KR102521669B1 - Sandwich panel and method for producing the same - Google Patents

Abstract

One aspect of the present invention provides a sandwich panel which comprises: a core material which includes an insulating material; a first plate material which contains a polymer provided on one side of the core material; a second plate material which includes a polymer provided on the other side of the core material; at least one scratch groove which is provided on a surface where the first plate material and the second plate material are attached to the core material; and an adhesive layer which is provided between the core material, and the first plate material and the second plate material, and is provided inside the scratch groove.

Description

Sandwich panel and method for producing the same {Sandwich panel and method for producing the same}

One aspect of the present invention relates to a sandwich panel and a manufacturing method thereof, and more particularly, to a sandwich panel having excellent chemical resistance and a manufacturing method capable of continuously manufacturing the same.

A sandwich panel is a building material used for prefabricated buildings, and is generally referred to as a panel. In general, it is composed of a pair of steel plates, and the inside of the pair of steel plates is filled with insulating materials such as Styrofoam, urethane, glass wool, and mineral wool as an inner material to supplement the insulation problem of metal materials as building materials.

Sandwich panel is easy to use because it is easy to finish the construction with a simple process because the insulation material is integrally included, and it is easy to manufacture because it is easy to produce in large quantities. It is widely used in architecture.

On the other hand, as in general buildings, sandwich panels are mainly used as building materials for roofs, walls, floors, etc. in livestock pig houses. It is characterized by the generation of a lot of highly corrosive chemicals, so when using a sandwich panel surrounded by a conventional metal plate, corrosion and deterioration occur on the surface, reducing the lifespan of the building and increasing the risk of collapse. There has been a problem of low usability.

In particular, when a metal material with high thermal conductivity and low specific heat is used for the purpose installed inside the pig house, it is difficult to manage the internal temperature according to the external temperature during the day and night, and the temperature deviation is severe depending on the location even inside the pig house. there is

Republic of Korea Patent Publication No. 10-2017-0140111

Sandwich panel according to one aspect of the present invention is excellent in chemical resistance and corrosion resistance, particularly resistance to ammonia and methane, to provide a sandwich panel having excellent chemical resistance even in an environment where corrosive gases such as ammonia or methane gas exist The purpose.

An object of the present invention is to provide a sandwich panel capable of solving the problem of rapid deterioration in adhesive strength between a sheet material and a core material due to penetration of moisture (steam) into the adhesive layer between the core material.

In addition, an object of the present invention is to provide a sandwich panel that has high specific heat, increases constant temperature in the room without using a separate insulating foam, and is easy to clean because of a smooth surface.

In addition, an object of the manufacturing method of a sandwich panel according to another aspect of the present invention is to provide a manufacturing method capable of continuously producing a sandwich panel having chemical resistance and corrosion resistance.

Sandwich panel according to one aspect of the present invention,

A core material containing an insulator;

A first plate member including a polymer provided on one side of the core member;

a second plate material including a polymer provided on the other surface of the core material;

at least one or more scratch grooves provided on surfaces where the first plate member and the second plate member are attached to the core member; and

It is characterized in that it comprises an adhesive layer provided between the core material, the first plate material and the second plate material, and inside the scratch groove.

At this time, it is preferable that the sandwich panel has a rectangular shape, and that the scratch grooves are continuously formed in a longitudinal direction from one short side to the other short side.

In addition, the width:length ratio of the scratch groove is preferably 1:1 to 1:2.

In addition, the scratch groove preferably has a width of 0.1 to 0.2 mm and a depth of 0.1 to 0.4 mm.

In addition, the first plate material and the second plate material preferably have specific heats of 1.0 to 1.5 J/g·K.

In addition, it is preferable that the first plate and the second plate have a thickness of 1.5 to 2.0 mm and a diameter of 20 cm to 70 cm.

In addition, the first material constituting the first plate member preferably has a flexural modulus of 2.0 to 2.5 GPa as measured by the ASTM D790 test method.

In addition, the polymer preferably includes a phenol-based polymer or a phenol-based copolymer resin synthesized by including bisphenol A as a monomer.

In addition, the first material,

With the polymer,

It may include at least one selected from the group consisting of bakelite, polyurethane, ethylene propylene, chloroprene, and butyl rubber.

A method for manufacturing a sandwich panel according to another aspect of the present invention,

A first and second plate preparation step of preparing a first plate and a second plate including a polymer having a thickness of 1.5 to 2.0 mm by winding them into a roll having a diameter of 20 cm to 70 cm, respectively;

A core material preparation step of preparing a core material including an insulating material;

a supply step of transferring the core material, the first plate material, and the second plate material;

Forming a scratch groove on at least one of the surfaces of the first and second plates to be in close contact with the core;

An adhesive liquid spraying step comprising spraying an adhesive liquid on at least one surface of the first plate material and the second plate material that are continuously supplied;

An adhesive layer forming step in which the sprayed adhesive liquid forms an adhesive layer between the plate materials and the core material and in the scratch groove; and

It is characterized in that it includes a bonding step of bonding the first plate material to one surface of the core material, and bonding the second plate material 30 to the other surface of the core material 20.

At this time, the scratch groove is preferably formed continuously along the longitudinal direction in which the first plate material or the second plate material is supplied.

In addition, the first material constituting the first plate material and the second plate material is preferably prepared by mixing a masterbatch containing a polycarbonate-based resin with the polymer.

In addition, the master batch,

At least one selected from the group consisting of calcium carbonate, talc, talc, silica, alumina, bakelite, carbon nanotube (CNT), graphene, whisker, glass bubble, carbonate silane coupling agent, and polyethylene wax and stearate It is preferable to further include a functional additive containing a.

In addition, the functional additive is preferably included in 3 to 20% by weight of the total amount of the masterbatch.

As described above, the sandwich panel according to one aspect of the present invention has an advantage of high durability because it is not corroded by chemical gases such as ammonia by using a material having excellent chemical resistance and corrosion resistance for the plate material.

In addition, the method for manufacturing a sandwich panel according to another aspect of the present invention uses a polymer material having a bending property that can be formed and supplied in a roll form, so that a continuous process and production equipment can be utilized. There is an effect of increasing the manufacturing productivity of the panel.

In addition, the sandwich panel according to one aspect of the present invention includes a polymer material having a low weight or specific gravity compared to conventional materials, and thus has sufficient strength to perform the supporting function of the structure while being lightweight, and has excellent strength to weight ratio. there is

In addition, since the sandwich panel according to one aspect of the present invention is located inside the building during construction, both the first and second plates use a material containing a polymer, and have a high specific heat and low thermal conductivity compared to metal-based materials, so the internal It has the advantage of having good constant temperature to keep the temperature constant, and has the advantage of cleaning or managing the inside because there is no need to form a separate insulation layer or insulation foam coating on the inner surface.

In addition, the sheet material of the sandwich panel according to one aspect of the present invention has a thicker thickness than the conventional metal sheet material, so that the heat capacity can be increased, and the time for operating the electric heater to maintain constant temperature can be reduced, thereby reducing power consumption.

Even if the effects are not explicitly mentioned here, the effects described in the following specification expected by the technical features of the present invention and their provisional effects are treated as described in the specification of the present invention.

1 is a perspective view showing the structure of a sandwich panel according to an embodiment of the present invention.
Figure 2 is a diagram schematically showing the ASTM D790 test method.
3 is a process chart showing a manufacturing process of a sandwich panel according to an aspect of the present invention.
4 is a simplified view of a manufacturing apparatus according to an embodiment of the present invention.
5 is a structural diagram of a scratch groove forming unit in a manufacturing apparatus according to an embodiment of the present invention.
6 is an operation diagram illustrating a state in which scratch grooves are formed in a zigzag pattern on a plate by the manufacturing apparatus according to an embodiment of the present invention.
7 is a structural diagram of an embodiment of a needle assembly according to an embodiment of the present invention.

Hereinafter, a sandwich panel 1 and a manufacturing method thereof according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings. This invention may be embodied in many different forms and is not limited to the embodiments set forth herein.

Prior to describing the present invention in detail below, it is understood that the terms used herein are intended to describe specific embodiments and are 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 a person of ordinary skill in the art unless otherwise specified.

Throughout this specification and claims, the terms "comprise", "comprise" and "comprising", unless stated otherwise, are meant to include a stated object, step or group of objects, and steps, and any other object However, it is not used in the sense of excluding a step or a group of objects or a group of steps.

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

In the drawings, the width, length, thickness, etc. of components may be exaggerated for convenience. When describing the drawings as a whole, it is described from the observer's point of view, and when one component is said to be "above/below" or "above/below" another component, this is not only the case of being "directly above/below" another component. , including the case where there is another component in the middle.

<First aspect>

Sandwich panel 1 according to one aspect of the present invention includes a first plate 10, a second plate 30, and a core 20 positioned between the first plate 10 and the second plate 30. It is a sandwich panel (1) including. 1 is a perspective view showing the structure of a sandwich panel according to an embodiment of the present invention.

The first plate member 10 is a wide plate member formed by being contacted at one side of the core member 20 or laminated on the core member 20 and made of a first material. To support the structure of the sandwich panel 1, it is preferable to use a material with excellent mechanical properties such as strength, durability, and scratch resistance for the first plate material 10, and it is mainly used in pigs, livestock barns, and chemicals. A material with excellent chemical resistance and corrosion resistance to chemicals such as methane, ammonia or amine so that it can be used as a structural material or interior/exterior material for buildings such as factories or warehouses, especially for interior partitions or hollow ceilings It is preferable to use

For example, the first plate 10 is a polymer resin-based material that has better chemical resistance and less corrosion than conventionally used steel plates, stainless alloys, or other metal materials for structural materials, which is used as a first material. Preferably, the polymer resin may include a phenol-based polymer or a phenol-based copolymer resin synthesized by including bisphenol A as a monomer, and for example, a polycarbonate-based resin is preferably used as the first material. .

More specifically, when a polycarbonate-based resin is used as the first material, 4,4'-dihydroxydiarylalkane-based polycarbonate, particularly a phosgene method of reacting bisphenol A and phosgene or bisphenol A and diphenyl carbonate A bisphenol A-based polycarbonate obtained by a transesterification method in which a diester carbonate is reacted is preferably used.

In addition, a part of bisphenol A is substituted with 2,2-bis(4-hydroxy-3,5-dimethylphenyl)propane or 2,2-bis(4-hydroxy-3,5-dibromophenyl)propane Modified bisphenol A-based polycarbonates and flame retardant bisphenol A-based polycarbonates can also be used.

In the case of using an organic material such as a polymer resin instead of a metal material for the first plate 10, chemical resistance or corrosion resistance can be easily obtained, but the polymer resin lacks ductility or malleability compared to metal and is difficult to mold. There may be problems in continuous production, and the strength to support the structure may be insufficient.

When the first material according to the present invention is used as the first plate member 10, it is possible to provide a sandwich panel 1 capable of substituting conventional materials with mechanical characteristics to be described later.

First, it is preferable that the first material is manufactured and introduced in a roll form in order to be applied to the continuous sandwich panel 1 production process.

At this time, the first material constituting the first plate member 10 has a low flexural modulus and flexural strength, so that it can be flexibly bent when a bending force is applied, and can be returned to its original state or easily stretched by elastic deformation, so that it can be rolled in a roll form. It is preferable that it is a material having the characteristic of being able to be wound.

In the process of manufacturing the first plate 10, the first material is provided in a rolled state in the form of a roll, so that the sandwich panel of the present invention is continuously utilized by using the existing manufacturing method and manufacturing apparatus of the sandwich panel (1) ( 1) can be manufactured, which means that the flexural strength and flexural modulus of general polymer resin materials are higher than materials such as steel plates, or the material is difficult to stretch again after being bent, which is difficult to supply and use as a raw material in a rolled state. It has a difference in that it solves the point and can be utilized in the form of a roll.

In this specification, flexural strength means the strength that a material can withstand when flexural pressure is applied. A test piece having a rectangular cross section is placed on a support and a load is applied to the center of the test specimen between the two supports to bend it. It can be tested by measuring the load applied to the test piece by applying a load at a constant rate until it reaches 5% or external rupture occurs, for example, it can be measured through the three-point bending test of ISO 178 or ASTM D790. It may be used, and preferably, the ASTM D790 test method may be used.

In addition, in the present specification, the flexural modulus is a mechanical property that evaluates the degree of resistance to bending or stiffness of a material, and is a value obtained by dividing stress by deformation amount for a load applied in a vertical direction to a flat material, When a graph of strain against material stress is shown, it can be calculated as the slope of the initial straight line section. In general, the higher the flexural modulus of a material is, the more difficult it is to bend the material.

The flexural modulus may be measured through a three-point flexure test of ISO 178 or ASTM D790, and in one embodiment, the flexural modulus of the material was measured using the ASTM D790 test method.

Specifically, according to a preferred embodiment of the present invention, the first plate material 10 manufactured from the first material characterized in that the flexural modulus and flexural strength are lower than a specific value preferably has a flexural modulus of 2.0 to 2.5 GPa, 2.1 to 2.47 GPa, 2.2 to 2.43 GPa, preferably 2.25 to 2.40 GPa, more preferably 2.3 to 2.39 GPa. If the flexural modulus of the first plate 10 is higher than the corresponding range, it is difficult to wind it in a roll form. In particular, when winding close to the core of the roll, the bent first plate 10 in a portion with a small radius of curvature is irreversibly deformed or has physical properties. Problems such as deterioration and cracking may occur.

In addition, the first plate member 10 preferably has a flexural strength of 90 to 120 MPa, 93 to 117 MPa, 95 to 115 MPa, preferably 97 to 110 MPa, and more preferably 98 to 106 MPa. When the flexural strength of the first plate 10 is higher than the corresponding range, it becomes difficult to wind the first plate 10 in a roll form as in the case where the flexural modulus is high. Problems such as irreversible deformation of the first plate 10, deterioration of physical properties, and occurrence of cracks may occur.

Due to the bending characteristics of the first plate 10, the first plate 10 may be wound on a roll having a diameter of 20 to 70 cm, for example, a diameter of 30 to 60 cm, preferably a diameter of 45 to 55 cm. has the advantages of

Second, the first material needs to be a material that can support the entire structure and can withstand external impact, for example, it is preferable to have excellent IZOD impact strength.

Izod impact strength is an item tested according to test standards ASTM D 256, KS M ISO 180, ISO 180, etc., and is a test that evaluates the degree of toughness and brittleness of a material by applying an impact load to a material specimen, using a hammer on the specimen The resulting value is the height at which the hammer bounces when it is destroyed by impact, and it is calculated by dividing the energy absorbed by the sample by the cross-sectional area and expressed in J/m.

Izod impact strength is mainly used as a test applicable to various materials such as unfilled compounds, filled or reinforced compounds, molded and extruded materials, sheets, films, mats, fabrics, and reinforcing materials.

In the case of the above-mentioned first material, it is preferable that the impact strength is 650 to 900 J/m as measured by ASTM D256-10, and 700 to 900 J/m so that it can withstand impact and withstand sufficient force to support the structure. m, preferably 705 to 900 J/m, 708 to 900 J/m or more.

If the impact strength of the first material is lower than the corresponding weight, it does not have sufficient resistance to external impact, so problems such as difficulty in performing the support function of the structure or reduction in lifespan due to impact may occur.

Thirdly, the first material is preferably lighter than a conventional metal material, which is advantageous for weight reduction and has excellent physical properties. For example, it is preferable to have a high specific strength representing strength per unit mass.

As the specific strength is higher, it is possible to obtain a strong support structure and strength while lowering the weight of the sandwich panel 1, so that production and construction are advantageous, so economic efficiency can be increased. Preferably, the specific strength of the first material is preferably 45,000 to 60,000 Nm/kg, preferably 50,000 to 60,000 Nm/kg, and preferably 52,000 to 56,000 Nm/kg.

In the case of polycarbonate resin usable as the first material, yield strength is about 62.1 MPa, and the density of polycarbonate is 0.00119 g/mm ³ . (The volume of 27.6 g of polycarbonate is 23224.4 mm ³ ) The value of specific strength calculated by dividing the yield strength by the density is about 56,883 m/kg, which is included in the specific strength range.

If the value of the specific strength is lower than the corresponding range, it is necessary to use a heavier and thicker first plate 10 to obtain the same strength or physical properties, so there is a problem in that production efficiency decreases and construction efficiency using the product decreases. .

Additionally, the first material according to one embodiment has a flexural strength of 106 MPa or less, measured by the ASTM D790 test method, and an excellent flexural modulus of 2,39 GPa or less, so that it can be formed in a roll form. Despite this, the tensile strength measured by the ASTM D638-14 test method is as strong as 70,4 MPa, and has self-extinguishing properties, so it has the advantage of being good for use as a plate material for sandwich panels (1).

Meanwhile, the first plate 10 may be manufactured by adding additional additives to the first material, and a master batch is added to impart color or other additional functionality to the first plate 10. It can be.

Specifically, after uniformly dispersing fillers or additives in the polymer resin and preparing a master batch containing the fillers or additives to make the physical properties of the product uniform, the concentration and amount of the master batch are calculated to polymerize the polymer. It is preferable to prepare a first material having a desired composition by adding it to a resin.

On the other hand, in the case of using a polycarbonate-based resin as the first material of the first plate member 10. It has excellent releasability on the surface, so it is not contaminated well, and it has the advantage that it can be easily removed even when contaminants are on the surface.

Due to the above characteristics of the first material, the first plate 10 may not require a separate coating or film to improve releasability or contamination resistance on the surface, but the first plate 10 Since it is integrally formed without including an interface or a laminated structure inside, it has the advantage of being able to clean the surface using a high-pressure washer, etc. It can save a lot of operating cost.

When using a masterbatch, it has the advantage of being able to customize the product while adjusting the desired color or product characteristics, and the color masterbatch used to obtain the desired color and the functional masterbatch used to impart special functions can be used. can

More specifically, as the functional masterbatch, a flame retardant masterbatch that improves flame retardancy, an antistatic masterbatch that can prevent static electricity, a slip masterbatch that prevents adhesion between materials, and an antibacterial masterbatch that has antibacterial properties can be used. can

The first plate material 10 used in the sandwich panel 1 according to an embodiment of the present invention is manufactured from a first material manufactured using a masterbatch, and it is possible to use a color masterbatch, but the color is limited. It is preferable to include a functional masterbatch capable of improving the flexural modulus and flexural strength so that it can be used as a sheet material for the sandwich panel (1) by being rolled up in a roll form and then flattened.

In the sandwich panel (1) according to one aspect of the present invention, it is preferable that the master batch introduced into the first material is made of polycarbonate, and a master batch having an opaque or bright color that can reduce temperature change through heat reflection is used. is also desirable

On the other hand, at this time, functional additives included in the master batch include calcium carbonate, talc, talc, silica, alumina, bakelite, carbon nanotube (CNT), graphene, whisker, glass bubbles, carbonate silane coupling agent and polyethylene At least one selected from the group consisting of wax and stearate may be used.

When one or more of calcium carbonate, talc, talc, silica, alumina, bakelite, whisker, or glass bubble is used, the flexural modulus and flexural strength can be improved by being mixed with a polymer material, and the chemical resistance and corrosion resistance can be improved. can be obtained

When carbon nanotubes or graphene are included, there are advantages in that moisture resistance and corrosion resistance are improved, and flexural modulus and flexural strength are also improved, and when a carbonate silane coupling agent is used, flexural modulus can be improved, and polyethylene wax and stearic acid Moisture resistance and chemical resistance can be improved when salt is included.

The content of the additive may be 3 to 20% by weight of the total masterbatch, preferably 5 to 15% by weight. If the content of the additives in the masterbatch is too low, the amount of the masterbatch used to obtain the desired physical properties increases, and if the content of the additives is too high, the original physical properties of the resin are impaired, and it is difficult to uniformly disperse the additives in the masterbatch. there is.

The first plate 10 of the sandwich panel 1 according to an embodiment of the present invention has a higher specific heat than the first plate 10, and specifically, the specific heat may be 1.0 to 1.5 J/g K, and 1.1 to 1.4 j/g·K, preferably 1.2 to 1.3 J/g·K.

By using the first plate material 10 with high specific heat, it is advantageous to improve internal constant temperature by minimizing the temperature difference caused by the sandwich panel 1, and it is possible to save night heating costs by releasing heat stored during the day at night. .

On the other hand, it is preferable that the first material of the first plate material 10 and the second plate material constituting the sandwich panel 1 according to the embodiment have a higher thermal conductivity than that of the core material 20. More specifically, the thermal conductivity of the first material may be 0.1 to 5.0 W/m K, preferably 0.12 to 2.0 W/m K, 0.15 to 1.0 W/m K, or 0.18 to 0.2 W /m·K is also preferable.

In order to control the specific heat and thermal conductivity of the first material as described above, at least one selected from the group consisting of bakelite, polyurethane, ethylene propylene, chloroprene and butyl rubber may be added to the first material, more preferably Preferably, the specific heat is 1.5 J/g·K or more, and polyurethane is preferably added.

When the above additives are added to the first material in an amount of 0.01 to 5 wt%, for example, 0.01 to 2 wt%, preferably 0.02 to 1.0 wt%, an effect of increasing the specific heat of the first plate 10 can be obtained and mechanical strength Although there is an advantage that can be improved, if it is added more than the corresponding range, there may be a problem of deteriorating flexural elasticity or flexural strength.

In addition, in addition to the method of adjusting the specific heat and thermal conductivity characteristics of the first material and additives, it is also desirable to further optimize the heat capacity and thermal conductivity characteristics of the entire sandwich panel 1 by controlling the thickness of the first plate member 10.

Specifically, the thickness of the first plate 10 is preferably 1.5T to 2T, preferably 2T, when T, which is a unit mainly used in the art, is used instead of mm as a thickness unit. The thickness of the two-plate member 30 is preferably 0.4T to 0.5T, preferably 0.5T.

Here, 1T can be understood as a unit representing length equal to 1mm.

Here, the thickness of the first plate 10 may be 1 to 5 times the thickness of the second plate 30, preferably 3 to 5 times, and preferably 3.8 to 4.2 times.

If the thickness range of the first plate member 10 and the second plate member 30 is out of the corresponding range, the production efficiency of the product may be lowered or economic feasibility may be deteriorated.

In addition, if the thickness of the first plate material 10 is too thin, the strength is weak and the mechanical properties of the sandwich panel are weak and easily damaged, and if the thickness is too thick, it is difficult to manufacture and use the first material in the form of a sandwich sandwich There is a problem that mass production of the panel 1 becomes difficult and economical efficiency decreases.

As described above, due to the effect of improving the constant temperature of the first plate 10, it is possible to obtain sufficient constant temperature without forming a foam layer for improving the constant temperature on the inner surface in the prior art, and the formation of the foam In the case of using the first plate member 10, the problem of internal cleaning and management and the problem of industrial waste can also be solved considering that cleaning and management are convenient and the material can be recycled.

The sandwich panel 1 of the present invention includes the second plate 30 together with the first plate 10 described above, wherein the second plate 30 is formed by being laminated on the other side of the core 20, , The first plate material 10 is provided on the opposite side of the laminated core material 20 to form a structure in which the core material 20 is provided between the first plate material 10 and the second plate material 30.

Here, the second plate material may use a polymer material similar to the first plate material, and may use the same first material as the first plate material described above, and may have a different thickness from or the same as the first plate material depending on the purpose.

In the sandwich panel 1, the core material 20 provided between the first plate 10 and the second plate 30 may be a filler having a non-woven fiber structure in which fibers are entangled with each other, polystyrene (styrofoam), At least one material selected from the group consisting of polyurethane, PUR, PIR, glass wool, and mineral wool may be used as the core material 20 . For example, it is preferable to use an insulating material such as expanded polystyrene (EPS) as the core material 20 .

Expanded polystyrene is foamed by adding a foaming agent such as pentane or butane to polystyrene resin, heating it to a high temperature and generating bubbles under high pressure at the same time. It has excellent properties such as light weight.

The core material 20 is included for maintaining strength and a role as a heat insulating material in the sandwich panel 1 when used for internal purposes of a building. The thickness may vary depending on the location or purpose where the sandwich panel 1 is constructed. For example, in the case of a mid-ceiling, a core material 20 of 100T to 150T may be used.

In addition, the core material 20 is preferably a material having semi-incombustible or flame retardant properties, and the density of the core material 20 may vary depending on the degree of foaming and foaming conditions of the material, but is 19 to 21 kg/m ³ , 19.7 to 19.7 kg/m 3 , 20.9 kg/m ³ , preferably 20 to 20.9 kg/m ³ .

If the thickness of the core material 20 is too thin, the insulation performance is lowered, and if the thickness is too thick, there is a problem of increasing weight, which is undesirable. If the density is too low, there is a problem that the strength is not sufficient and the supporting force is insufficient.

In addition, the sandwich panel 1 according to this aspect of the present invention includes an adhesive layer 40 for bonding the above-described first plate material 10 and the second plate material 30 to the core material 20 on both sides of the core material 20 It is preferable to include in

At this time, in order to improve the adhesive strength between the first plate material 10 and the second plate material 30 and the core material 20, the surface of the adhesive surface of the first plate material 10 is treated before spraying the adhesive liquid to the surface. By forming the scratch groove 33, it is possible to improve the adhesive strength between the first plate member 10 and the core member 20 through the adhesive layer 40.

The adhesive force between the first and second plates made of polymer material and the core is very important. If the adhesive force is weak, moisture (steam) penetrates the adhesive layer between the polymer plate and the core over time, and the adhesive force between the two rapidly decreases. because problems arise.

Therefore, it is important to prevent water vapor from penetrating by forming the adhesive layer 40 very robustly from the beginning. At this time, the scratch groove 33 is a groove penetrating into the inside from the surface of the plate member, formed in plurality with a width of 0.1 to 0.2 mm and a depth of 0.1 to 0.4 mm, and extending continuously in the longitudinal direction of the plate member to the outside. to minimize the exposed area of the adhesive layer.

That is, a typical sandwich panel has a rectangular shape, and when the movement direction from short side to short side is referred to as the longitudinal direction, scratch grooves are continuously formed in the longitudinal direction from one short side to the other short side.

The width:length ratio of the scratch groove 33 is preferably 1:1 to 1:2. If the above range is exceeded, the adhesive layer is not completely filled in the groove, and thus the adhesive strength is reduced.

These scratch grooves are different from those in which the depth, width, and direction of extension are bent perpendicular to the longitudinal direction of the plate material in order to secure the conventional contact area.

Also, the distance between the scratch grooves is preferably 1 cm to 6 cm. When the scratches are formed in a zigzag pattern, the distance between the scratch grooves may be wider, and when the scratches are formed in a straight line, the distance between the scratch grooves may be narrower. Therefore, it is preferably 3 to 6 cm when formed in a zigzag pattern and 1 to 3 cm when formed in a straight line.

The adhesive layer 40 is a layer formed for bonding the core material 20 and the first plate material 10 or the core material 20 and the second plate material 30, and bonding the core material 20 and the first plate material 10. A first adhesive layer 40 to do and a second adhesive layer 40 to bond the core material 20 and the second plate material 30 may be respectively provided.

The adhesive layer 40 is preferably formed by applying an adhesive liquid to the surface of the core material 20 or the plate material. For example, it is preferable to form the adhesive layer 40 by applying a foamable adhesive to the surface and then foaming it.

The adhesive liquid forming the adhesive layer 40 may be a polyurethane adhesive liquid, and may be utilized as a foamable adhesive liquid by reacting the first liquid and the second liquid, and more specifically, the first liquid and the second liquid may be mixed in advance. In a state where it is not, after being sprayed and mixed on one side of the core material 20 or plate material to be bonded, it may be foamed immediately before bonding is made.

Here, the first liquid is an isocyanate-based mixture containing isocyanate, and the isocyanate is preferably an isocyanate compound having a structure that can be used as a reactant for synthesizing polyurethane, for example, 2,4-toluene di aromatic polyisocyanates such as isocyanate, 2,6-toluene diisocyanate, 2,4'-diphenylmethane diisocyanate, polymethylene polyphenylene polyisocyanate, and polyethylene polyphenyl isocyanate; aliphatic polyisocyanates such as hexamethylene diisocyanate; alicyclic polyisocyanates such as isophorone diisocyanate; Aryl aliphatic polyisocyanates, such as xylene diisocyanate, etc. can be used individually or in mixture.

An embodiment of the present invention discloses a first liquid containing methylene diphenyl diisocyanate (MDI), and a heat-resistant filler and foaming properties are additionally added to the first liquid to improve the physical properties of the adhesive liquid and the properties of the sandwich panel (1). Other additives such as fillers may be further included.

In this case, the additive may be included within 20wt% of the total first liquid, preferably 10 to 20 wt%.

The second liquid preferably contains a compound containing two or more alcohol groups in one molecule, and when mixed with the first liquid, polyurethane may be synthesized by reacting with the isocyanate-based compound included in the first liquid.

The second liquid preferably contains a polyol having three or more alcohol groups in one molecule or a glycol compound having two alcohol groups, and for example, polypropylene glycol may be used.

The second liquid may include an amine compound that can control the reaction time by performing a catalyst role during the polyurethane synthesis reaction and can be used as a curing agent. As the amine compound, a tertiary amine compound is preferably used, for example Dimethylethanol amine (DMEA), dimethylcyclohexyl amine (DMCHA), pentamethylenediethylene triamine (PMDETA), tetramethylene-hexyldiamine (TMHDA) or 1, 4 diaza bicyclo (2, 2, 2) octane and the like can be used.

The second liquid may further include a surfactant or a foam stabilizer, and for example, a polyalkylene oxide-modified polydimethylsiloxane compound having at least one of the structures shown in Formula 1 is preferably used.

(Formula 1)

Additionally, the second liquid may further contain a catalyst for accelerating the curing of the prepolymer by accelerating the reaction of isocyanate groups, such as dibutyltin dilaurate, dioctyltin dilaurate, and dibutyltin. Organotin compounds such as dioctoate, dibutyltin diacetate, dibutyltin dichloride and dibutyltin diacetylacetonate, bismuth compounds such as bismuth trioctoate and bismuth tris (neodecanoate), and mixtures thereof Any one or more selected from may be selected.

Table 1 shows the composition of the first liquid used in a preferred embodiment of this aspect, and Table 2 shows the composition of the second liquid in detail.

chemical name Gwan Eung-myeong and Lee Myung-myeong CAS number content(%) polyethylene polyphenyl Polymethylene polyphenyl 9016-87-9 55 to 65 isocyanate isocyanate 4,4-methylene diphenyl 4,4-Methylenediphenyl 101-68-8 15 to 24 diisocyanate Diisocyanates additive Silica, Potassium Carbonate, Talc - 10 to 30

chemical name Gwan Eung-myeong and Lee Myung-myeong CAS number content(%) Polypropylene glycol PROPYLENE GLYCOL 25322-69-4 85 to 95 POLYMER Tertiary amine 1,4-DIAZABICYCLO (2.2.2) 280-57-9 1 to 3 OCTANE Surfactant POLYALKYLENEOXIDE MODIFIED 68937-55-3 1~2 POLYDIMETHYLSILOXANE Water DIHYDROGEN OXIDE 7732-18-5 3 to 5

Figure 2 is a view schematically showing the ASTM D790 test method used to measure the flexural modulus and flexural strength of the plate in the present invention. The plate material is flatly raised and fixed on a pair of supports, and a load is applied downward between the supports, and the flexural strength and flexural modulus of elasticity can be measured by calculating the deformation amount of the plate material according to the applied load. The calculation method can be obtained by conventional specific experimental methods and common technical knowledge.

For example, as a test piece, a test piece having a length of 80 mm, a thickness of 4 mm, and a width of 10 mm can be manufactured and used, and the flexural strength (MPa) can be calculated as the following formula, where b is not shown, but the test piece is the width (mm), h and L are in mm, and F is in N.

The flexural modulus represents the amount of change in flexural strength (or stress) according to the amount of deformation, and can be expressed as the following equation.

<Second aspect>

The present invention includes a method for manufacturing a sandwich panel (1) according to one aspect of the present invention, and the sandwich panel (1) manufactured by the manufacturing method may be the above-described sandwich panel (1). Hereinafter, the structure and configuration of the sandwich panel 1 are described by omitting the same parts as those described in the foregoing aspects.

Figure 3 is a flow chart schematically showing the sandwich panel manufacturing method of this aspect.

The manufacturing method of the sandwich panel can be described including the following steps, specifically, (a) containing a polymer having moisture resistance and corrosion resistance and having a thickness of 1.5 to 2.0 mm (1.5T to 2,0T). Preparing the first and second plates by winding and shaping the first and second plates 10 and 30 in a roll form, (b) preparing a core 20 including a heat insulating material (20) preparation step, (c) supply step of transferring the core material, the first plate material 10 and the second plate material 30 wound in a roll form, (d) the first plate material 10 and the second plate material ( 30) forming a scratch groove on at least one of the surfaces to be in close contact with the core material, (e) spraying the adhesive liquid on at least one surface of the first plate material 10 and the second plate material 30 that are continuously supplied. An adhesive liquid spraying step comprising the step of doing, (f) an adhesive layer forming step in which the sprayed adhesive liquid forms an adhesive layer 40 between the plate materials and the core material and in the scratch groove, and (g) of the core material 20 It is preferable to include a bonding step of laminating the first plate material 10 on one surface and bonding the second plate material 30 to the other surface of the core material 20 with an adhesive layer 40.

Hereinafter, each step described above will be described in detail.

(a) The step of preparing the first and second plates may include forming them according to the shape and width (or width) of the panel to be manufactured, and winding them into rolls. At this time, the first and second plates may be formed. Preferably, the preparatory steps are performed together.

Here, it is preferable that the material included in the first and second plate members 30 is used as the material mentioned in the foregoing aspect, and description of the same part is omitted.

The first plate material 10 and the second plate material 30 are wound in a roll form to enable continuous production, and after being wound in a roll form, they are processed into a flat surface again so that they can be manufactured into a sandwich panel 1 with flexural elasticity. It is preferable to use a material that is excellent and does not cause discoloration or cracking problems.

For example, the first plate 10 and the second plate 30 are prepared in a predetermined shape and width. In particular, in the sandwich panel 1 of the present invention, the first material constituting the first plate 10 is It is made of a material containing a polymer resin.

At this time, it is necessary to prepare a first material plate formed and manufactured in a roll form so that the sandwich panel 1 can be continuously produced using the first material containing a polymer resin, and a general polymer resin is molded into a roll form. In the case of the first material, unlike the problem of cracking or loss of elasticity, in the case of the first material, the elastic properties of the material can be greatly improved by uniformly dispersing the filler using the masterbatch. There are advantages to what is possible.

Here, the first material is preferably a polymer material having excellent chemical resistance, for example, a polycarbonate-based resin.

(b) The core material 20 preparation step is a step of preparing the core material 20 having the same shape and width as the plate material, after foaming and manufacturing the core material 20 including a heat insulating material to a desired thickness and density, and then to a predetermined size. In the step of preparing by processing, it is preferable to use the same core material 20 as the core material 20 described in the above-mentioned side.

(c) the supply step of transferring the core material, the first plate material 10 and the second plate material 30 wound in a roll form, the first and second plate materials 30 wound in a roll form are continuously unwound from the roller, This is a step of supplying and continuously supplying the core material 20 to the conveyor. At this time, each roller has a diameter of 20 to 70 cm, for example, a diameter of 30 to 60 cm, preferably a diameter of 45 to 55 cm. For example, the supply may be performed so that the first plate 10 is disposed on the lower part of the core 20 and the second plate 30 is placed on the upper part, and the supply speed may be the same.

(d) forming scratch grooves is a step of forming continuous scratch grooves on the surfaces of the first and second plates in contact with the core material before spraying the adhesive solution. The scratch groove is a groove that penetrates into the inside from the surface of the plate formed to prevent water vapor from penetrating the adhesive layer from the beginning by forming it very fast. , It is a groove that continuously extends in the longitudinal direction of the plate material, minimizing the area where the adhesive layer is exposed to the outside.

The width:length ratio of the scratch groove is preferably 1:1 to 1:2. If the above range is exceeded, the adhesive layer is not completely filled in the groove, and thus the adhesive strength is reduced.

These scratch grooves are different from those in which the depth, width, and direction of extension are bent perpendicular to the longitudinal direction of the plate material in order to secure the conventional contact area.

Also, the distance between the scratch grooves is preferably 1 cm to 6 cm. The scratch grooves extend along the conveying direction and can be made in a zigzag shape or in a straight line. When the scratches are formed in a zigzag pattern, the distance between the scratch grooves becomes wider. this may be narrowed. Therefore, it is preferably 3 to 6 cm when formed in a zigzag pattern and 1 to 3 cm when formed in a straight line.

(e) The adhesive liquid spraying step is a step of spraying and mixing the first liquid and the second liquid on one side of each sheet material when the wound first plate material 10 and the second plate material 30 are continuously unwound and supplied. .

The adhesive liquid spraying step includes spraying a first liquid and a second liquid containing different components to one side of the first plate 10 and the second plate 30, wherein the adhesive liquid is in the form of two liquids. It is preferable that the adhesive liquid is sprayed separately from the first liquid and the second liquid, and the first liquid and the second liquid are mixed on the sprayed surface.

The first solution is a solution containing an isocyanate-based compound as described in the above aspect, and it is preferable to apply an amount of 35 to 45 g per 1 m of panel length, more specifically, depending on the season, in summer, the length of the panel is 1 m. It is preferable to apply 37g per meter, and 42g per 1m of panel length in winter.

As described above, the second liquid is a solution that contains an alcohol-based compound and can react with the second liquid to synthesize polyurethane, and it is preferable to apply an amount of 35 to 45 g per 1 m of panel length. , More specifically, it is preferable to apply 37 g per 1 m of panel length in summer and 42 g per 1 m of panel length in winter depending on the season.

(f) In the adhesive layer forming step, the first and second liquids, which were separated from each other, are sprayed on one surface of the panel to form an adhesive surface. A reaction occurs between the compounds of the second liquid to synthesize a polyurethane-based compound.

The reaction rate of the polyurethane-based compound is controlled by the catalyst and tertiary amine contained in the second liquid, the hardness after reaction can be controlled, and the heat resistance or foaming characteristics can be further improved through other additives contained in the first liquid. can

(g) bonding step is a step of bonding the core material 20 and the plate material to each other with the adhesive layer 40 by sequentially stacking and compressing the first plate material 10, the core material 20, and the second plate material 30. At this time, the core material 20 is preferably prepared in the same shape and width as the first plate material 10 and the second plate material 30, and the manufactured sandwich panel may be cut and produced according to a length desired by a user.

In the sandwich panel manufacturing method of the present invention, despite the fact that the first plate 10 and the second plate 30 are polymer resins, they are prepared in a roll form and then continuously unwound and supplied by a roller, and an adhesive layer 40 is formed on the surface thereof. It is characterized in that all of the process can be performed under a continuous process, from the process of finally pressing the core material 20 between the panels in an adhered state, and as a result, the production economy is excellent and the sandwich panel 1 of constant quality is produced. It can be.

In addition, a step of forming a scratch groove is included, so that the plate material and the core material can be strongly bonded to prevent moisture from penetrating into the adhesive layer between the plate material and the core material, which are polymer resins.

<Third Aspect>

A third aspect of the present invention is a manufacturing apparatus for a sandwich panel. Figure 4 is a simplified view of the manufacturing apparatus, Figure 5 is a structural diagram of the scratch groove forming unit in the manufacturing apparatus.

According to this, the sandwich panel manufacturing apparatus includes a first roller 110, a second roller 210, a first scratch groove forming unit 120, a first adhesive spraying unit 130, and a second scratch groove forming unit 220. ), and a second adhesive spraying unit 230.

The first roller 110 and the second roller 210 are rollers on which the first plate 10 and the second plate 30 are wound, respectively, and the rollers have a diameter of 20 to 70 cm, for example, a diameter of 30 to 60 cm. cm, preferably between 45 and 55 cm in diameter. At this time, the first plate material and the second plate material are polymer materials, and a material that can be wound around a roller should be used.

The first scratch groove forming part 130 and the second scratch groove forming part 230 are continuous on the surface where the first plate material 10 and the second plate material 30 come into contact with the core material 20 before the adhesive is sprayed. It is a device for forming scratch grooves.

The first scratch groove forming part 120 includes first supports 121 and 122 , a first holder 123 , and a first needle assembly 125 . The support is a structure to support the support, and is provided with two on both sides. Both ends of the support are connected to the support and a plurality of needle assemblies are attached to the support. Including, the needle continuously forms a scratch groove on the surface of the plate with the restoring force by the elastic member.

Optionally, the cradle 123 is connected as a connecting means by the hydraulic device 127 and can swing from side to side. In this case, a rail 129 is provided, and a sliding groove into which the rail is inserted is provided on the bottom of the cradle. . When the cradle swings from side to side, the scratch groove formed by the needle may be made in a zigzag pattern. 6 is an operation diagram illustrating a state in which scratch grooves are formed in a zigzag pattern on a plate material.

The second scratch groove formation part 220 may also be configured in the same way, and includes a second support 221 , a second cradle 223 , and a second needle assembly 225 .

7 is a structural diagram of a needle assembly according to an embodiment, and the needle assembly 125 includes a needle 1251, a casing 1253, and an elastic means 1255. The needle 1251 is exposed to the outside of the casing while retaining restoring force by an elastic means compressed inside the casing, so that scratch grooves 33 can be formed in the plate material to be transported.

Needle assemblies 127 are provided in plural, and it is preferable that the interval formed by the needles is 1 cm to 6 cm. In particular, when the scratches are formed in a zigzag pattern, the distance between the scratch grooves may be wider, and when the scratches are formed in a straight line, the distance between the grooves may be narrower. Therefore, it is preferably 3 to 6 cm when formed in a zigzag pattern and 1 to 3 cm when formed in a straight line.

The adhesive spraying unit 130 is a device for forming an adhesive layer by spraying an adhesive liquid between the core material and the plate material.

The features, structures, effects, etc. illustrated in each of the above-described embodiments can be combined or modified with respect to other embodiments by those skilled in the art in the field to which the embodiments belong. Therefore, contents related to these combinations and variations should be construed as being included in the scope of the present invention.

1: sandwich panel
10: first plate
20: heart
30: second plate
40: adhesive layer
110: first roller
210: second roller
120: first scratch groove forming unit
125: needle assembly
1251: needle
1253: Casing
1255: elastic means
130: first adhesive injection unit
220: second scratch groove forming unit
230: second adhesive injection unit

Claims (14)

A core material including an insulating material having at least one material selected from the group consisting of polystyrene (Styrofoam), polyurethane, PUR, PIR, glass wool, and mineral wool;
A material that is adhered to one side of the core material and has bending properties that can be molded and supplied in the form of a roll, which includes a polymer and is wound into a roll having a thickness of 1.5 to 2.0 mm and a diameter of 20 cm to 70 cm for continuous production. A first plate made of a first material that can be; and
A material that is adhered to the other side of the core material and has bending properties that can be molded and supplied in the form of a roll, and is continuously produced by being wound into a roll having a thickness of 1.5 to 2.0 mm and a diameter of 20 cm to 70 cm, including a polymer. a first plate material made of a first material that may be a second plate material including a polymer;
at least one or more scratch grooves provided on surfaces where the first plate member and the second plate member are attached to the core member; and
A sandwich panel comprising an adhesive layer provided between the core material, the first plate material and the second plate material, and inside the scratch groove.
The first material and the second material include a phenolic polymer or a phenolic copolymer resin synthesized by including bisphenol A as a monomer as the polymer, and have a flexural modulus of 2.0 to 2.5 GPa as measured by the ASTM D790 test method , A sandwich panel produced continuously with chemical resistance. According to claim 1,
The sandwich panel has a rectangular shape, and the scratch groove is continuously formed in a longitudinal direction from one short side to the other short side. According to claim 2,
The width: length ratio of the scratch groove is 1: 1 to 1: 2 sandwich panel. According to claim 3,
The scratch groove is a sandwich panel having a width of 0.1 to 0.2 mm and a depth of 0.1 to 0.4 mm. According to claim 1,
The first plate material and the second plate material have a specific heat of 1.0 to 1.5 J / g K. According to claim 1,
The first plate and the second plate may have a thickness of 1.5 to 2.0 mm and a diameter of 20 cm to 70 cm, which may be wound on a roll. According to claim 6,
The first material constituting the first plate has a flexural modulus of 2.0 to 2.5 GPa measured by the ASTM D790 test method. According to claim 7,
The polymer is a sandwich panel comprising a phenol-based polymer or a phenol-based copolymer resin synthesized by including bisphenol A as a monomer. According to claim 8,
The first material,
With the polymer,
A sandwich panel comprising at least one selected from the group consisting of bakelite, polyurethane, ethylene propylene, chloroprene and butyl rubber. As a material having bending characteristics that can be formed and supplied in the form of a roll, the first and second plates containing a polymer having a thickness of 1.5 to 2.0 mm are rolled into rolls with a diameter of 20 cm to 70 cm, respectively. Preparation step of preparing the first and second plates by winding;
A core material preparation step of preparing a core material including an insulating material;
a supply step of transferring the core material, the first plate material, and the second plate material;
Forming a scratch groove on at least one of the surfaces of the first and second plates to be in close contact with the core;
An adhesive liquid spraying step comprising spraying an adhesive liquid on at least one surface of the first plate material and the second plate material that are continuously supplied;
An adhesive layer forming step in which the sprayed adhesive liquid forms an adhesive layer between the plate materials and the core material and in the scratch groove; and
Sandwich panel manufacturing method comprising a bonding step of bonding the first plate material to one surface of the core material, and bonding the second plate material to the other surface of the core material. According to claim 10,
The scratch groove is a sandwich panel manufacturing method continuously formed along the longitudinal direction in which the first plate material or the second plate material is supplied. According to claim 11,
The method of manufacturing a sandwich panel in which the first material constituting the first plate and the second plate is manufactured by mixing a masterbatch containing a polycarbonate-based resin with the polymer. According to claim 12,
The master batch,
At least one selected from the group consisting of calcium carbonate, talc, talc, silica, alumina, bakelite, carbon nanotube (CNT), graphene, whisker, glass bubble, carbonate silane coupling agent, and polyethylene wax and stearate Method for producing a sandwich panel further comprising a functional additive comprising a. According to claim 13,
The method of manufacturing a sandwich panel in which the functional additive is included in 3 to 20% by weight of the total amount of the masterbatch.

Images