KR20170099428A - Dual composite material duct - Google Patents

Abstract

A dual composite material duct is disclosed. The dual composite material duct comprises: a corrosion resistant layer comprising SR841 resin; and a reinforcement layer comprising DS-200 resin. The present invention has an improved mechanical physical property.

Description

Dual composite material duct < RTI ID = 0.0 >

The present invention relates to a dual composite duct, which comprises mixing a finely precipitated Grade Mineral Flame retardants (finely-grained mineral flame retardant) with a reactive resin based on acrylic resin or metal-cyanate (MMA) The present invention relates to a dual composite material duct which improves productivity by reducing the influence on hardenability and viscosity, has flame retardancy and fire resistance, and improves mechanical properties to maintain structural strength even in the event of a fire.

1 shows the structure of a conventional phenolic resin duct.

Referring to FIG. 1, a conventional phenolic resin duct 100 includes a corrosion resistant layer 110, an intermediate layer 120, and an outermost layer 130.

The corrosion resistant layer 110 is a corrosion / flame prevention layer, the intermediate layer 120 is an anticorrosion preventing layer, and the outermost layer 130 is a corrosion prevention layer.

In the conventional duct 100, the corrosion resistant layer 110 is made of ordinary vinyl ester resin and the outermost layer 130 is made of phenol resin. The intermediate layer 120 serves to hold the corrosion resistant layer 110 and the outermost layer 130 because the characteristics of the two resins are different from each other.

The problem with such a conventional phenol resin duct 100 is that the interlayer peeling phenomenon occurs due to the difference in shrinkage ratio between the corrosion resistant layer 110 and the outermost layer 130 after curing or after a certain period of time. To prevent this, an intermediate layer 120 serving as a bonding is used. There is a limit to the bonding role of the intermediate layer 20.

In addition, since the conventional phenol resin duct 100 requires a separate process for forming the intermediate layer 20, there is a problem that a labor cost is large and a manufacturing time is long.

Another problem with conventional phenolic resin ducts 100 is their shrinkage. After all the FRP products are installed in the field, shrinkage occurs due to natural hardening. Especially, in the case of the m-phenol resin duct, such shrinkage is seriously occurring. As a result, the peeling phenomenon between the corrosion resistant layer 110 and the outermost layer 130 causes the substances in the phenol resin duct 100 to come out to the outside and damage the product.

FIG. 2 shows the phenomenon that the materials in the conventional phenolic resin duct shown in FIG. 1 come out and damage the product.

FIG. 3 shows the cross-section of the phenolic resin duct, moisture release and cracking.

There is a cracking phenomenon of the phenol resin itself. This is because as the phenolic resin is cured, the moisture contained in the phenolic resin itself is discharged to the outer surface of the phenolic resin duct 100, thereby breaking the phenolic resin itself.

Another problem of the conventional phenol resin duct 100 is caused by the characteristics of the phenol resin itself. That is, the mechanical strength is weak.

On the other hand, problems related to maintenance (a / s) in the field of the conventional phenolic resin duct 100 are as follows.

If an a / s occurs due to the problems mentioned above, it is necessary to perform field work, but the field work is very difficult due to hardening problem. For example, when the phenol resin duct 100 is straight, it may be manufactured at a factory to replace the problematic parts, but the fittings can not cope with such a problem.

The fittings should be made of T (T), Elbow, etc. Since most custom work is done in the field, there is a problem in repairing because there is no hardening problem or hardening furnace when working in the field.

Also, the cost of a / s entering due to the delamination problem becomes a burden.

There is a furan resin duct which complements the problem of peeling and corrosion resistance due to shrinkage of existing phenolic resin duct (100).

Fig. 4 shows the structure of a conventional furan resin duct.

Referring to FIG. 4, it can be seen that the furan resin duct 400 has a different structure from the phenol resin duct 100.

First, the furan resin duct 400 is advantageous in that it is made of a single structure, that is, a furan resin alone. The furan resin duct 400 has a corrosion resistant layer and an outermost layer made of one resin and has no intermediate layer 120 for bonding the corrosion resistant layer 110 and the outermost layer 130 as in the case of the phenol resin duct 100 .

However, the problem is that the hardener added to the furan resin is sensitive to weather and sensitive to the rate, so there is a high risk of explosion and fire in the field.

FIG. 5 shows an explosion phenomenon according to elapsed time after mixing of the curing agent.

In addition, such a furan resin duct 400 also has a problem in that it consumes much time and labor due to the problem of the ratio of the hardener in the manufacturing process and the sensitivity to summer and winter weather.

In addition, in the case of the furan resin duct 400, it is necessary to perform a two-step process in which it is cured separately at room temperature after curing at room temperature and then cured at room temperature and then cured at room temperature. Therefore, the production per day of duct 6M is about 4 per day. Production is falling that much.

Since the furan resin duct 400 is a temperature sensitive product, it must be kept at a room temperature of 25 ° C during production, that is, it must have a constant temperature and humidity facility, and is sensitive to a temperature cycle at the time of high temperature curing.

Fig. 6 shows the appearance of the duct from the curing furnace.

Referring to FIG. 6, it can be seen that there is sensitivity to the curing temperature.

It is an object of the present invention to provide a dual composite duct having improved flame retardancy and fire resistance as well as improved productivity.

It is another object of the present invention to provide a double composite duct having improved mechanical properties to maintain structural strength even in the event of fire.

To achieve the above object, the present invention provides a double composite duct

A corrosion resistant layer made of SR841 resin; And

Reinforcing layer composed of DS-200 resin;

And a control unit.

Here, it is preferable that the corrosion resistant layer is constituted by adding a flame retardant to the SR841 resin.

It is preferable to further include an outermost layer composed of a UV coating, a kelcoat, and a flame retardant paint to finish the reinforcing layer.

Here, the DS-200 resin is a mixture of mineral resin (Finely Precipitated Grade) mineral flame retardants (finely solidified mineral flame retardant) based on styrene, acryl or methacrylic acid (MMA) as a polymer compound do.

The double composite duct according to the present invention not only improves productivity but also has flame retardancy and fire resistance.

Further, the double composite material duct according to the present invention has an effect of having improved mechanical properties to maintain the structural strength even in the event of fire.

1 shows the structure of a conventional phenolic resin duct.
FIG. 2 shows the phenomenon that the materials in the conventional phenolic resin duct shown in FIG. 1 come out and damage the product.
FIG. 3 shows the cross-section of the phenolic resin duct, moisture release and cracking.
Fig. 4 shows the structure of a conventional furan resin duct.
FIG. 5 shows an explosion phenomenon according to elapsed time after mixing of the curing agent.
Fig. 6 shows the appearance of the duct from the curing furnace.
7 shows the construction of a double composite duct according to the present invention.
8 shows a barrier structure of a multi-laminate composite duct.
9 shows a photograph of the specimen after carbonization.
Figure 10 shows the shape of the mandrel.
Figure 11 shows the winding of a masking tape on a mandrel.
Figure 12 illustrates applying an elongated organic veil.
Figure 13 shows forming a Corrosion Resistance Barrier Barrier (CRFB).
Fig. 14 shows the shape before demoulding.
Fig. 15 shows the shape after demoulding.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

FIG. 7 shows the construction of a double composite material duct according to the present invention. The left side of FIG. 1 shows a circular duct and the right side of FIG. 1 shows a square duct.

Referring to FIG. 7, a dual composite duct 700 according to the present invention includes a corrosion resistant layer 710, a reinforcing layer 720, and an outermost layer 730.

The corrosion-resistant layer 710 is made of SR841 resin, which is a super corrosion resistant resin, and a certain amount of flame retardant is added to impart flame retardancy.

The reinforcing layer 720 is made of DS-200 resin.

The outermost layer 730 is finished with UV coating, kelcoat, and flame-retardant paint according to the construction company for finishing.

The advantage of the dual composite duct 700 according to the present invention is that it has both FRP mechanical properties and corrosion resistance and flame retardancy.

And it has the advantage of excellent workability and productivity because it has the workability of ordinary FRP.

■ Outline and characteristics of DS-200 resin:

The DS-200 resin is a mixture of styrene, acrylic or methacrylic acid (MMA) -based reactive resin (Finely Precipitated Grade) and Mineral Flame retardants (fine-grained mineral flame retardant) And viscosity, as well as improving flame retardancy and fire resistance, as well as improving mechanical properties to maintain structural strength even in the event of fire.

The DS-200 reactive resin is a polymer having a styrene bond in the molecule in the MMA type resin. The unsaturated polyester resin (polyester for short) is hybridized, and when the catalyst (curing agent) is added, the curing reaction occurs, Which is a reactive resin for causing a polymerization reaction to occur in the thermosetting resin.

This chemical compound has a carbon double bond (C = C) structure and maximizes the flame retardancy of the resin itself. The most important chemical component of this product system is Methyl Methyacrylate Reactive Resin (MMA).

The MMA copolymerization reactive resin is a copolymer resin produced through a complicated and rigid polymerization reaction process having a specific double carbon bond structure with Acrylic Acid and Methacrylic Acid Ester.

The polymerization of the DS-200 reactive resin is accomplished by the addition of a powder hardener (DMA dimethyl aniline). The nature of this curing process makes it different from other reactive resins consisting of a liquid phase and a liquid cure accelerator that must be mixed at precise proportions for total curing.

That is, in the DS-200 reactive resin, DMA has a unique role in inducing chemical polymerization. DMA acts as a catalyst for the chemical reaction and does not affect the physical properties of the fully cured resin.

The DS-200 resin styrene bond and the chemical structure and reaction mechanism of MMA are shown in the following figure.

 Features of DS-200 Refractory Resin vs. Phenol and Furan Resin and FRs Filled UPR

 ▶ Room temperature hardening

 ▶ Does not contain formaldehyde

 ▶ No need for acid catalyst - Peroxide hardening

 ▶ No need for post curing (at 80 ℃) - Increase productivity

 ▶ Storage stability (2 months ~ 6 months)

 ▶ Excellent mechanical strength

 ▶ Excellent workability in commercial molding method (manual, winding, drawing, etc.)

 ■ Fire Resistance Features

  ▶ Does not contain halogen / CMR (carcinogen, mutagenic, reproductive toxicant).

  ▶ It has flame retardancy and fire resistance: it maintains structural strength even in case of fire

▶ Approvals: Completely hardened laminate satisfies fire standards such as British Standards and International Marine Organization (IMO Certification).

British Standards

BS 476 Part 6: 1989 - i and I indices less than 6 and 12 respectively

BS 476 Part 7: 1997 - Class 1/0.

Section E15 of the Building Regulations 1985, for a Class 0 structure.

BS 6853 1999: Interior Vertical Surface (Table 2) - Category 1a.

Epiradiateur (NFP 92, 501, NFF 16-101) - M1, F0.

International Marine Organization  (IMO Certification)

MSC 61 (67), Annex 1, Pt2 (Smoke and toxicity test) Satisfies both bulkheads, walls and ceilings.

A653 (16): 1996, amended by MSC 61 (67): Annex 1, Pt5, (Surface flammability)

It meets all IMO standards and is considered a low flame spread in compliance with the standards of the International Convention on Safety of Life at Sea, 1974.

Comparison of DS-200 fire resistance test against phenol and furan resin (BIO) No TEST ITEM UNIT TEST SPEC. Criteria PHENOL BIO DS-200      FIRE RETARDENT LOW SMOKE TEST One Oxygen index
(LimitingOxygenIndex) LOI ASTMD2863
ISO4589-2 LOI≥40 40.4 56.4 71.2 2 Flame propagation
(FlameSpread) ASTME84
ISO5658-2 CFE20 20KW / 20.8 25.8 28 Qsb 1.5 1.5 MJ / 3.91 3 11.87 3 Smoke density
(SmokeDensity) Smoke
Density IMO FTP CODE
PART2 200 (ceiling, wall materials, etc.) 123.3 Flaming
mode
(ASTM
E662) Ds (1.5 min)? 50 50 36.8 3.6 0.16 Ds (4 min)? 100 100 64.9 38.6 25.7 Ds (10 min)? 200 200 111 72.6 120.1 4 Gas toxicity
(ToxicGas) BS 6853 Annex B.2 R? 0.39 0.75 0.23

■ Knowledge Base

 ▶ Composition / Information on ingredients

Name and content of ingredients Ingredient Name Ingredient Name CAS number content(%) Styrene 100-42-5 ≥10 - <25 Methyl Methacrylate 80-62-6 ≥20 - <25 Maleic Anhydride 108-31-6 ≥ 0.1 - <0.3 Phthalic Anhydride 85-44-9 ≥ 0.1 - <0.3

  ▶ Pot Life

DMA 0.4% and Perkadox 50X 2% parts are added to DS-200 resin and cured.

Depending on the curing conditions, 0 ~ 0.4% (based on the resin content) is added as retardant as shown below.

The retarder (F-2) Gel-Time (20) / minute 0 13.5 0.10% 20 0.20% 30 0.40% 40

  ▶ Chemical Properties (Chemical Properties)

The chemical analysis of the DS-200 resin is shown in Table 4.

Property Unit DS-200 Appearance - White Brown Viscosity at 25 ℃ cp.s 1,800 3,700 Density at 25 ℃ gcm-3 1.8 Volatile Content % 30 Stability at 20 ° C Months > 6 HDT 175

  ▶ Mechanical Strength

The mechanical analysis of the DS-200 laminate is as follows.

Property Unit DS-200 Tensile Strength ASTM D 638 97.6 Mpa Tensile Modulus 11.7 Gpa Compression Strength ASTM D 695 173 Mpa Compression Modulus 13.0 Gpa Flexual Strength ASTM D 790 79.2 Mpa Flexual Modulus 8.74 Gpa Barcol Hardness 55

  ▶ Health and Safety

The DS-200 resin is a liquid resin that reacts at room temperature and should be stored at a temperature of 15 ° C for easy viscosity change. Direct skin contact may cause dermatitis depending on the constitution (wash with water or alcohol immediately after handling)

Hereinafter, a method of manufacturing a double composite material duct according to the present invention will be described.

Ducts are divided into a) "Corrosive Fire Barrier (CRFB)", B) "Structural Corrosion / Fire Barrier" (SCFB) and can optionally be added for third UV protection and outdoor installation . Generally, the total corrosion barrier is the total laminate thickness.

8 shows a barrier structure of a multi-laminate composite duct.

The SR841LV resin system is completely composed of CRFB.

Thus, the SR841LV resin system is typically 2.0-3.0 mm thick (0.08-0.12 inches). The thickness of the resin used did not exceed 3.0 mm (0.12 inches). Thus, in either case, the thickness of the SR841LV resin system is 3.0 mm (0.12 inches). And should be less than about 3.0 mm (0.12 in.) Using DS-200 resin and filament winding. The thickness of the SCFB depends on the overall duct diameter.

- Corrosive fire barrier "(CRFB) is the first contact point between chemical and fire. It should be produced using one of the following:

a. For a wide range of corrosion resistance, a novolak type epoxy vinyl ester resin (novolak epoxy acrylate)

b. Acid resistance is typically a hydroxyl group resin (eg, PF, RF, PRF, PMF, PEF, REF, or other derivatives).

c. Other things are equally available in some applications.

- Structural Corrosion Fire Barrier "(SCFB) provides the necessary corrosion and fire resistance while providing structural support for structural / fire protection components." Corrosion / Fire Barrier "is fabricated using a fire resistant composite. Generally, filament winding is used.

- Carbonization length measurement by flame retardant content

In the above test, 300 ducts are cut in half, and the inner surface of the duct is fired with fire, and then burned with gas soot for about 5 minutes.

Table 6 shows the carbonization length measurement results.

Flame Retardant Content (%) Length (mm) Carbonization length (mm) Psalm 1 54 850 130 Psalm 2 52 850 140 Psalm 3 50 850 170 Psalm 4 48 850 340 Psalm 5 46 850 550 Psalm 6 44 850 720 Psalm 7 42 850 840

9 shows a photograph of the specimen after carbonization.

As shown in FIG. 9, when the content of the flame retardant is 54%, the carbonization length is 130 mm. When the content of the flame retardant is lower, the carbonization length tends to increase, and when the content of the flame retardant is high, the flame retardant performance is increased.

However, when the content of the flame retardant is more than 54%, there is a problem in operation because the viscosity of the resin increases due to the flame retardant filler when the product is made.

The optimal working and flame retardant performance is good at 54% and the flame retardant percentage can be adjusted according to the flame retardant grade of the manufacturer.

2. Material related

- Generic Name Procuct  Designation

    1. Vinyl Ester Resin:   SR841LV

    2. Acrylic Resin         DS-200    

- Generic Name Procuct  Designation

    One. DMA          DiMethyl Aniline

    2. CO-NAPH (6%)          Cobalt Naphthenate 3. MEKPO (50%)          Mehyl Ethyl Ketone Peroxide

    4. UCT-15-260 Nitrogen-phosphorous

    5. L40-LV Dibenzol peroxide monomer

- Generic Name General Specification Description

1. Organic Veil 19 g / m ² 35 g / m ² Reemay, Nexus, Halar orequivalent

2.Chopped Strand Mat 380 or 450 g / m ² E-Glass, ECR-Glass or Basalt

3. Woven Roving 570 or 580 g / m ² Basalt, ECR-Glass or E-Glass

4. Filament Winding Glass (FWG) 2200 or 2400-Tex   ECR-Glass, E-Glass or

                                                       Basalt

 3. Production

Co-Naph and MEKPO are used for common FRP operations.

Co-Naph is an accelerator and MEKPO is for curing. Co-Naph should be added first before adding the hardener. It can be put in advance by the resin manufacturer. Or may be added before use. The addition amount varies depending on temperature and gel time. The quantity ratio is added based on 100 parts of SR841LV resin

- Based on room temperature 25 ° C (curing conditions) based on the following recommendations:

Co- Naph  = 0.5 to 2.0 pphr MEKPO  = 0.5 to 2.0 pphr Gel-time = 30-minutes

- Prepare MEKPO.

MEKPO concentrate 55% is used.

Always perform a gel cup test to check the gel time. It should also be carried out periodically throughout the day and is very important in hot weather.

- Before adding Co-Nap, add other additives and mix them one at a time.

If you are adding more crumbs (such as UCT-15-260 (0% to 54% or the like)) it is advisable to mix before use

- Steel (or FRP) mandrel is adopted according to the straight length of the duct to be produced. The external dimension of the mandrel is the internal dimension of the duct to be manufactured. The mandrel is used with the manufacturing filament winding equipment of the required duct. Equipment is more known as "filament winding" or "winder".

Figure 10 shows the shape of the mandrel.

A suitable mold release agent system is useful for product demoulding

The use of corrugated cardboard is not good. Use of a suitable release agent directly on the mandrel surface results in a better, more consistent product.

Apply the release agent to the mandrel surface and apply the following disposable release film

- Set the winder to slow rotation

A release film such as slit mylar (typically 15-25 cm) is applied as a single layer to the mandrel at a spiral angle of about 20 °. Masking tape is used to fix the release film at the beginning and allow the film to be evenly pressed. The operator winds up the film by 10%. (Mylar release film acts as mold release agent)

Figure 11 shows the winding of a masking tape on a mandrel.

- Application of thermosetting CRFB

In this step, Co-Naph is mixed with the thermosetting CRFB resin. If necessary, add UCT-15-260 (0% to 54%) or optional additives to SR841LV resin thoroughly using an electric drill mixer

SR841LV and additives are premixed but the curing agent is mixed

Mixed SR841LV resin is applied to release film Mylar with a paint roller (typically 20 cm wide)

The long cut organic veil is applied to the mandrel with minimal overlap.

The resin attaches the organic veil to the mandrel. It is important that there is no gap.

Figure 12 illustrates applying an elongated organic veil.

The SR841LV resin will be well impregnated in the veil. The second operator rubs under the appropriate pressure and is well impregnated and removes all bubbles and wrinkles. This is a skilled work.

If the operator uses too much pressure, too much resin can be impregnated and too few can be impregnated if too weak pressure is applied. If so, apply a resin roller to the bale.

Pouring the SR841LV resin into the organic veil, applying it with a paint roller and rolling it will result in a Corrosion Resistant Fire Barrier (CRFB) on the inside surface of the duct.

Apply 450 times of long-cut mat layer 2 and impregnate with resin

Figure 13 shows forming a Corrosion Resistance Barrier Barrier (CRFB).

Alternative method: a long-cut mat 450 with 10% overlap on a wet surface and a 20-degree spiral

And all bubbles are removed with a FRP serrated roller.

(In the case of small ducts, the mandrel must be stopped.)

- SCFB application

DS -200 Resin:

L40 - LV Hardener: 0.80 to 1.50 pphr (approximate)

DMA ( dimethy aniline) Accelerator 0.25 to 0.50 pphr (approximate)

Put the appropriate amount of (DS-200) resin into a clean container and record the resin weight.

The next step is the entire winding application phase.

The SCFR resin mixed with the hardener is poured into the resin bath of the filament machine.

Pull the filament-winding glass fibers through the resin to pass them well and place them in the desired position of the mandrel

The operator begins to rotate the mandrel and the other operator removes excess resin along the length of the mandrel with a rubber roller (or other resin removal device).

Can be used to squeeze the resin from the mandrel by folding the edge. Filament-winding glass fiber can be used to make a pull-out chin strap. Then trim it later.

The filament winding resin system consists of (DS-200 resin + DMA promoter + L40-LV hardener) and does not remove the resin from the resin bath and continues to work.

Then wrapped in a spiral of about 20 degrees from the next vertical and then repeated in the same pattern at the next opposing angle. Each layer squeezes excess resin and squeezes it out.

Check the thickness if the required number is wound. If desired, cut the glass strands and roll the end of the duct out with a paint roller.

At this stage all excess resin is removed and visual inspection is carried out.

Applying fresh DS-200 resin one more time will help to get a very good ducted surface.

Remove all excess resin after removing all bubbles This step is very important.

A release film such as a slit mylar (typically 15-25 cm) is applied as a single layer at a spiral angle of about 20 degrees.

- The last step

The mandrel rotation is stopped, the mandrel is separated from the filament winding and cured, the mandrel must be kept in a slow rotation.

It can be cured at room temperature for about one hour and an after-hardening can be accelerated by using an infrared heat lamp or oven. However, since excessive heat can damage the surface of the duct, subsequent curing is recommended.

It is necessary to confirm whether the curing has been carried out before the demolding, at room temperature (20 C) for 3 hours or until the Barcol hardness reaches 35. This can be done in a variety of ways, usually with a hardness test. Generally, tap the outside of the duct with a screwdriver to make a clear sound. (If the sound is dull, it is uncured)

Fig. 14 shows the shape before demoulding.

The surface can be finished with an optional outer coating before demolding. (Forming the outermost layer)

Fig. 15 shows the shape after demoulding.

Remove mandrel and corrugated paper (and release film)

etc

- Flame retardant related

CRFB SR841 Add flame retardant to resin only.

0 to 54% of a flame retardant of UCT-15-260 is added.

Stiffening layer (SCFB) Since DS-200 resin is a flame retardant resin, no flame retardant is added.

- Intermediate material role separation related

The DS-200 reactive resin is a polymer having a styrene bond in a molecule in an MMA type resin. The unsaturated polyester resin (polyester for short) is hybridized and a curing reaction occurs when a catalyst (curing agent) (polymerization process) occurs in the thermosetting resin.

And the SR841 resin is also UPR resin (polyester), so the bond strength between the two resins is good.

100 ... phenol resin duct 110 ... corrosion resistant layer
120 ... middle layer 130 ... outermost layer
400 ... Furan resin duct
700 ... double composite duct 710 ... corrosion resistant layer
720 ... middle layer 730 ... outermost layer

Claims (5)

A corrosion resistant layer made of SR841 resin; And
Reinforcing layer composed of DS-200 resin;
A double composite duct comprising a plurality of ducts.
The dual composite material duct of claim 1, wherein the corrosion resistant layer comprises a flame retardant added to the SR841 resin.
The dual composite material duct according to claim 2, wherein the flame retardant is UCT-15-260 and 0 to 54% of the flame retardant is added.
The dual composite material duct of claim 2, further comprising an outermost layer of UV coating, kelcoat, and flame retardant paint to finish the reinforcing layer.
The DS-200 resin according to claim 1, wherein the DS-200 resin is a mixture of (Finely Precipitated Grade) Mineral Flame retardants (finely solidified mineral flame retardant) with a reactive resin based on styrene, acrylic or methacrylic acid (MMA) Wherein the duct is a double composite duct.

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