KR102571155B1 - Limited-uncombustible high pressure laminate - Google Patents

Abstract

The present invention relates to an incombustible high-pressure molded plywood.

Description

Incombustible high-pressure molding plywood {LIMITED-UNCOMBUSTIBLE HIGH PRESSURE LAMINATE}

The present invention relates to an incombustible high-pressure molded plywood.

The floor of a building structure is generally made of concrete and cement.

At this time, if the floor of the building structure made of concrete and cement is exposed as it is, not only the aesthetics deteriorates, but also the cold air rises. It blocks the cold air coming from it.

One such floor decoration material is a wooden floor.

Hardwood floors are made of thinly layered hardwood, and due to the nature of hardwood, they have an excellent touch and can control humidity.

However, hardwood flooring has problems in that it is easily deformed when excessively dry or wet, and is easily scratched or damaged by external impact.

In addition, there is an ondol floor as one of the floor decoration materials. Ondol flooring is manufactured by laminating a thin natural veneer as the surface layer on the upper surface of the base layer made of plywood. However, ondol floors have a problem in that they are easily scratched or scratched by external impacts, similar to wooden floors.

In order to solve the above problems of hardwood floors, recently, a laminated floor has been proposed as disclosed in Utility Model Registration No. 20-0283034 (published on July 31, 2002). Laminate flooring is a laminate of a surface layer including a paper or fibrous substrate impregnated with a thermosetting resin such as melamine resin or phenolic resin on the upper surface of a base layer made of MDF (Medium Density Fibreboard) or HDF (High Density Fiberboard). Compared to ondol flooring, it is resistant to dents and scratches, so the surface durability is relatively strong, but there is a problem of being sensitive to moisture because thermosetting resin is used as the surface layer, and it gives users a cold feeling, and the surface expressed in artificial printing is hardwood flooring Compared to this, there was a problem that the natural texture of hardwood fell a lot.

On the other hand, recently, a steel floor has been proposed to solve the problem of the ondol floor. Laminate flooring is a surface layer laminated on the upper surface of a base layer made of plywood, and includes a paper or fibrous substrate impregnated with a thermosetting resin such as melamine resin or phenolic resin like laminate flooring. It is strong and has the advantage of minimizing damage.

In this case, the surface layer of the laminate floor or the laminate floor may further include a transparent layer and a printing layer, and in this case, a thermosetting resin such as melamine resin or phenolic resin was used as a resin used for the transparent layer and the printing layer.

That is, the thermosetting resin-impregnated paper and kraft layer included in the surface layer in conventional flooring materials such as laminated flooring or steel flooring all use thermosetting resins such as melamine resin or phenol resin, and the thermosetting resin-impregnated paper and kraft layer The included surface layer is referred to as HPL (High Pressure Laminate).

Recently, in addition to the basic flooring materials as described above, finishing materials in cabins such as railroad cars and ships and alternative materials thereof are also composed of HPL.

For example, in the case of HPL, since it can express various colors or designs, it has many advantages in terms of implementing the design of architectural partition panels, but has a limitation that it cannot provide even non-combustibility due to the nature of the flame retardant material, and thus it is suitable for ships and railroads. When used, it is excellent in terms of color and design, but it is known to cause accidents with large-scale human casualties in the event of a fire.

In the case of existing HPL, general flame retardant materials are used instead of non-combustible materials, and in this case, problems such as the risk of causing serious problems to the human body due to gas generation due to combustion in the event of a fire occur.

In order to solve this problem, various studies have been attempted to secure the stability of combustion while developing flame retardant products in terms of product design and color, but there has been a problem that they cannot be used in railways, vehicles or ships due to thickness and material problems. . In addition, in order to use it for railways, vehicles, or ships, it is necessary to secure the durability of HPL itself, which must maintain a certain structure even in the event of a fire, along with the non-combustible characteristics of HPL itself.

Therefore, attempts have been made to develop HPL for railways, vehicles, and ships, which should be resistant to fire and have a suitable thickness, but satisfactory results have not been obtained so far, and research on this has been continuously conducted.

Korean Patent Publication No. 10-2022-0141338

The present invention controls the thickness and thermal conductivity of the non-combustible kraft layer, and in particular, includes a filler under specific conditions in the non-combustible composition, which minimizes heat conduction in the event of a fire along with non-combustible characteristics to maintain a certain structure by not causing deterioration of adhesives or the like It relates to a nonflammable high-pressure molded plywood with high durability.

An exemplary embodiment of the present specification is an incombustible kraft layer; And an impregnated base material provided on one side or both sides of the incombustible kraft layer. , The incombustible kraft layer includes an incombustible composition, and the incombustible composition includes a filler including expanded graphite (EG) and silicone rubber, and based on 100 parts by weight of the filler, the silicone rubber is 50 parts by weight or more and 70 parts by weight or less. It provides a non-flammable high-pressure molded plywood comprising a.

An exemplary embodiment of the present specification provides an incombustible high-pressure molded plywood containing 10 parts by weight or more and 40 parts by weight or less based on 100 parts by weight of the incombustible composition.

In one embodiment of the present specification, the expanded graphite based on 100 parts by weight of the filler provides an incombustible high-pressure molded plywood containing 30 parts by weight or more and 50 parts by weight or less.

In the present application, the impregnated substrate provides a non-flammable high-pressure molded plywood comprising a paper plate containing a melamine resin.

In one embodiment of the present specification, the incombustible composition further includes a thermosetting resin, and the thermosetting resin is a melamine resin, a urea resin, a phenolic resin, an unsaturated polyester resin, a urethane resin, an epoxy resin, a polyester resin, and an acrylic resin. , It provides an incombustible high-pressure molded plywood comprising at least one selected from polyvinyl acetate resin.

In one embodiment of the present specification, the incombustible kraft layer provides an incombustible high-pressure molded plywood having a one-layer or multi-layer structure.

In one embodiment of the present specification, the thermosetting resin provides an incombustible high-pressure molded plywood containing 50 parts by weight or more and 70 parts by weight or less based on 100 parts by weight of the incombustible composition.

In one embodiment of the present specification, it provides an incombustible high-pressure molded plywood that further comprises an overlayer on top of the impregnated substrate.

In one embodiment of the present specification, the thickness of the impregnated substrate provides an incombustible high-pressure molded plywood that is 1 mm or more and 50 mm or less.

The thickness of the incombustible kraft layer of one embodiment of the present specification is 1 mm or more and 1 cm or less, and the thermal conductivity of the incombustible kraft layer satisfies that 10 W / mK or less. That is, the non-combustible kraft layer is characterized in that the thickness and thermal conductivity of the non-combustible kraft layer satisfy the above range while having a non-combustible feature by including an incombustible material in the event of a fire.

Accordingly, in the event of a fire, the material itself has a non-flammable characteristic that is not ignited by default, and at the same time, the adhesive strength between the non-combustible kraft layer and the additional substrate and the adhesive for bonding is low, so that the adhesive strength can be maintained constant, even in the event of a fire. It has a feature that can prevent the occurrence of problems such as collapse and detachment of HPL.

That is, in the case of conventional non-combustible HPL, non-combustible materials were used and had the characteristic of not burning in the event of a fire. However, when used as an internal material for railways and ships, non-combustibility is important, but securing durability so that the structure does not collapse in the event of a fire is also an important factor.

In general, adhesives are basically used for lamination between non-combustible kraft layers, impregnated substrates or additional layers. In the case of nonflammable HPL, it has a characteristic of not burning, but if the thermal conductivity is not controlled accordingly, heat is transferred to the adhesive. In the case of a commonly used silicone-based adhesive, when heat is transferred, gelation occurs and adhesive strength is increased. loss, and accordingly, the HPL collapsed and there was a problem that durability was not secured.

However, in the case of the present invention, the thermal conductivity was adjusted by including an incombustible composition of a specific composition in the incombustible kraft layer as described above. Accordingly, the main object is to have very excellent durability in the event of a fire because it is very resistant to fire and has low thermal conductivity so that heat is not transferred to the adhesive.

In addition, the product according to the present application is characterized in that the flame is also removed when the ignition source is removed as a material to buy time for people to evacuate when the fire is delayed by delaying the fire.

Before describing the present invention, some terms are first defined.

In the present specification, when a part "includes" a certain component, it means that it may further include other components, not excluding other components unless otherwise stated.

In the present specification, 'p to q' means a range of 'p or more and q or less'.

Hereinafter, it will be described in detail with reference to the drawings so that those skilled in the art can easily practice the present invention. However, the present invention may be embodied in many different forms and is not limited to the description below.

An exemplary embodiment of the present specification is an incombustible kraft layer; And an impregnated base material provided on one side or both sides of the incombustible kraft layer. , The incombustible kraft layer includes an incombustible composition, and the incombustible composition includes a filler including expanded graphite (EG) and silicone rubber, and based on 100 parts by weight of the filler, the silicone rubber is 50 parts by weight or more and 70 parts by weight or less. It provides a non-flammable high-pressure molded plywood comprising a.

In this application, the non-combustible high-pressure molded plywood may be referred to as a flame-resistant high-pressure molded sheet.

Incombustible high-pressure molded plywood according to the present application has a non-combustible characteristic that the material itself is not ignited basically in the event of a fire, and at the same time, the adhesive strength between the non-combustible kraft layer and the additional substrate and the adhesive for bonding is low, so that the adhesive strength is maintained constant. Therefore, even in the event of a fire, it has a feature capable of preventing the occurrence of problems such as collapse of the structure and separation of the HPL.

In one embodiment of the present application, the impregnated substrate may be prepared by impregnating the cellulose paper with abrasion-resistant silica or alumina evenly distributed overlay paper with a melamine resin.

In one embodiment of the present application, the impregnated substrate is impregnated with a resol-type phenolic resin at a weight ratio of 0.3 to 0.6 relative to the weight of the kraft layer of 80 to 300 g / m 2 at the bottom, and then heated in an oven at 80 to 220 ° C. The first layer dried and semi-cured for ~ 60 seconds, and the upper layer is impregnated with melamine resin at a weight ratio of 0.4 to 1.5 relative to the weight of the kraft layer of 80 to 300 g / m 2, and then impregnated with melamine resin in an oven at 80 to 220 ° C. It may be formed by laminating and bonding the second layer dried and semi-cured for 0.5 to 3 minutes.

An overlay layer may be further included on top of the impregnated substrate according to the present application, which may be used as a decorative layer having transparency.

In one embodiment of the present application, the thickness of the impregnated substrate may satisfy 1 mm or more and 50 mm or less.

In another exemplary embodiment, the thickness of the impregnated substrate may be 1 mm or more and 50 mm or less, 5 mm or more and 40 mm or less, 10 mm or more and 30 mm or less, specifically 20 mm.

In one embodiment of the present application, the impregnated substrate may be provided on both sides of the incombustible kraft layer.

In one embodiment of the present application, the impregnated substrate may be provided on one side of the incombustible kraft layer.

In one embodiment of the present application, the thickness of the incombustible kraft layer may be 1 mm or more and 1 cm or less.

In another exemplary embodiment, the thickness of the incombustible kraft layer may satisfy a range of 10 mm or more and 80 mm or less, preferably 20 mm or more and 60 mm or less, and more preferably 25 mm or more and 50 mm or less.

It is characterized in that the thickness of the incombustible kraft layer satisfies the above range. In general, the problem can be solved by increasing the thickness in order to lower the thermal conductivity. However, when the thickness of the non-combustible kraft layer is increased beyond the above range, the weight of the non-combustible kraft layer itself increases, durability is not secured, and process and cost losses are large. If the thickness is less than the above range, even if a specific incombustible composition described later is used Since the thermal conductivity is not secured, problems with durability occur in the event of a fire. That is, when included in the above range, the thermal conductivity can be optimally adjusted even in the event of a fire, and also has the characteristics of securing economic feasibility in the production process.

In one embodiment of the present application, the thermal conductivity of the incombustible kraft layer may satisfy a range of 10 W / mK or less.

In another exemplary embodiment, the thermal conductivity of the incombustible kraft layer may satisfy a range of 10 W / mK or less, 8 W / mK or less, 5 W / mK or less, and the lower limit is not limited, but 0.1 W / mK or more, 1 A range of W/mK or more may be satisfied.

In this application, thermal conductivity means the degree to which an object having a specific size and shape actually transfers heat. That is, in general, thermal conductivity may indicate the degree of heat transferred to another object when the temperature of one object changes with respect to two objects having different temperatures.

In the present application, the thermal conductivity can be measured by using a measuring instrument (LFA).

In general, adhesives are basically used for lamination between non-combustible kraft layers, impregnated substrates or additional layers. In the case of nonflammable HPL, it has a characteristic of not burning, but if the thermal conductivity is not controlled accordingly, heat is transferred to the adhesive. In the case of a commonly used silicone-based adhesive, when heat is transferred, gelation occurs and adhesive strength is increased. loss, and accordingly, the HPL collapsed and there was a problem that durability was not secured.

However, in the case of the present invention, the thermal conductivity was adjusted by including an incombustible composition of a specific composition in the incombustible kraft layer as described above. Accordingly, the main object is to have very excellent durability in the event of a fire because it is very resistant to fire and has low thermal conductivity so that heat is not transferred to the adhesive.

In the present application, the incombustible kraft layer includes an incombustible composition, and the incombustible composition may include a filler including expanded graphite (EG) and silicone rubber.

In the present application, the incombustible kraft layer may include the incombustible composition as it is.

In the present application, the incombustible kraft layer may include a cured product of the incombustible composition.

In the present application, the incombustible kraft layer may include a dried product of the incombustible composition.

In the present application, the incombustible composition is characterized in that it includes a filler.

In the present application, the filler includes expanded graphite (EG) and silicone rubber.

In this application, the filler is used as a role of adjusting thermal conductivity. In general, non-combustible compositions include non-combustible materials. However, in the case of a metal such as aluminum, which is an incombustible material, the thermal conductivity is very high, so the thermal conductivity is formed high.

However, the present application was able to adjust the thermal conductivity along with the non-combustible characteristics by using the filler together with the non-combustible material.

In the present application, the incombustible composition includes a filler including expanded graphite (EG) and silicone rubber, and the silicone rubber includes 50 parts by weight or more and 70 parts by weight or less based on 100 parts by weight of the filler, and the filler 100 Based on parts by weight, the expanded graphite may include 30 parts by weight or more and 50 parts by weight or less.

In another embodiment, the silicone rubber is 50 parts by weight or more and 70 parts by weight or less, preferably 55 parts by weight or more and 65 parts by weight or less, more preferably 55 parts by weight or more 60 parts by weight based on 100 parts by weight of the filler. May include the following.

In another embodiment, the expanded graphite is 30 parts by weight or more and 50 parts by weight or less, preferably 35 parts by weight or more and 45 parts by weight or less, more preferably 40 parts by weight or more 45 parts by weight based on 100 parts by weight of the filler. May include the following.

As described above, the filler satisfies the above weight range, and in the case of expanded graphite, it has some combustible materials, but it has the characteristics of being able to solve the problem of combustibility and adjusting the thermal conductivity by including the above range. In the case of silicone rubber, it is used for thermal conductivity, and when it is included in the above range, it has a feature that can form a desired thermal conductivity.

In one embodiment of the present application, the filler may include 10 parts by weight or more and 40 parts by weight or less based on 100 parts by weight of the incombustible composition.

In another embodiment, based on 100 parts by weight of the incombustible composition, the filler is 10 parts by weight or more and 40 parts by weight or less, preferably, the filler is 10 parts by weight or more and 30 parts by weight or less based on 100 parts by weight of the incombustible composition. Preferably, it may include 10 parts by weight or more and 20 parts by weight or less.

As described above, the filler may include some combustible materials and may have a weak feature against fire when used in excess of the above range, and may cause a problem in that thermal conductivity is not secured when included below the above range.

In one embodiment of the present application, the incombustible coating composition may further include a binder.

In this case, the binder may include a silicone resin binder.

In one embodiment of the present application, the incombustible composition further includes a thermosetting resin, and the thermosetting resin is a melamine resin, a urea resin, a phenolic resin, an unsaturated polyester resin, a urethane resin, an epoxy resin, a polyester resin, an acrylic resin, It provides an incombustible high-pressure molded plywood comprising at least one selected from polyvinyl acetate resin.

Specifically, the thermosetting resin may include a phenol resin and an acrylic resin.

In one embodiment of the present application, the thermosetting resin provides an incombustible high-pressure molded plywood comprising 50 parts by weight or more and 70 parts by weight or less based on 100 parts by weight of the incombustible composition.

In another embodiment, the thermosetting resin is present in an amount of 50 parts by weight or more and 70 parts by weight or less, preferably 60 parts by weight or more and 70 parts by weight or less, more preferably 65 parts by weight or more and 70 parts by weight based on 100 parts by weight of the incombustible composition. May include the following.

In one embodiment of the present application, the incombustible high-pressure molded plywood may be composed of an impregnated substrate / kraft layer / impregnated substrate, in which case the incombustible kraft layer is a semi-incombustible high-pressure molded plywood having a one-layer or multi-layer structure. to provide.

The thickness of the high-pressure molded plywood can be adjusted by using the kraft layer in multiple layers, and generally a 3-layer or 6-layer structure can be used.

Hereinafter, the technology according to the present invention will be described in more detail through examples and manufacturing examples of the present invention.

<Production Example>

[Formation of impregnated substrate]

Melamine resin and formaldehyde or acrylic resin and formaldehyde, a plasticizer, etc. were mixed, stirred, and heated to synthesize a resinous material and applied to the top of the paper board, at which time the thickness was 20 mm.

[Formation of non-combustible kraft layer]

- Preparation of non-combustible compositions

An incombustible composition satisfying the composition of Table 1 was prepared.

In this case, in Filler-1, the weight ratio of expanded graphite:silicone rubber is 55:45, in Filler-2, the weight ratio of expanded graphite:silicone rubber is 60:40, in Filler-3, only expanded graphite is used, and in Filler-4 is a case in which only silicone rubber is used, filler-5 corresponds to a case in which the weight ratio of expanded graphite:silicone rubber is 25:75, and filler-6 corresponds to a case in which the weight ratio of expanded graphite:silicone rubber is 55:45.

In addition, a mixed composition of a phenol resin and an acrylic resin was used as the thermosetting resin.

In Table 1, it corresponds to parts by weight based on 100 parts by weight of the total incombustible composition.

Binder (silicone resin binder) filler thermosetting resin Example 1 10 Filler-1: 20 70 Example 2 10 Filler-2: 20 70 Example 3 15 Filler-1: 15 70 Example 4 15 Filler-2: 15 70 Comparative Example 1 10 Filler-3: 20 70 Comparative Example 2 10 Filler-4: 20 70 Comparative Example 3 10 Filler-5: 20 70 Comparative Example 4 10 Filler-6: 20 70 Comparative Example 5 10 Filler-1: 20 70 Reference example 1 10 Filler - 1:45 45

After preparing the incombustible composition as described above, the incombustible coating composition was applied on the impregnated substrate to prepare an incombustible high-pressure molded plywood satisfying the thickness and thermal conductivity of Table 2 below.

Incombustible kraft layer thickness (mm) Thermal conductivity (W/mK) Non-combustible features durability Flame retardant performance test Example 1 25 3 O O O Example 2 30 4 O O O Example 3 25 3.5 O O O Example 4 30 3.7 O O O Comparative Example 1 25 - X X X Comparative Example 2 25 - X X X Comparative Example 3 25 31 O X X Comparative Example 4 25 22 O X X Comparative Example 5 25 2.8 O X X Reference example 1 25 4 Δ O O

In Table 2, the combustion test was conducted for three incombustible high-pressure molded plywoods with 29 cm x 19 cm specimens.

In Table 2, the non-combustible characteristics are indicated by Δ when the non-combustible high-pressure molded plywood is prepared and then fire is applied for 10 minutes when it does not burn, Δ when some soot is generated, and X when burned.

In Table 2, durability is O when there is no abnormality in the adhesion of the non-flammable high-pressure molded plywood when the manufactured non-flammable high-pressure molded plywood is heated to 50 ° C, 75 ° C, and 100 ° C and heated for 30 minutes, If the plywood cracked or fell, an X was marked.

In Table 2, the flame retardant performance test is in accordance with Article 4 of the National Fire Agency Notification No. 2022-29, and the remaining flame time is less than 5 seconds, the remaining time is less than 20 seconds, the carbonization area is less than 40cm ² , the carbonization length is less than 20cm, and the smoke density is less than 400. If satisfied, it was marked with O, otherwise it was marked with X.

As can be seen in Examples 1 to 4 of Table 2, when a fire occurs, the material itself has a non-flammable characteristic that is not ignited, and at the same time, the adhesive between the non-combustible kraft layer and the additional substrate and the adhesive for bonding has low adhesive strength. This can be maintained constant, and it was confirmed that it has a feature that can prevent problems such as collapse of the structure and detachment of the HPL even in the event of a fire.

Comparative Example 1 and Comparative Example 2 correspond to the case of not having the filler composition according to the present application. In this case, it was confirmed that the high-pressure molded plywood was burnt and lost to the extent that the thermal conductivity could not be measured. In the case of Comparative Examples 3 and 4, when the filler composition according to the present application is not satisfied, it has non-combustible characteristics, but it is confirmed that a problem occurs in the durability of the non-combustible high-pressure molded plywood due to high thermal conductivity. In Comparative Example 5, the composition is the same as that of Example 1, but the thickness of the incombustible kraft layer is thick. Even in this case, thermal conductivity can be secured, but it is heavy and eventually durability is poor.

For reference, the same case as Reference Example 1 corresponds to the case of including an excessive amount of filler. Since the filler is made of some combustible materials, it can be confirmed that the thermal conductivity range satisfies a certain range, but some soot is generated, and it can be confirmed that the filler is weak against fire compared to the embodiment.

Through the above-described experiments, it was confirmed that the incombustible high-pressure molded plywood according to the present application can be used as an internal material for a railway vehicle or a ship.

Claims (9)

non-combustible kraft layer; and
Incombustible high-pressure molded plywood comprising a; impregnated substrate provided on one side or both sides of the incombustible kraft layer,
The thickness of the incombustible kraft layer is 1 mm or more and 1 cm or less,
The thermal conductivity of the incombustible kraft layer is 10 W / mK or less,
The non-combustible kraft layer includes a non-combustible composition,
The incombustible composition includes a filler including expanded graphite (EG) and silicone rubber,
Based on 100 parts by weight of the incombustible composition, the filler includes 10 parts by weight or more and 20 parts by weight or less,
Based on 100 parts by weight of the filler, the silicone rubber is 55 parts by weight or more and 60 parts by weight or less; and 40 parts by weight or more and 45 parts by weight or less of the expanded graphite. delete delete The method of claim 1,
The impregnated substrate is incombustible high-pressure molded plywood comprising a paper plate containing a melamine resin. The method of claim 1,
The incombustible composition further includes a thermosetting resin,
The thermosetting resin is a nonflammable high-pressure molded plywood comprising at least one selected from a melamine resin, a urea resin, a phenolic resin, an unsaturated polyester resin, a urethane resin, an epoxy resin, a polyester resin, an acrylic resin, and a polyvinyl acetate resin. The method of claim 1,
The incombustible high-pressure molded plywood of which the incombustible kraft layer is a one-layer or multi-layer structure. The method of claim 5,
The thermosetting resin is incombustible high-pressure molded plywood comprising 50 parts by weight or more and 70 parts by weight or less based on 100 parts by weight of the incombustible composition. The method of claim 1,
Incombustible high-pressure molded plywood further comprising an overlay layer on top of the impregnated substrate. The method according to claim 1, wherein the thickness of the impregnated substrate is incombustible high-pressure molded plywood of 1 mm or more and 50 mm or less.