KR102619050B1 - A method for manufacturing non-flammable styrofoam - Google Patents

Abstract

The present invention relates to a method for producing non-combustible styrofoam, and more specifically, to a composition preparation step of preparing a non-combustible composition; A foaming step of foaming polystyrene resin granules to form a foam; A coating step of forming a coating layer by coating the non-flammable composition on the surface of the foam; A molding step of putting the foam on which the coating layer is formed into a mold and pressurizing it to produce styrofoam molded into a mold shape; and a drying step of drying the Styrofoam.
The present invention can provide a method of manufacturing non-combustible Styrofoam that delays the combustion rate in the event of a fire, minimizes the generation of toxic gases, and has excellent flame retardancy, non-combustibility, insulation, durability, sound absorption, and adhesiveness.

Description

Method for manufacturing non-flammable styrofoam {A method for manufacturing non-flammable styrofoam}

The present invention relates to a method for producing non-combustible styrofoam, and more specifically, to a composition preparation step of preparing a non-combustible composition; A foaming step of foaming polystyrene resin granules to form a foam; A coating step of forming a coating layer by coating the non-flammable composition on the surface of the foam; A molding step of putting the foam on which the coating layer is formed into a mold and pressurizing it to produce styrofoam molded into a mold shape; and a drying step of drying the Styrofoam.

Styrofoam is widely used as an insulation material used in walls, ceilings, and floors of buildings and as a filling material for sandwich panels.

Styrofoam is formed by foaming polystyrene resin, and is widely used in various facilities as well as interior and exterior building materials because it is economical and has excellent water resistance, heat insulation, soundproofing, and cushioning properties.

However, Styrofoam is vulnerable to heat due to its lack of flame retardancy, and in the event of a fire, polystyrene, a component of Styrofoam, combusts and emits smoke, odor, and toxic gases, so not only does the fire spread quickly, but it also has the fatal problem of rapidly increasing casualties. .

Therefore, the demand for flame-retardant Styrofoam, which compensates for these shortcomings of Styrofoam, is steadily increasing, and legal regulations related to this are continuously being strengthened.

Meanwhile, the conventional technology relates to a method of manufacturing Styrofoam by coating the surface of foam particles with a flame retardant, or mixing foam particles and gypsum liquid or red clay, and the flame retardant coated on the surface of the foam particles is lost during the Styrofoam manufacturing process. In the event of a fire, the internal foam particles can easily burn, and excellent flame retardancy cannot be achieved due to uneven mixing of foam particles and gypsum liquid or red clay.

Therefore, it is necessary to develop Styrofoam that delays the combustion speed in the event of a fire, minimizes the generation of toxic gases, and has excellent flame retardancy.

Korean Patent Publication No. 10-1137837 Korean Patent Publication No. 10-0762540

The present invention is intended to solve the problems of the prior art, and provides a method for manufacturing non-combustible styrofoam that retards the combustion rate in the event of a fire, minimizes the generation of toxic gases, and has excellent flame retardancy, incombustibility, insulation, durability, sound absorption, and adhesiveness. The purpose is to provide.

In addition, the present invention aims to provide non-combustible styrofoam that coats styrofoam with a non-combustible composition to a certain thickness, so that the coating layer does not peel off even when used for a long period of time, and has excellent flame retardancy, incombustibility, insulation, durability, sound absorption, and adhesiveness.

In order to achieve the above object, the present invention includes a composition preparation step of preparing a non-flammable composition;

A foaming step of foaming polystyrene resin granules to form a foam;

A coating step of forming a coating layer by coating the non-flammable composition on the surface of the foam;

A molding step of putting the foam on which the coating layer is formed into a mold and pressurizing it to produce styrofoam molded into a mold shape; and

It provides a method of manufacturing non-combustible Styrofoam including a drying step of drying the Styrofoam.

In one embodiment of the present invention, the non-flammable composition contains sodium silicate, potassium silicate, activated carbon, red clay, and water.

In one embodiment of the present invention, the non-flammable composition contains 30 to 70 parts by weight of potassium silicate, 5 to 20 parts by weight of activated carbon, 5 to 20 parts by weight of red clay, and 1 to 20 parts by weight of water based on 100 parts by weight of sodium silicate. It is characterized by

In one embodiment of the present invention, the non-flammable composition is 1 to 10 weight of an acrylate group-containing silane coupling agent, a copolymer of 2-hydroxyethyl acrylate (HEA) and 2-hydroxyethyl methacrylate (HEMA). It is characterized by additionally including a part.

In one embodiment of the present invention, the activated carbon is prepared through (a) a primary carbonization step of carbonizing rice husk to produce primary carbide;

(b) a secondary carbonization step of carbonizing the primary carbide to produce secondary carbide;

(c) a tertiary carbonization step of carbonizing the secondary carbide to produce tertiary carbide; and

(d) It is characterized in that it is manufactured by a method comprising the step of pulverizing the tertiary carbide.

Additionally, the present invention provides non-combustible styrofoam manufactured by the above manufacturing method.

The present invention can provide a method of manufacturing non-combustible Styrofoam that delays the combustion rate in the event of a fire, minimizes the generation of toxic gases, and has excellent flame retardancy, non-combustibility, insulation, durability, sound absorption, and adhesiveness.

In addition, the present invention coats a non-combustible composition on Styrofoam to a certain thickness, thereby providing non-combustible Styrofoam that does not peel off the coating layer even when used for a long period of time and has excellent flame retardancy, non-combustibility, heat insulation, durability, sound absorption, and adhesiveness.

The present invention will be described in detail below based on examples. The terms, examples, etc. used in the present invention are merely illustrative to explain the present invention in more detail and aid the understanding of those skilled in the art, and the scope of rights of the present invention should not be construed as limited thereto.

Technical terms and scientific terms used in the present invention, unless otherwise defined, represent meanings commonly understood by those skilled in the art in the technical field to which this invention pertains.

The present invention includes a composition preparation step of preparing a non-flammable composition;

A foaming step of foaming polystyrene resin granules to form a foam;

A coating step of forming a coating layer by coating the non-flammable composition on the surface of the foam;

A molding step of putting the foam on which the coating layer is formed into a mold and pressurizing it to produce styrofoam molded into a mold shape; and

It relates to a method of manufacturing non-combustible Styrofoam including a drying step of drying the Styrofoam.

The non-flammable composition may include sodium silicate, potassium silicate, activated carbon, red clay, and water.

The non-flammable composition may include 30 to 70 parts by weight of potassium silicate, 5 to 20 parts by weight of activated carbon, 5 to 20 parts by weight of red clay, and 1 to 20 parts by weight of water, based on 100 parts by weight of sodium silicate.

The sodium silicate is used to improve flame retardancy and adhesion, and can be used in solid form or as a solution.

The sodium silicate solution can be prepared by adding at least one selected from the group consisting of water, vegetable oil, machine oil, grease, kerosene, mineral oil, paraffin oil, and acetic acid compound to sodium silicate and then stirring.

The potassium silicate is used to improve adhesion, incombustibility, insulation, and durability, and is preferably used in an amount of 30 to 70 parts by weight based on 100 parts by weight of sodium silicate.

When the content of potassium silicate satisfies the above numerical range, incombustibility, insulation, and durability can be maximized.

The activated carbon is used to improve incombustibility, insulation, and durability, and is preferably used in an amount of 5 to 20 parts by weight based on 100 parts by weight of sodium silicate.

When the content of activated carbon satisfies the above numerical range, incombustibility, insulation, and durability can be maximized.

The activated carbon includes (a) a primary carbonization step of carbonizing rice husk to produce primary carbide;

(b) a secondary carbonization step of carbonizing the primary carbide to produce secondary carbide;

(c) a tertiary carbonization step of carbonizing the secondary carbide to produce tertiary carbide; and

(d) It can be produced by a method including the step of pulverizing the tertiary carbide.

Step (a) is a primary carbonization step of carbonizing rice husk to produce primary carbide. The rice husk can be primary carbonized by increasing the temperature from 100°C to 300°C and maintaining it at 300°C for 30 minutes to 3 hours.

The first carbonization step may be performed under an inert gas, and nitrogen, argon, neon, helium, etc. may be used as the inert gas.

The inert gas can be injected at a rate of 10 mL/min to 100 mL/min, and when the injection rate satisfies the above numerical range, adsorption, non-flammability, heat insulation, etc. can be maximized.

The first carbonization step can remove moisture, volatile components, impurities, etc. contained in rice husk.

The temperature increase rate in the first carbonization step is preferably 1°C/min to 10°C/min, and when the temperature increase rate satisfies the above numerical range, adsorption, non-flammability, heat insulation, etc. can be maximized.

In addition, the present invention can use rice husk and rice husk simultaneously as raw materials for activated carbon, and the weight ratio of rice husk and rice husk is preferably 100:1 to 20.

When the weight ratio of rice husk and rice husk satisfies the above numerical range, adsorption, non-flammability, insulation, etc. can be maximized.

In addition, in the present invention, rice husk, rice husk and rice straw can be used simultaneously as raw materials for activated carbon, and the weight ratio of rice husk, rice husk and rice straw is preferably 100:1 to 20:1 to 10.

When the weight ratio of rice husk, rice husk, and rice straw satisfies the above numerical range, adsorption, incombustibility, and insulation properties can be maximized.

In addition, the present invention can simultaneously use rice husk, rice husk, rice straw, and sawdust as raw materials for activated carbon, and the weight ratio of rice husk, rice husk, rice straw, and sawdust is preferably 100:1 to 20:1 to 10:1 to 5.

When the weight ratio of rice husk, rice husk, rice straw, and sawdust satisfies the above numerical range, adsorption, non-flammability, and insulation properties can be maximized.

Step (b) is a secondary carbonization step of carbonizing the primary carbide to produce secondary carbide. The temperature is raised from 300°C to 600°C and maintained at 600°C for 30 minutes to 3 hours to perform secondary carbonization. You can.

The secondary carbonization step may be performed under an inert gas, and nitrogen, argon, neon, helium, etc. may be used as the inert gas.

The inert gas can be injected at a rate of 10 mL/min to 100 mL/min, and when the injection rate satisfies the above numerical range, adsorption, non-flammability, heat insulation, etc. can be maximized.

It is preferable that the temperature increase rate in the secondary carbonization step is 1°C/min to 10°C/min, and when the temperature increase rate satisfies the above numerical range, adsorption, non-flammability, heat insulation, etc. can be maximized.

In the secondary carbonization step, water vapor or carbon dioxide can be injected, and the water vapor or carbon dioxide can be injected at a rate of 0.1 mL/h to 0.5 mL/h, and if the injection rate satisfies the above numerical range, it is adsorbent and non-flammable. , insulation properties, etc. can be maximized.

The water vapor or carbon dioxide can increase the pores and specific surface area of activated carbon by removing organic substances and inorganic substances contained in rice husk.

Step (c) is a tertiary carbonization step of carbonizing the secondary carbide to produce tertiary carbide. The temperature is raised from 600°C to 900°C and maintained at 900°C for 30 minutes to 3 hours to perform tertiary carbonization. You can.

The tertiary carbonization step may be performed under an inert gas, and nitrogen, argon, neon, helium, etc. may be used as the inert gas.

The inert gas can be injected at a rate of 10 mL/min to 100 mL/min, and when the injection rate satisfies the above numerical range, adsorption, non-flammability, heat insulation, etc. can be maximized.

The temperature increase rate in the tertiary carbonization step is preferably 1°C/min to 10°C/min, and when the temperature increase rate satisfies the above numerical range, adsorption, non-flammability, heat insulation, etc. can be maximized.

In the third carbonization step, water vapor or carbon dioxide can be injected, and the water vapor or carbon dioxide can be injected at a rate of 0.5 ml/h to 1 ml/h, and if the injection rate satisfies the above numerical range, it is adsorbent and non-flammable. , insulation properties, etc. can be maximized.

The water vapor or carbon dioxide can increase the pores and specific surface area of activated carbon by removing organic substances and inorganic substances contained in rice husk.

In addition, the present invention can use water vapor and carbon dioxide at the same time, and the volume ratio of water vapor and carbon dioxide is preferably 60 to 80:20 to 40.

When the volume ratio of water vapor and carbon dioxide satisfies the above numerical range, adsorption, non-flammability, and insulation properties can be maximized.

The step (d) is a step of pulverizing the tertiary carbide. The produced tertiary carbide is cooled and then pulverized using a known pulverizing means to obtain activated carbon of a certain size.

The pulverized activated carbon can be dried through a known drying means, and through this, the moisture content of the activated carbon can be adjusted.

In addition, in the present invention, after step (d), the surface of the activated carbon is treated with an acrylate group-containing silane coupling agent, a copolymer of 2-hydroxyethyl acrylate (HEA) and 2-hydroxyethyl methacrylate (HEMA). It can be treated with, and the copolymer can improve the adsorption properties and bonding power of activated carbon.

The acrylate group-containing silane coupling agent includes 3-methacryloxypropylmethyldimethoxysilane, 3-methacryloxypropyltrimethoxysilane, 3-methacryloxypropylmethyldiethoxysilane, and 3-methacryloxypropyltri. These include ethoxysilane, 3-acryloxypropyltrimethoxysilane, methacryloxymethyltriethoxysilane, and methacryloxymethyltrimethoxysilane.

The weight ratio of the acrylate group-containing silane coupling agent, 2-hydroxyethyl acrylate (HEA) and 2-hydroxyethyl methacrylate (HEMA) is preferably 2 to 10:100:20 to 50, and the above values Within this range, binding force and adsorption characteristics can be maximized.

The copolymer is used in an amount of 2 to 10 parts by weight based on 100 parts by weight of activated carbon. If the content is less than 2 parts by weight, the effect of addition is insignificant, and if it exceeds 10 parts by weight, the specific surface area decreases.

In addition, in the present invention, after step (d), the surface of the activated carbon is treated with an acrylate group-containing silane coupling agent, an acrylic acid-based monomer, 2-hydroxyethyl acrylate (HEA), and 2-hydroxyethyl methacrylate (HEMA). ) can be treated with a copolymer, and the copolymer can improve the adsorption characteristics and bonding power of activated carbon.

The acrylic acid-based monomers include acrylic acid, methacrylic acid, carboxylic ethyl acrylate, carboxylic ethyl methacrylate, carboxylic pentyl acrylate, carboxylic pentyl methacrylate, itaconic acid, maleic acid, fumaric acid, methyl acrylic acid, ethyl acrylic acid, These include butyl acrylic acid, 2-ethylhexyl acrylic acid, decyl acrylic acid, methyl methacrylic acid, ethyl methacrylic acid, butyl methacrylic acid, 2-ethylhexyl methacrylic acid, and decyl methacrylic acid.

The weight ratio of the acrylate group-containing silane coupling agent, acrylic acid-based monomer, 2-hydroxyethyl acrylate (HEA), and 2-hydroxyethyl methacrylate (HEMA) is 2~10:30~60:100:20~ Preferably it is 50.

The copolymer is used in an amount of 2 to 10 parts by weight based on 100 parts by weight of activated carbon. If the content is less than 2 parts by weight, the effect of addition is insignificant, and if it exceeds 10 parts by weight, the specific surface area decreases.

The activated carbon has excellent incombustibility, insulation, adsorption, and deodorizing properties, and its low price allows it to be effectively used in fields such as noncombustible materials, insulation materials, adsorbents, and catalysts.

The red clay is used to improve deodorizing properties and antibacterial properties, and is preferably used in an amount of 5 to 20 parts by weight based on 100 parts by weight of sodium silicate.

When the content of red clay satisfies the above range, non-flammability, deodorizing properties, and antibacterial properties can be maximized.

The water is used to control the concentration of the composition and to harden the composition, and the water content is preferably 1 to 20 parts by weight based on 100 parts by weight of sodium silicate.

When the water content satisfies the above numerical range, incombustibility, durability, and insulation properties can be maximized.

In addition, the composition may further include cement, and the cement may be any known cement such as Portland cement, slag cement, alumina cement, gypsum cement, or plastic cement, without limitation.

The cement is preferably used in an amount of 1 to 10 parts by weight based on 100 parts by weight of sodium silicate, and when the cement content satisfies the above numerical range, incombustibility, insulation, and durability can be maximized.

Additionally, the composition may further include sand, and the sand is preferably used in an amount of 1 to 10 parts by weight based on 100 parts by weight of sodium silicate.

When the sand content satisfies the above numerical range, incombustibility, insulation, and durability can be maximized.

In addition, the composition may further include an acrylate group-containing silane coupling agent, a copolymer of 2-hydroxyethyl acrylate (HEA) and 2-hydroxyethyl methacrylate (HEMA).

The weight ratio of the acrylate group-containing silane coupling agent, 2-hydroxyethyl acrylate (HEA) and 2-hydroxyethyl methacrylate (HEMA), is preferably 2 to 10:100:20 to 50.

The copolymer is preferably used in an amount of 1 to 10 parts by weight based on 100 parts by weight of sodium silicate, and when the content of the copolymer satisfies the above numerical range, incombustibility, adhesiveness and insulation can be maximized.

In addition, the composition may further include an acrylate group-containing silane coupling agent, an acrylic acid-based monomer, and a copolymer of 2-hydroxyethyl acrylate (HEA) and 2-hydroxyethyl methacrylate (HEMA).

The weight ratio of the acrylate group-containing silane coupling agent, acrylic acid-based monomer, 2-hydroxyethyl acrylate (HEA), and 2-hydroxyethyl methacrylate (HEMA) is 2~10:30~60:100:20~ Preferably it is 50.

The copolymer is preferably used in an amount of 1 to 10 parts by weight based on 100 parts by weight of sodium silicate, and when the content of the copolymer satisfies the above numerical range, incombustibility, adhesiveness and insulation can be maximized.

In addition, the composition may further include a silane coupling agent containing an acrylate group, a silane coupling agent containing an epoxy group, and a silane coupling agent oligomer prepared by reacting bisphenol A (BPA) and 2-hydroxyethyl acrylate (HEA). .

The epoxy group-containing silane coupling agent includes 2-glycidoxyethylmethyldimethoxysilane, 2-glycidoxyethylmethyldiethoxysilane, 3-glycidoxypropylmethyldimethoxysilane, and 3-glycidoxypropylmethyldiethoxy. Silane, 2-glycidoxyethyltrimethoxysilane, 2-glycidoxyethyltriethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropyltriethoxysilane, 2-(3 ,4-Epoxycyclohexyl)ethylmethyldimethoxysilane, 2-(3,4-epoxycyclohexyl)ethylmethyldiethoxysilane, 3-(3,4-epoxycyclohexyl)propylmethyldimethoxysilane, 3-( 3,4-Epoxycyclohexyl)propylmethyldiethoxysilane, 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, 2-(3,4-epoxycyclohexyl)ethyltriethoxysilane, 3- (3,4-epoxycyclohexyl)propyltrimethoxysilane, 3-(3,4-epoxycyclohexyl)propyltriethoxysilane, etc.

The weight ratio of the acrylate group-containing silane coupling agent, the epoxy group-containing silane coupling agent, bisphenol A (BPA), and 2-hydroxyethyl acrylate is preferably 2 to 10:100:10 to 30:20 to 50.

The weight average molecular weight of the oligomer is preferably 5,000 to 50,000 g/mol.

The oligomer is preferably used in an amount of 1 to 10 parts by weight based on 100 parts by weight of sodium silicate, and when the content of the oligomer satisfies the above numerical range, incombustibility, adhesiveness and insulation can be maximized.

In addition, the composition may further include coal ash, and the coal ash is preferably used in an amount of 1 to 10 parts by weight based on 100 parts by weight of sodium silicate.

When the content of coal ash satisfies the above numerical range, incombustibility, durability, and insulation properties can be maximized.

In addition, the composition may further include briquette material, and the briquette material is preferably used in an amount of 1 to 10 parts by weight based on 100 parts by weight of sodium silicate.

When the content of briquette material satisfies the above numerical range, incombustibility, durability, and insulation properties can be maximized.

In addition, the composition may additionally include shell particles, and as shells, oyster shells, red shells, clam shells, lily shells, abalone shells, etc. can be used without limitation.

The content of shell particles is preferably 1 to 10 parts by weight based on 100 parts by weight of sodium silicate, and when the content satisfies the above numerical range, incombustibility, durability and insulation can be maximized.

The foaming step is a step of forming a foam by foaming polystyrene resin granules, and a known foaming process can be used.

The coating step is a step of forming a coating layer by coating the non-flammable composition on the surface of the foam, and the thickness of the coating layer can be appropriately adjusted by changing the content ratio of the composition and the foam.

Coating methods include a method of immersing a foam of a certain size in a composition and a method of spraying and coating the foam onto the foam.

The coating layer may be formed as a single layer or may be formed as two or more layers as needed. When the coating layer is two layers, the thickness of the first coating layer and the second coating layer may be the same or different.

The molding step is a step of putting the foam on which the coating layer is formed into a mold and pressurizing it to produce Styrofoam molded into a mold shape, and a known molding process can be used.

The drying step is a step of drying the Styrofoam, and dried Styrofoam can be produced by drying at 20 to 80° C. for 1 to 10 hours.

In addition, the present invention includes a coating step of forming a coating layer by coating the non-flammable composition on the dried Styrofoam after the drying step; And it may further include a drying step of drying the Styrofoam on which the coating layer has been formed through the coating step.

Additionally, the present invention relates to non-combustible Styrofoam manufactured by the above manufacturing method.

The non-combustible Styrofoam is coated with a non-combustible composition on the Styrofoam to a certain thickness, so there is no peeling of the coating layer even when used for a long period of time, and it has excellent flame retardancy, incombustibility, heat insulation, durability, sound absorption, and adhesiveness, so it can be used stably for a long period of time.

The present invention will be described in detail below through examples and comparative examples. The following examples are merely illustrative for carrying out the present invention, and the content of the present invention is not limited by the following examples.

(Example 1)

After drying the rice husk, removing impurities, and putting it into a carbonization device, the temperature was raised from 100°C to 300°C at a rate of 5°C/min and maintained at 300°C for 1 hour to perform primary carbonization of the rice husk. At this time, nitrogen was injected at 50 mL/min.

The primary carbide was heated from 300°C to 600°C at a rate of 5°C/min and maintained at 600°C for 1 hour to perform secondary carbonization. At this time, nitrogen was injected at 50 mL/min and water vapor was injected at 0.3 mL/h.

The secondary carbide was heated from 600°C to 900°C at a rate of 5°C/min and maintained at 900°C for 1 hour to perform tertiary carbonization. At this time, nitrogen was injected at 50 mL/min and water vapor was injected at 0.7 mL/h.

The tertiary carbide was cooled and pulverized to prepare activated carbon.

A non-flammable composition was prepared by mixing 100 parts by weight of sodium silicate, 50 parts by weight of potassium silicate, 10 parts by weight of the activated carbon, 10 parts by weight of red clay, and 10 parts by weight of water.

Polystyrene resin granules were expanded to form a foam, and then the non-flammable composition was coated on the surface of the foam to form a coating layer.

The foam on which the coating layer was formed was placed in a mold, and then molded at 0.7 atm and 103° C. to produce styrofoam molded into a mold shape.

The Styrofoam prepared in the molding step was dried at 50°C for 3 hours to produce non-flammable Styrofoam.

(Example 2)

Non-combustible Styrofoam was manufactured in the same manner as in Example 1, except that activated carbon prepared using 100 parts by weight of rice husk and 10 parts by weight of rice husk was used instead of rice husk.

(Example 3)

Prepare a copolymer by mixing and reacting 5 parts by weight of 3-methacryloxypropyltrimethoxysilane, 100 parts by weight of 2-hydroxyethyl acrylate (HEA), and 30 parts by weight of 2-hydroxyethyl methacrylate (HEMA). did.

Activated carbon was surface treated with the above copolymer, and 5 parts by weight of the copolymer was used per 100 parts by weight of activated carbon.

Non-combustible Styrofoam was manufactured in the same manner as in Example 1, except that the surface-treated activated carbon was used.

(Example 4)

Prepare a copolymer by mixing and reacting 5 parts by weight of 3-methacryloxypropyltrimethoxysilane, 100 parts by weight of 2-hydroxyethyl acrylate (HEA), and 30 parts by weight of 2-hydroxyethyl methacrylate (HEMA). did.

Non-combustible Styrofoam was manufactured in the same manner as in Example 1, except that a composition containing 5 parts by weight of the above copolymer was used.

(Example 5)

5 parts by weight of 3-methacryloxypropyltrimethoxysilane, 100 parts by weight of 3-glycidoxypropyltrimethoxysilane, 20 parts by weight of bisphenol A (BPA), and 30 parts by weight of 2-hydroxyethyl acrylate (HEA) Oligomers were prepared by mixing and reacting. At this time, the weight average molecular weight of the oligomer was 30,000 g/mol.

Non-combustible Styrofoam was manufactured in the same manner as in Example 1, except that a composition containing 5 parts by weight of the above oligomer was used.

(Comparative Example 1)

The rice husk was heated from 100°C to 900°C at a rate of 5°C/min and maintained at 900°C for 1 hour to carbonize the rice husk. At this time, nitrogen was injected at 50 mL/min and water vapor was injected at 0.3 mL/h.

The carbide was cooled and pulverized to prepare activated carbon.

Non-combustible Styrofoam was manufactured in the same manner as in Example 1, except that the activated carbon was used.

(Comparative Example 2)

Non-combustible Styrofoam was manufactured in the same manner as Example 1, except that activated carbon was not used.

The properties of the non-combustible Styrofoam manufactured from the above examples and comparative examples were measured, and the results are shown in Table 1 below.

(nonflammable)

Incombustibility was measured according to the method of Korean Industrial Standard KS F 2271.

(Afterflame time)

Flame retardancy was measured according to KOFEIS 1001, and residual flame time refers to the time from when the flame of the burner is removed until the flame is raised and combustion ceases.

(heat resistance)

After producing a coating film from the composition, the dimensional change rate of the coating film was measured according to KS K ISO 3759.

(water resistance)

After preparing a coating film from the composition, the coating film was immersed in water at 20°C for 7 days, and then the condition of the coating film was observed and marked as excellent, good, average, or poor.

division Example Comparative example One 2 3 4 5 One 2 nonflammable
(Flame retardant grade) One One One One One 3 3 Afterflame time
(candle) 8 4 3 4 3 21 30 Dimensional change rate
(%) 2.2 1.3 1.4 1.2 1.0 8.9 9.2 water resistance Great eminence eminence eminence eminence error error

From the results in Table 1, Examples 1 to 5 are excellent in incombustibility, heat resistance, durability and water resistance, and in particular, Examples 2 to 5 have the best properties.

On the other hand, it can be seen that the characteristics of Comparative Examples 1 and 2 are inferior to those of Examples.

Claims (5)

A composition preparation step of preparing a non-flammable composition;
A foaming step of foaming polystyrene resin granules to form a foam;
A coating step of forming a coating layer by coating the non-flammable composition on the surface of the foam;
A molding step of putting the foam on which the coating layer is formed into a mold and pressurizing it to produce styrofoam molded into a mold shape; and
In the method of manufacturing non-combustible Styrofoam, including a drying step of drying the Styrofoam,
The non-flammable composition includes sodium silicate; potassium silicate; activated carbon; ocher; a silane coupling agent containing an acrylate group, a copolymer of 2-hydroxyethyl acrylate (HEA) and 2-hydroxyethyl methacrylate (HEMA); A silane coupling agent containing an acrylate group, a silane coupling agent containing an epoxy group, a silane coupling agent oligomer prepared by reacting bisphenol A (BPA) and 2-hydroxyethyl acrylate (HEA); and water,
The non-flammable composition includes 30 to 70 parts by weight of potassium silicate, 5 to 20 parts by weight of activated carbon, 5 to 20 parts by weight of red clay, 1 to 10 parts by weight of the copolymer, 1 to 10 parts by weight of the oligomer, and A method of manufacturing non-combustible Styrofoam, characterized in that it contains 1 to 20 parts by weight of water.
delete delete According to paragraph 1,
The activated carbon is
(a) Primary carbonization step of carbonizing rice husk to produce primary carbide;
(b) a secondary carbonization step of carbonizing the primary carbide to produce secondary carbide;
(c) a tertiary carbonization step of carbonizing the secondary carbide to produce tertiary carbide; and
(d) A method of producing non-combustible styrofoam, characterized in that it is manufactured by a method comprising the step of pulverizing the tertiary carbide.
Non-combustible Styrofoam manufactured by the manufacturing method of claim 1.