KR102642563B1 - Method for manufacturing semi-combustible panel and semi-combustible panel manufactured therefrom - Google Patents

Abstract

The present invention relates to a method of manufacturing a semi-non-combustible panel and a semi-non-combustible panel manufactured therefrom. More specifically, it relates to a method of manufacturing an eco-friendly semi-non-combustible panel with excellent inter-sheet adhesive strength and a semi-non-combustible panel manufactured therefrom. will be.
The method of manufacturing a semi-non-combustible panel according to the present invention includes the steps of S1) preparing a board containing coal ash; S2) applying adhesive to at least one side of the board; S3) obtaining a base plate by laminating a melamine sheet containing melamine resin on the board coated with the adhesive; and S4) pressuring the base plate to penetrate and cure the adhesive on the board.

Description

Method for manufacturing semi-combustible panel and semi-combustible panel manufactured therefrom}

The present invention relates to a method of manufacturing a semi-non-combustible panel and a semi-non-combustible panel manufactured therefrom. More specifically, it relates to a method of manufacturing an eco-friendly semi-non-combustible panel with excellent inter-sheet adhesive strength and a semi-non-combustible panel manufactured therefrom. will be.

Generally, semi-non-combustible (flame retardant, non-combustible) panels have been made using gypsum as the main material. Gypsum itself has a stable crystalline state, so it is highly stable against changes in humidity and temperature, and is widely used as an interior material because there is no concern about stretching or deformation such as distortion, sagging, or cracking after construction. In addition to these gypsum panels, non-flammable and fire-resistant panels such as ceramic panels and porcelain panels are used.

However, these gypsum panels, ceramic panels, and porcelain panels have disadvantages such as relatively high cost due to the high cost of raw materials for manufacturing and processing costs through high-temperature firing, and insufficient fire resistance, etc.

Meanwhile, thermal power generation among power generation facilities, unlike hydroelectric power generation, wind power generation, which are affected by the environment, and nuclear power generation, which is limited by the facility installation area, can be built even in large cities with high demand for electricity, has economical construction costs, and has a short construction period. Because of its advantages, Korea is increasing the construction of thermal power plants at the government level.

Since thermal power generation uses coal as the main energy source, as thermal power generation facilities and power generation increase, the amount of coal ash generated increases proportionally every year. Coal ash is ash generated after burning oiled or anthracite coal in a thermal power plant and is divided into fly ash and bottom ash. When coal is burned, about 10% of coal ash is generated. Therefore, a large amount of waste coal ashes are generated due to the use of thermal power plants, and the need to prevent environmental pollution and promote recycling and recycling of waste is emerging as an important concern for governments around the world.

The technology to turn waste into effective resources by using coal ash as a raw material for products, which is having difficulties with its disposal both nationally and in industrial sites, is a technology that can eliminate environmental pollutants at the source, solving the problem of environmental pollution and making it a valid resource. It can bring about effects such as securing resources and improving the quality of life of local residents through the recycling effect. Furthermore, the need for more active utilization is required because it can create significant added value in a country like Korea that is not rich in resources.

Recently, in order to solve this problem, technology for a fireproof board using coal ash has been developed, as disclosed in the method of manufacturing a fireproof board using coal ash in Republic of Korea Patent Publication No. 10-1098266. In this way, panels (boards) made from coal ash as the main material are lighter than gypsum and have better fire resistance, heat resistance, and strength. In addition, the problem of environmental pollution can be solved by reusing waste that causes environmental pollution.

Conventionally, when panels using coal ash are used as building interior materials, patterned paper (sheets) are attached to them for a sleek aesthetic. However, when the patterned paper is glued to the panel as is, its adhesiveness is poor, which limits its use for interior materials such as architectural interior materials, furniture, and sinks that require various designs.

Accordingly, an eco-friendly semi-non-combustible panel applicable to furniture and building materials and a manufacturing method thereof were disclosed in Republic of Korea Patent Publication No. 10-1695624. This panel manufacturing method allows the expression of various designs by laminating separate surface materials on one or both sides of the coal ash panel, but there is still a limitation in that only specific surface materials are possible. In addition, the adhesion between the coal ash panel and the surface material is not very high, so there is a disadvantage that defects frequently occur when actually used as an interior material.

: Republic of Korea Patent Publication No. 10-1098266 : Republic of Korea Patent Publication No. 10-1695624

The purpose of the present invention is to provide a method for manufacturing an environmentally friendly semi-non-combustible panel with excellent inter-sheet adhesive strength, and a semi-non-combustible panel manufactured therefrom.

The method of manufacturing a semi-non-combustible panel according to the present invention includes the steps of S1) preparing a board containing coal ash; S2) applying adhesive to at least one side of the board; S3) obtaining a base plate by laminating a melamine sheet containing melamine resin on the board coated with the adhesive; and S4) pressurizing the base plate at room temperature to penetrate and cure the adhesive on the board.

In the semi-non-combustible panel manufacturing method according to an embodiment of the present invention, after step S3) and before step S4), S3-1) inserting the base plate into a roller to infiltrate the adhesive into the board; It may further include.

In the semi-non-combustible panel manufacturing method according to an embodiment of the present invention, in step S4), pressurization may be performed under a pressure of 135 to 160 kgf/cm2.

In the semi-non-combustible panel manufacturing method according to an embodiment of the present invention, in step S4), pressurization may be performed for 20 to 60 hours.

In the semi-non-combustible panel manufacturing method according to an embodiment of the present invention, the adhesive may have a viscosity of 85 to 98 Pa·s, as measured according to KS M 3700.

In the semi-non-combustible panel manufacturing method according to an embodiment of the present invention, the adhesive may be a water-based flame retardant adhesive.

In the method of manufacturing a semi-noncombustible panel according to an embodiment of the present invention, the adhesive contains 1 to 6 parts by weight of a plasticizer based on 100 parts by weight of the base resin, and the base resin includes a vinyl acetate-ethylene copolymer, Plasticizers may include cyclohexane dicarboxylate-based compounds.

The semi-non-combustible panel according to the present invention includes a board containing coal ash; an adhesive layer formed by applying an adhesive on at least one surface of the board; An adhesion reinforcement layer located between the board and the adhesive layer, where the board and the adhesive are mixed; and a melamine sheet laminated on the adhesive layer.

In the semi-non-combustible panel according to an embodiment of the present invention, the thickness of the adhesive reinforcement layer with respect to the total thickness (D) of the board may be 0.01D to 0.3D.

The semi-non-combustible panel manufacturing method according to the present invention allows the adhesive to penetrate and cure on the board, thereby producing a semi-non-combustible panel with high adhesive strength between the board and the sheet.

In addition, as the adhesive penetrates and hardens while maintaining pressure, bending of the manufactured flame retardant panel is prevented, making it possible to manufacture high quality semi-non-combustible panels.

The semi-non-combustible panel according to the present invention has a reinforced adhesive layer and has high adhesion between the board and the sheet, so it can be used as a variety of construction materials.

Figure 1 is a block diagram simulating a semi-noncombustible panel manufacturing method according to an embodiment of the present invention;
Figure 2 is a perspective view of a semi-non-combustible panel according to an embodiment of the present invention;
Figure 3 is a cross-sectional view of the semi-non-combustible panel shown in Figure 2;
Figure 4 is a photograph of a pressurizer used in manufacturing a semi-non-combustible panel according to an embodiment of the present invention.

Unless otherwise defined, the technical and scientific terms used in this specification have the meanings commonly understood by those skilled in the art to which this invention pertains, and the gist of the present invention is summarized in the following description and accompanying drawings. Descriptions of known functions and configurations that may unnecessarily obscure are omitted.

Additionally, as used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly dictates otherwise.

In addition, units used without special mention in this specification are based on weight, and as an example, the unit of % or ratio means weight % or weight ratio, and weight % refers to the amount of any one component of the entire composition unless otherwise defined. It refers to the weight percent occupied in the composition.

In addition, the numerical range used in this specification includes the lower limit and upper limit and all values within the range, increments logically derived from the shape and width of the defined range, all double-defined values, and the upper limit of the numerical range defined in different forms. and all possible combinations of the lower bounds. Unless otherwise specified in the specification of the present invention, values outside the numerical range that may occur due to experimental error or rounding of values are also included in the defined numerical range.

The term 'comprise' in this specification is an open description with the same meaning as expressions such as 'comprising', 'contains', 'has' or 'characterized by', and includes elements that are not additionally listed, Does not exclude materials or processes.

Conventionally, when panels using coal ash are used as building interior materials, patterned paper (sheets) are attached to them for a sleek aesthetic. However, when the patterned paper is glued to the panel as is, its adhesiveness is poor, which limits its use for interior materials such as architectural interior materials, furniture, and sinks that require various designs. Accordingly, it has been possible to express various designs by laminating separate surface materials on one or both sides of the coal ash panel, but there is still a limitation in that only specific surface materials are possible. In addition, the adhesion between the coal ash panel and the surface material is not very high, so there is a disadvantage that defects frequently occur when actually used as an interior material.

The semi-non-combustible panel manufacturing method according to the present invention allows the adhesive to penetrate and harden the board to manufacture a semi-non-combustible panel with high adhesion between the boards and sheets, and firmly adheres sheets (patterned paper) of various materials to the board. It is possible to manufacture semi-non-combustible panels with various aesthetics. In addition, as the adhesive penetrates and hardens while maintaining pressure, bending of the manufactured flame retardant panel is prevented, making it possible to manufacture high quality semi-non-combustible panels with high flatness.

Figure 1 is a block diagram showing a method of manufacturing a semi-non-combustible panel according to an embodiment of the present invention.

Referring to Figure 1, the method for manufacturing a semi-non-combustible panel according to the present invention includes the steps of S1) preparing a board containing coal ash; S2) applying adhesive to at least one side of the board; S3) obtaining a base plate by laminating a melamine sheet containing melamine resin on the board coated with the adhesive; and S4) pressuring the base plate to penetrate and cure the adhesive on the board.

Specifically, step S1) is a step of preparing a board containing coal ash (board preparation step). The board containing coal ash is not particularly limited as long as it contains coal ash and is known as a conventional fire-resistant, semi-fireproof, non-combustible and flame-retardant board. Specifically, coal ash contains highly fire-resistant silica and aluminum oxide, and the content is generally known to be in the range of 40 to 60 wt% for silica and 20 to 40 wt% for aluminum oxide, but the composition ratio varies depending on the coal mining area. It is natural that things may vary. Coal ash is classified into fly ash and bottom ash, and the coal ash used for the board containing the coal ash in step S1) may be composed of only fly ash and bottom ash, or may be in a mixed form. Coal ash has porous spherical particles and has good processability, and the particle size is generally 1 to 200 μm, preferably 1 to 100 μm. In addition, if necessary, it is possible to pulverize coal ash into a fine size of 10 μm or less with a pulverizer in order to improve the efficiency of fireproof, non-combustible, and flame-retardant boards. The content of coal ash in the board is not particularly limited. It is possible to use a coal ash content of 30 to 70 wt%, more advantageously 40 to 60 wt% for flame retardant properties. In the above range, it is advantageous for the adhesive to penetrate the board surface in steps S4) and S3-1), which will be described later. Of course, the board containing coal ash may further include other additives such as conventional inorganic binders, organic binders, reinforcing agents, and pore forming agents.

After step S1), step S2) of applying adhesive to at least one surface of the board is performed.

In step S2) (adhesive application step), application is not particularly limited as long as it is a conventionally known adhesive application method. Specifically, the application method may be a conventional method such as spreader coating, spin coating, bar coating, slot die coating, spray coating, dip coating, and gravure coating. Specifically, the adhesive can be coated on one or both sides of a board containing coal ash using a spreader.

The thickness at which the adhesive is applied to the board in step S2) is not particularly limited as long as it is a thickness that can exhibit adhesive force. As an example, adhesive may be applied on the board to a thickness of 0.01 to 1 cm.

The adhesive is not particularly limited as long as it is known as a conventional architectural/industrial adhesive. Specifically, the adhesive may be a water-based flame retardant adhesive. This type of adhesive is environmentally friendly and is suitable for maintaining the flame retardant effectiveness of the board when applied to semi-non-combustible panels.

Specifically, the adhesive may have a viscosity measured based on KS M 3700 of 85 to 98 Pa·s, more specifically 90 to 95 Pa·s. In the above range, the adhesive penetrates into the board, but the adhesive remains appropriately on the surface and can exhibit high adhesive strength.

Specifically, the adhesive contains 1 to 6 parts by weight of a plasticizer based on 100 parts by weight of the base resin, the base resin includes a vinyl acetate-ethylene (VAE) copolymer, and the plasticizer may include a cyclohexane dicarboxylate-based compound. there is. This type of adhesive is environmentally friendly because it contains vinyl acetate-ethylene copolymer as a base resin and does not use brominated flame retardants compared to synthetic rubber latex used in conventional flame retardant adhesives. In addition, by applying an eco-friendly cyclohexane dicarboxlate-based compound with excellent flame retardancy as a plasticizer, the adhesive strength is increased and it can be applied as an eco-friendly material.

The base resin contains vinyl acetate-ethylene (VAE) copolymer, and may advantageously use only vinyl acetate-ethylene (VAE) copolymer. The base resin may be an aqueous emulsion in which vinyl acetate-ethylene (VAE) copolymer is dispersed in an aqueous medium, specifically, vinyl acetate-ethylene (VAE) copolymer particles are dispersed in water. At this time, the average particle diameter of the particles of the base resin is not particularly limited. Specifically, the average particle diameter of the base resin particles may be 100nm to 3㎛, more specifically 700nm to 2㎛. The average particle diameter can be measured according to conventional particle size distribution measurement methods such as optical microscopy and light scattering measurement.

The vinyl acetate-ethylene (VAE) copolymer may have a weight average molecular weight of 100,000 g/mol to 700,000 g/mol or less. In the above range, it can have excellent adhesive properties and have an appropriate viscosity that can penetrate the board surface in the subsequent steps S4) and S3-1). The weight average molecular weight (Mw) of the vinyl acetate-ethylene (VAE) copolymer may refer to polyvinyl chloride and polystyrene conversion values, respectively, measured by gel permeation chromatography (GPC).

The plasticizer may be a cyclohexane dicarboxylate-based compound, specifically, a cyclohexane dicarboxylate-based compound containing two C _4-10 alkyl groups. In a cyclohexane dicarboxylate-based compound, the two alkyl groups may be the same or different from each other. More specifically, the two alkyl groups are the same and may be C _4-10 alkyl groups. More specifically, the two alkyl groups are C _4-8 straight chain alkyl groups such as n-butyl; Alternatively, it may be a C _6-10 branched chain alkyl such as ethylhexyl, isononyl, etc. The above plasticizer can improve adhesion and low-temperature stability along with the base resin, vinyl acetate-ethylene (VAE) copolymer.

More specific examples include di(2-ethylhexyl)cyclohexane-1,4-dicarboxylate (DEHCH), diisononylcyclohexane-1,2- Diisononyl cyclohexane-1,2- dicarboxylate (DINCH), Di (2-ethylhexyl) cyclohexane- 1,2-dicarboxylate; DOCH), or dibutyl cyclohexane-1,4-dicarboxylate (DBCH), etc., and any one or a mixture of two or more of these may be used. Advantageously, the plasticizer may be Diisononyl cyclohexane-1,2-dicarboxylate (DINCH). DINCH, along with the vinyl acetate-ethylene (VAE) copolymer as the base resin, maintains the viscosity of the adhesive within the above range in the subsequent step S4), thereby ensuring proper penetration and curing of the adhesive into the board.

Step S3) (sheet laminating step) is a step of obtaining a base plate by laminating a melamine sheet containing melamine resin on the board coated with the adhesive. The melamine sheet is not particularly limited as long as it is a conventionally used melamine sheet. Specifically, melamine-impregnated paper in which the substrate is immersed in melamine resin can be used. A base plate is manufactured by laminating melamine sheets on one or both sides of a board to which adhesive is applied.

Step S4) (secondary penetration step) includes pressing the base plate obtained in step S3) at room temperature to penetrate and cure the adhesive on the board. In step S4), the pressure is 135 to 160 kgf/ It can be carried out under cm2 pressure, specifically 140 to 160 kgf/cm2. At this time, the pressurization is performed at room temperature (20 ± 5°C) without heating. Additionally, pressurization may be performed at room temperature for 20 to 60 hours, specifically 40 to 50 hours. Under these pressurized conditions, the adhesive can penetrate the surface of the board. Through this pressurization, the adhesive can be placed both on and on the surface of the board, further strengthening the adhesion between the board and the sheet. At this time, the surface of the board refers to an area exposed to the outside, and may refer to an area that is 0.2D or less in thickness (D) of the board. On the surface means in contact with the surface. In addition, in step S4), as the curing of the adhesive is completed in a pressurized state, bending of the board and wrinkles of the sheet due to curing by the curing agent can be prevented, making it possible to manufacture a higher quality flame retardant panel.

In the semi-non-combustible panel manufacturing method according to an embodiment of the present invention, after step S3) and before step S4), step S3-1) inserting the base plate into a roller to infiltrate the adhesive onto the board. It may further include ;. The roller of step S3-1) (first penetration step) can be the roller of the spreader used when applying the adhesive in step S2), but of course, it can also be performed using a separate roller. As the first adhesive is added to the board in step S3-1), the penetration of the adhesive into the board occurs more smoothly in step S4), allowing the adhesive to penetrate evenly into the board surface. Accordingly, the melamine sheet can be adhered to the board with stronger adhesive force, making it possible to manufacture a semi-non-combustible panel with greater durability. In addition, in step S3-1), air bubbles formed between the melamine sheet and the adhesive or between the adhesive and the board are removed using a roller, making it possible to manufacture a high-quality semi-non-combustible panel with a uniform surface.

2 to 3 show a semi-non-combustible panel according to an embodiment of the present invention.

Referring to Figures 2 and 3, the semi-non-combustible panel according to the present invention includes a board (10) containing coal ash; an adhesive layer 30 formed by applying an adhesive on at least one surface of the board 10; An adhesion reinforcement layer (20) located between the board (10) and the adhesive layer (30), where the board (10) and the adhesive are mixed together; and a melamine sheet 50 laminated on the adhesive layer 30. Such a semi-non-combustible panel has high adhesion between the board 10 and the sheet 50 due to the adhesive reinforcement layer 20, so it can be used as a variety of construction materials.

Specifically, such a semi-non-combustible panel may be manufactured through the semi-non-combustible panel manufacturing method of the present invention described above.

The board 10 containing coal ash, the adhesive, and the melamine sheet 50 have the same configuration as the coal ash board, adhesive, and melamine sheet of the above-described manufacturing method, and detailed descriptions thereof will be omitted below.

The adhesive reinforcement layer 20 is formed between the board 10 and the adhesive layer 30, and is formed by a portion of the adhesive of the adhesive layer penetrating into the surface of the board. Accordingly, the surface of the board 10 is mixed with coal ash, other additives, and adhesives. A semi-non-combustible panel including such an adhesion reinforcement layer 20 can have superior durability as the adhesive force between the board 10 and the melamine sheet 50 is strengthened. Therefore, it is easy to apply to interior materials.

Specifically, the thickness of the adhesion reinforcement layer 20 relative to the total thickness (D) of the board is not particularly limited. The thicker the board 10 is, the thinner the thickness occupied by the adhesion reinforcement layer 20 may be. Specifically, the thickness occupied by the adhesion reinforcement layer 20 with respect to the total thickness (D) of the board may be 0.01D to 0.3D, more specifically, 0.1 to 0.2D, but is of course not limited thereto. However, within the above range, the desired effect of the adhesion reinforcement layer 20 can be obtained and the compressive strength of the board may not be reduced.

Hereinafter, the present invention will be described in more detail based on examples and comparative examples. However, the following Examples and Comparative Examples are only one example to explain the present invention in more detail, and the present invention is not limited by the following Examples and Comparative Examples.

[Example 1]

Adhesive (6500, viscosity: 93 Pa·s, Sungwoo Plus Co., Ltd.) was applied to both sides of the coal ash board (containing 50w% fly ash) using a spreader, and then melamine sheets (thickness of 0.7 mm) were laminated to produce a base plate. . Afterwards, a semi-non-combustible panel was manufactured by pressing both sides of the base plate through a presser (FIG. 4) at room temperature (20 ± 5°C) at a pressure of 150 kgf/cm2 for 48 hours.

[Example 2]

In Example 1, a semi-noncombustible panel was manufactured in the same manner as Example 1, except that the base plate was placed on the roller of the spreader and then pressed before pressing the base plate.

[Example 3]

In Example 1, a semi-noncombustible panel was manufactured in the same manner as Example 1, except that the pressurization was performed at a pressure of 130 kgf/cm2 for 48 hours.

[Example 4]

In Example 1, a semi-noncombustible panel was manufactured in the same manner as Example 1, except that the pressurization was performed at a pressure of 150 kgf/cm2 for 1 hour.

[Example 5]

In Example 1, a semi-noncombustible panel was manufactured in the same manner as Example 1, except that the pressurization was performed at a pressure of 130 kgf/cm2 for 1 hour.

[Example 6]

In Example 1, a semi-noncombustible panel was manufactured in the same manner as Example 1, except that an adhesive having a viscosity of 84 Pa·s was used.

[Example 7]

In Example 1, a semi-noncombustible panel was manufactured in the same manner as Example 1, except that an adhesive having a viscosity of 99 Pa·s was used.

[Comparative Example 1]

In Example 1, a semi-noncombustible panel was manufactured in the same manner as Example 1, except that the press plate of the press was heated to 60°C.

(Experiment 1)_Measurement of adhesion

The adhesion of the manufactured semi-non-combustible panel was measured. The adhesion (peel strength) between the board and the melamine sheet was measured using the 180° peel test method (ISO 8510-2). The results are listed in Table 1 below.

(Experiment 2)_Appearance evaluation

The surface defects of the manufactured semi-non-combustible panels were measured and their appearance was evaluated. After counting the number of defects (bubble) per unit area (20 cm × 20 cm), each sample was evaluated using a 10-point scale. The closer it is to 10, the more bubbles there are.

It means less.

Number of bubbles ~2 3~5 6~8 9~12 13~15 17~20 21~25 26~35 36~40 41~ converted score 10 9 8 7 6 5 4 3 2 One

division Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 Comparative Example 1 Peel strength (gf/㎜) 24.56 27.31 19.22 18.92 17.23 17.80 21.22 15.27 Appearance evaluation 9 10 9 8 7 6 6 4

Referring to Table 2, it was confirmed that the examples had excellent peel strength and excellent appearance compared to the comparative examples. In particular, it was confirmed that Examples 1 and 2 had excellent peel strength and appearance. In the case of Example 2, it was found that it had an absolutely beautiful appearance and that the adhesive strength (peel strength) was very high.

As described above, the present invention has been described with specific details, limited embodiments, and drawings, but these are provided only to facilitate a more general understanding of the present invention, and the present invention is not limited to the above embodiments, and the present invention Anyone skilled in the art can make various modifications and variations from this description.

Accordingly, the spirit of the present invention should not be limited to the described embodiments, and the scope of the patent claims described below as well as all modifications that are equivalent or equivalent to the scope of this patent claim shall fall within the scope of the spirit of the present invention. .

10: Board 30: Adhesion reinforcement layer
50: Adhesive layer 70: Melamine sheet

Claims (3)

S1) preparing a board containing 40 to 60 wt% of coal ash;
S2) applying adhesive to at least one side of the board;
S3) obtaining a base plate by laminating a melamine sheet containing melamine resin on the board coated with the adhesive;
S3-1) Inserting the base plate into a roller to infiltrate the adhesive into the board;
S4) pressurizing the base plate at room temperature to penetrate and cure the adhesive on the board;
The coal ash in step S1) is either fly ash or bottom ash, or a mixture of fly ash and bottom ash,
The adhesive in step S2) is a water-based flame retardant adhesive and has a viscosity of 85 to 98 Pa·s,
In step S4), pressurization is performed for 20 to 60 hours under a pressure of 135 to 160 kgf/cm2,
A method of manufacturing a semi-non-combustible panel in which the adhesive is penetrated into the surface of the board to form an adhesive reinforcement layer. According to paragraph 1,
The adhesive in step S2) contains 1 to 6 parts by weight of a plasticizer based on 100 parts by weight of the base resin,
The base resin includes a vinyl acetate-ethylene copolymer having a weight average molecular weight of 100,000 to 700,000 g/mol, and the plasticizer includes a cyclohexane dicarboxylate-based compound. A semi-non-combustible panel, characterized in that it is manufactured by the manufacturing method of claim 1 or 2.

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