be adjusted using a double-sided roller or a double-sided knife in the coating part, so the process is simpler than the horizontal coating method, and the coating thickness and uniformity of the resin can be maintained more consistently. It can be more economical because it can reduce the loss of

The fire resistant composite panel manufactured by the method for manufacturing a fire resistant composite panel of the present invention not only has excellent flame retardancy and heat resistance, but also can significantly improve the peeling phenomenon between the fiber and the resin, which has been a problem in the conventional fire resistant composite panel.

Through a specific embodiment of the present invention, a prepreg prepared using a blended resin composition containing a phenol-type resin and a novolak-type resin and a high heat-resistant fiber (main-woven fiber) is laminated and pressurized to heat a fire-resistant composite panel. When manufactured, it was confirmed that not only the tensile strength was improved, but also the flame retardancy and heat resistance were improved compared to the fire-resisting composite panel manufactured using the existing general glass fiber (plain weave, twill weave) and general resin.

The fire-resistance composite panel that can be applied to various uses according to the effect and manufacturing method of using high heat-resistant fiber and phenolic resin to solve the problems of flame retardancy, heat resistance, and peeling between raw materials and materials of the conventional composite panel of the present invention can provide

1 is a schematic view showing a fire resistant composite panel of the present invention.
Figure 2 is a schematic diagram showing the horizontal coating method of the present invention.
3 is a schematic view showing the vertical coating method of the present invention.
4 is a graph showing the physical properties of the fire resistant composite panel of Example 2.
5 is a graph showing the physical properties of the fire resistant composite panel of Comparative Example 1.
6 is a graph showing the average value of tensile strength according to each pressure during curing of the fire resistant composite panels of Comparative Examples 2-1 to 2-3.
7 is a graph showing the average value of tensile strength according to each pressure during curing of the fire resistant composite panels of Examples 4-1 to 4-3.

Hereinafter, the present invention will be described in more detail through examples. These Examples are for explaining the present invention in more detail, and the scope of the present invention is not limited by these Examples.

Preparation Example 1: Blended resin composition

60 to 94 wt.% resol-type phenolic resin (weight average molecular weight: about 500 to 1500), 0. to 10 wt.% novolac phenolic resin (weight average molecular weight: about 3,000 to 7,000), 5 to 30 wt.% hydroxide Aluminum, 0.1 to 10 wt.% calcium carbonate, and 0.1 to 3 wt.% coupling agent were mixed using a stirrer at room temperature to prepare a compounded resin composition.

Preparation Example 2: Preparation of prepreg

Fig. 2 shows a horizontal coating method for manufacturing a prepreg. Referring to FIG. 2 , a release substrate (release paper or film) and a fiber sheet were placed on the first unwinder of the horizontal coating machine.

The release substrate and the fiber sheet were moved to pass through the roller, and when passing the comma coater of the coating part of the horizontal coater, the blended resin composition was coated on the fiber sheet.

The coated fiber sheet was allowed to dry through the chamber.

The dried fiber sheet was laminated with the same type or different type of fiber sheet (the second high heat resistant fiber sheet) mounted on the second unwinder and the second driving unit of the horizontal coating machine.

The laminated fiber sheet was rewound in a first rewinder to prepare a prepreg.

The prepared prepreg was laminated in a predetermined lamination order according to the target product, and the laminated prepreg was cured by pressing (5 to 40 MPa) and heating (90 to 150° C.) while increasing the temperature sequentially in a hot press.

Example 1: Fireproof composite panel for fire door skin

Glass fiber (main weave), glass fiber mat (plain weave), glass fiber mat (plain weave), and glass fiber (main weave) were laminated in the order of the prepreg prepared in Preparation Example 2, and pressurized in a hot press (5 to 40 MPa) ) and heating (90 to 150° C.) while increasing the temperature sequentially, the laminated prepreg was cured.

The cured prepreg was cut into a fire-resistant composite panel for the skin of a fire door. Then, a fire door was manufactured by attaching the prepreg cut on both sides to the skin foam for the fire door.

Example 2: Manufacture of fire resistant composite panel for reinforcement

Using the same method as in Preparation Example 2, by laminating a main weave glass fiber, a plain weave glass fiber, a plain weave glass fiber, and a main weave glass fiber in order to form a thickness of 1T, and on it, a main weave glass fiber, a plain weave glass fiber, a plain weave After laminating glass fibers and main weave glass fibers to form a thickness of 2T, laminated glass fibers, plain weave glass fibers, plain weave glass fibers, and main weave glass fibers in this order to prepare a 3T thick fire resistant composite panel for reinforcing materials.

In addition to general plain weave glass fibers or twill glass fibers, main weave glass fibers were combined and used together with a resin composition comprising a phenol type resin and a novolak type resin to prepare a fire resistant composite panel for reinforcement of the present invention.

Comparative Example 1: Manufacture of general fire resistant composite panel

A fire resistant composite panel for reinforcing material with the same thickness as the fire resistant composite panel of Example 2 was manufactured using plain weave glass fiber and twill glass fiber without the main weave glass fiber.

Test Example 1: Measurement of Tensile Strength

The tensile strength of the fire-resistance composite panel including the main-woven glass fiber according to Example 2 and the fire-resistance composite panel according to Comparative Example 1 without the main-woven glass fiber was measured through a uniaxial compression test according to ASTM D3039 standard and compared did.

Tensile strength measurement result of fire resistant composite panel Tensile strength (MPa) Example 2 408-419 Comparative Example 1 220-250

As shown in Table 1, it can be seen that Comparative Example 1 corresponding to the conventional fire resistant composite panel has a tensile strength of around 200 MPa, and Example 2 prepared according to the present invention exceeds 400 MPa. Therefore, it can be confirmed that Example 2 prepared by the manufacturing method of the present invention provides improved tensile strength, including the main woven glass fiber, and can be used in various fields ( FIGS. 4 to 5 ).

Test Example 2: Measurement of physical properties according to the content of novolak-type phenolic resin

In the blended resin composition according to Preparation Example 1, a novolak-type phenolic resin; In order to confirm the effect on the tensile strength according to the content of the weight average molecular weight of 3,000 to 7,000, a blended resin composition was prepared by varying the content of the novolak-type phenolic resin, and the tensile strength was increased by preparing a prepreg according to Preparation Example 2 measured. At this time, the tensile strength was measured through a uniaxial compression test according to ASTM D3039 standard, and a resol-type phenolic resin having a weight average molecular weight of about 1,000 was used.

Measurement result of physical properties according to the content of novolac-type phenolic resin Tensile strength (MPa)
Novolac type phenolic resin unadded 3% added 6% added Example 3-1 769 895 811 Example 3-2 743 914 839 Example 3-3 759 839 813 Example 3-4 787 918 759 Example 3-5 684 883 747 Average 748.4 889.8 793.8

As shown in Table 2 above, the addition of the novolak-type phenolic resin (phenolic resin having a molecular weight of 3,000 to 7,000) applied to the present invention is UD (Uni-Directional: glass fiber in uniaxial direction by pultrusion method) used as a reinforcing material It has been verified through testing of FRP (Fiber Glass Reinforced Plastics: a molding method hardened by laminating reinforced plastics) of a fiber structure. It was confirmed that the physical properties increased when the novolac resin was added by increasing the binding force of the high heat-resistant fibers as the solid content of the fire-resistant composite panel increased due to the addition of the novolac-type phenolic resin compared to the non-added novolac-type phenolic resin.

Comparative Example 2: Manufacturing of fire resistant composite panel including CM

A continuous mat (CM) made of plain weave glass fibers and glass filaments as a fiber sheet without main weave glass fibers was composed of several layers of randomly oriented continuous fiber sheet layers, laminated, and cured in Comparative Example 2-1 to Comparative Examples 2-3 were prepared fire-resistance composite panels.

Test Example 3: Measurement of tensile strength according to pressure during curing

Manufactured according to Preparation Example 2, but as a fiber sheet, a plurality of plain weave glass fiber sheets and main weave glass fiber sheets were laminated to the thickness of a general fire resistant composite panel for tunnel reinforcement, and then cured, and then cured. 1 to Example 4-3, and the average value of the tensile strength according to the pressure during curing was measured according to ASTM D3039 standard.

The tensile strength 3 MPa pressure when curing the product 30 MPa pressure when curing the product 50 MPa pressure when curing the product Comparative Example 2-1 187 215 215 Comparative Example 2-2 216 223 197 Comparative Example 2-3 216 223 223 Comparative Example 2 Average 206.3 220.3 211.6 Example 4-1 401 423 407 Example 4-2 395 428 411 Example 4-3 426 437 410 Example 4 Average 407.3 429.3 409.3

As shown in Table 3, the tensile strength according to the pressure in the step of curing the fire resistant composite panel can be confirmed. When the fire-resistance composite panel is cured at a low pressure of 1 to 3 MPa, the impregnation of the high heat-resistant fiber is not completely made, which can cause peeling of each prepreg, and curing the fire-resistant composite panel at a high pressure exceeding 50 MPa In this case, the resin of the prepreg flows out due to the high pressure (Overflow), which also causes peeling, which may cause problems. Therefore, it is confirmed that the pressure of the step of curing the fire resistant composite panel of the present invention is best performed at 30 MPa. In addition, the tensile strength comparison results of Comparative Examples 2-1 to 2-3 and Examples 4-1 to 4-3 in Table 3, Comparative Examples 2-1 to 2-3 compared to Examples 4-1 to Examples It was confirmed that 4-3 provided improved tensile strength by including the plain glass fibers ( FIGS. 6 and 7 ).

Test Example 5: Heat resistance test result

As a result of heating the specimen of Comparative Example 1 and the specimen of Example 2 to a temperature of 200° C. in a closed space, the specimen of Example 2 started to ignite after about 400 seconds, but in the case of Comparative Example 1, about 60 seconds passed was then ignited. In the specimen of Comparative Example 1, an unpleasant odor was rapidly and strongly generated as compared to that of Example 2.

Test Example 6: Thermal insulation test result

After attaching the specimen of Comparative Example 1 and the specimen of Example 2 to the opening between the heating box and the low-temperature chamber, the internal temperature of the heating box was set to about 200 ° C. Measurements were made three times at intervals to obtain an average value. Compared to Comparative Example 1, the average value of Example 2 was low, and it was confirmed that the thermal insulation property was excellent.

In summary, according to the present invention, by applying a high heat-resistance fiber sheet coated with a compound resin composition containing a phenol resin to a fire-resisting composite panel, without the problem of peeling of the conventional fiber sheet and the coating layer, the tensile strength limit is overcome, and Heat and heat resistance can be improved.

From the above description, those skilled in the art to which the present invention pertains will be able to understand that the present invention may be embodied in other specific forms without changing the technical spirit or essential characteristics thereof. In this regard, it should be understood that the embodiments described above are illustrative in all respects and not restrictive. The scope of the present invention should be construed as being included in the scope of the present invention, rather than the above detailed description, all changes or modifications derived from the meaning and scope of the claims described below and their equivalents.

Claims (18)

preparing a blended resin composition containing a phenolic resin;
applying a blended resin composition to the first high heat-resistant fiber sheet and coating in a horizontal coating method;
A plurality of first high heat resistant fiber sheets coated with the blended resin composition are laminated, or a second high heat resistant fiber sheet of a different type from the first high heat resistant fiber sheet is coated with the blended resin composition, the first high heat resistant fiber Preparing a prepreg by laminating the sheet; and
After laminating the prepreg, comprising the step of curing through pressure heating,
The horizontal coating method includes: a first unwinder capable of fixing and mounting a first high heat-resistant fiber sheet; a first driving unit for moving the high heat resistant fiber sheet mounted on the first unwinder to the coating unit; a coating unit for coating by applying the compounded resin composition to a high heat-resistant fiber sheet; a drying unit for drying the first high heat resistant fiber sheet coated with the blended resin composition through the coating unit; a second unwinder capable of fixing and mounting a second high heat resistant fiber sheet of the same or different type as the first high heat resistant fiber sheet; The first high heat-resistance fiber sheet coated with the blended resin composition transferred through the drying unit is laminated, and the first high heat-resistance fiber sheet coated with the blended resin composition and the second high heat-resistant fiber sheet transferred from the second unwinder are laminated. a second driving unit for laminating heat-resistant fiber sheets and transferring them to the first rewinder; A first rewinder for constantly winding high heat resistant fibers laminated with only the first high heat resistant fiber sheet coated with the blended resin composition, or laminated with the second high heat resistant fiber sheet and the first high heat resistant fiber sheet coated with the blended resin composition ; A method for manufacturing a fire-resistant composite panel that is carried out in a horizontal coating device comprising a.
preparing a blended resin composition containing a phenolic resin;
applying a blended resin composition to the first high heat-resistant fiber sheet and coating in a vertical coating method;
A plurality of first high heat resistant fiber sheets coated with the blended resin composition are laminated, or a second high heat resistant fiber sheet of a different type from the first high heat resistant fiber sheet is coated with the blended resin composition, the first high heat resistant fiber Preparing a prepreg by laminating the sheet; and
After laminating the prepreg, it is a method of manufacturing a fire resistant composite panel comprising the step of curing through pressure heating,
The vertical coating method includes: a third unwinder capable of fixing and mounting the first high heat-resistant fiber sheet; an impregnation unit for impregnating the first high heat-resistant fiber sheet transferred from the third unwinder into the blended resin composition; a coating unit provided with double-sided rollers or double-sided knives for controlling the resin content of the first high heat-resistant fiber sheet impregnated in the impregnation unit; a drying unit for drying the first high heat-resistant fiber sheet coated with the blended resin composition through the impregnating unit and the coating unit; A method for manufacturing a fire resistant composite panel comprising a; a third rewinder for constantly winding the first high heat resistant fiber sheet dried in the drying unit.
3. The method of claim 1 or 2,
The compounding resin composition is a resol-type phenolic resin, a novolak-type phenolic resin, aluminum hydroxide, a coupling agent and a method of manufacturing a fire resistant composite panel comprising a calcium carbonate.
4. The method of claim 3,
The blended resin composition contains 60 to 94% by weight of the resol-type phenolic resin, 0.1 to 10% by weight of the novolak-type phenolic resin, 5 to 30% by weight of the aluminum hydroxide, and 0.1 to 3% by weight of the coupling agent and 0.1 to 10% by weight of the calcium carbonate, the method for producing a fire resistant composite panel.
4. The method of claim 3,
The resol-type phenolic resin has an average molecular weight of 300 to 1700 phenolic resin, a method of manufacturing a fire resistant composite panel.
4. The method of claim 3,
The resol-type phenolic resin has a nonvolatile content of 60 to 90% by weight, a method of manufacturing a fire resistant composite panel.
4. The method of claim 3,
The novolak-type phenolic resin has an average molecular weight of 3,000 to 7,000 phenolic resin, a method of manufacturing a fire resistant composite panel.
4. The method of claim 3,
The aluminum hydroxide is to have a particle size of 4 to 15㎛, a method of manufacturing a fire resistant composite panel.
4. The method of claim 3,
The coupling agent is an aqueous epoxy resin, or a method of manufacturing a fire resistant composite panel comprising a urethane resin.
4. The method of claim 3,
The method for producing a fire resistant composite panel, the calcium carbonate having a particle size of 1 to 50㎛.
3. The method of claim 1 or 2,
The high heat resistance fiber is aramid (Aramid), glass fiber stitch mat (Stitch mat), glass fiber fabric (Glass fabric), glass fiber continuous mat (Continuous Mat) and glass fiber nonwoven fabric (Glass paper) A group consisting of a combination thereof A method of manufacturing a fire resistant composite panel comprising at least one selected from
12. The method of claim 11,
The aramid is meta-aramid or meta-aramid and a mixture of para-aramid, a method of manufacturing a fire-resistant composite panel.
3. The method of claim 1 or 2,
The first high heat-resistant fiber sheet is made of a silane-treated glass fiber or a silane-treated phenolic glass fiber, a method of manufacturing a fire resistant composite panel.
3. The method of claim 1 or 2,
The prepreg is a method of manufacturing a fire resistant composite panel comprising one or more glass fibers selected from the group consisting of main glass fibers, plain weave glass fibers, and twill glass fibers.
3. The method of claim 1 or 2,
The curing step is performed at a pressure of 1 to 50 MPa and a temperature of 130 to 180 ℃, the method for producing a fire resistant composite panel.
A fire resistant composite panel manufactured by the manufacturing method of claim 1 or 2. delete delete

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