KR20180062082A - A Non-Combustible Composite Insulated Phenolic Foam And Polyurethane Foam Building Panel Structure and Manufacturing Method Thereof - Google Patents

Abstract

The present invention relates to composite phenol urethane panels with nonflammability for building construction. The present invention can easily and quickly install a wall used for exterior use in the building construction, and reduce the weight of a building by reducing the weight of the wall. For the above purpose, the present invention made a fire-retardant core structure using a phenolic foam material, and made use of a space which is larger than an existing floor area by making fire resistance, the best insulation effect and minimum wall thickness. In addition, the present invention aims to reduce construction costs and shorten a construction time of the wall by reducing a wall process, and to reduce a load of the building to increase seismic capacity and a life of the building.

Description

TECHNICAL FIELD [0001] The present invention relates to a non-combustible composite phenol urethane panel and a manufacturing method thereof,

The present invention relates to a building fire retardant composite phenol urethane panel, and more particularly, to a fire retardant composite phenol urethane panel which can easily and quickly install a wall used for exterior use in building construction, It has a structure that can reduce the load of the building. It is installed in a panel that uses fireproof materials to all parts of the panel to secure the inner and outer panels of the building from fire. .

As a type of wall used outside of a conventional building, concrete or cement block is stacked to form a masonry wall and a concrete wall which form a wall, and then a styrofoam, which is a heat insulating material, is installed on the wall, and a plastic mesh We used a lot of dry bit technology which was finished with chemical coating and finished the outer wall.

Styrofoam, which is a thermal insulation material used here, is flammable and spreads rapidly in case of fire, so that the fire often spreads vertically and horizontally. In addition, most of the styrofoam, which is the core part of the wall, continued to burn inside, and fire suppression from the outside was almost impossible.

And block-type masonry walls have low material cost, and the labor cost of concrete walls is considerably higher than other materials, air is long, and many wastes are produced after construction. However, the cement brick or concrete block is heavy because it has a heavy weight due to its heavy weight, and the concrete extrusion wall is too heavy to be used because of its heavy weight, Due to the weight, there is a problem of imposing a heavy load on the building structure.

In order to overcome the above problems, panels using lightweight concrete have been widely used. For example, "Lightweight concrete and its manufacturing method" of Korean Patent Laid-Open Publication No. 10-2004-0017144 (published Feb. 26, 2004) And a "light panel for exterior use in a building" of the Utility Model Registration No. 20-0338305 (registered on Mar. 01, 2004), however, it is still heavy, and there are many difficulties in insulation, sound insulation, And there is a problem.

Therefore, although it is preferable to use a structural panel that is easy to construct with a light weight in the building construction, there is no satisfactory one yet, and most of the materials forming the wall have insufficient effect on the insulation, I had to. Existing external composite panels were forced to use EPS, XPS or polyurethane foam cores for the core, which made them vulnerable to fire. Accordingly, a fire-retardant panel that is fireproof and fireproof is required.

Disclosure of Invention Technical Problem [8] Accordingly, the present invention has been made in view of the above problems, and it is an object of the present invention to provide a composite insulation panel in which a phenol foam of improved non- Phenolic Foam) to reduce the burden of load and to make fire resistant insulation panels with various shapes and various reinforcement structures.

The construction of the construction-retardant composite phenol urethane panel according to the present invention is characterized in that an incombustible finishing facer, a core composed of a non-combustible phenolic foam insulation and a fire retardant rigid foam urethane are combined with a non- Wherein a plurality of fixing clamps for fixing to the inside / outside structure of the building are used on the top, bottom, left and right sides of the back board, and the fixing clamp is formed by projecting a plurality of "a" A plurality of coupling holes for coupling with the outer wall structure are formed, and a backup material and a caulking are inserted and sealed in the clearance between the respective composite thermal insulation panels.

In the construction-retardant composite phenol urethane panel, a face material is disposed at the lower end of a mold having a rectangular rim, a phenolic foam is placed thereon at a rim portion of the face material, a rigid foamed urethane is placed therein, The backboard is mounted on a face plate with an adhesive, and the backboard is adhered on the heat insulating material core to form a fusion re-formation type. .

The structure of the panel according to the present invention is composed of a stone as a flame retardant panel material, a non-flammable material such as a tile, a core portion surrounding a hard foamed urethane which is a flame retardant in the central portion by providing a phenol foam block, The facings make the building look beautiful, the composite insulation core maximizes the insulation effect, and the backboard can be connected to the building frame.

Phenolic Foam is one of the best insulation materials among existing insulation materials. It is light and hard, minimizing the thickness of the wall due to the light weight of buildings and the best insulation effect.

In addition, it copes with the change of climate caused by global warming and is excellent in the fireproofing and insulation effect of the inner and outer walls of the building. It is possible to save the energy for heating / Installing this panel in a remodeling project that insulates the building can save a lot of energy. It is also a non-combustible material that can prevent the spread of fire when a fire occurs.

However, the phenol foam has a bonding strength of about 8 N / cm 2 for holding the face plate and the backboard, which is weaker than that of the rigid foamed urethane having about 12 N / cm 2, and the bonding strength of the phenol foam drops sharply at a panel size of less than 30 cm x 30 cm.

In order to compensate for this, we made use of the advantages of phenol foam and rigid foam urethane, and made a phenolic urethane panel with a construction-retardant composite.

In addition, the coefficient of expansion of the face material and the core material is different depending on the climate, so that the face material and the backboard are connected to each other by a clip using a clip to prepare for peeling.

1 shows a schematic outline of an architectural fire-retardant composite phenol urethane panel manufactured according to the present invention.
Fig. 2 shows the composition of a composite phenol foam block and a hard foamed urethane core.
FIGS. 3 and 4 are views showing the combined structure of the construction-retardant composite phenol urethane panel.
Figure 5 shows the first stationary clamp used to engage the panel with the wall or structure.
Figure 6 shows a second securing clamp used to engage the panel with a wall or structure.
7 to 12 are views showing a connection state between a wall or a structure to be combined with a construction-retardant composite phenol urethane panel.
13 and 14 are flowcharts showing the manufacturing process of the phenol foam core composite insulation panel.

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

Hereinafter, the embodiments of the present invention will be described in detail with reference to the accompanying drawings. Hereinafter, the present invention will be described in further detail with reference to the accompanying drawings. The inventor should not be construed to limit the invention to any ordinary or preliminary meaning and the inventor shall not be interpreted as being in conformity with the technical idea of the present invention based on the principle that the inventor can properly define the concept of the term And the meaning and concept of.

FIG. 1 shows a schematic outline of a construction-incombustible composite phenol urethane panel manufactured according to the present invention. The structure of the construction-incombustible composite phenol urethane panel of the present invention is basically composed of a panel flame retardant facer material 1, a phenol foam insulation material core 2 And a back board 3. The panel flame retardant material 1 is made of flame retardant material such as stone or tile, the phenolic foam insulation material core 2 is made of non-flammable material, the back board 3 is made of cement board It can be made of non-combustible material using magnesium board. The phenol foam core composite thermal insulation panel is mounted on an inner or outer wall structure or a steel square pipe using first and second fixing clamps 40 and 50 made of a galvanized steel plate or a stainless steel plate.

The panel face plate 1 can be made of a non-flammable material such as stone, tile or the like which can be used as a wall face plate or a face plate which can be adhered to the phenol foam insulation core 2. The thickness of the panel non-cohesive face material is approximately 10 to 20 mm, the width and length are approximately 900 mm × 600 mm, and the standard of the panel non-cohesive face material 1, that is, the specification of the panel, may be changed depending on the form of the building.

Fig. 2 shows a specific configuration of a heat insulating material core 2 made of phenolic material used in a fire-retardant composite phenol urethane panel. As shown in Fig. 2, the heat-insulating core 2 has a rigid foamed urethane core 5 at the center thereof and a plurality of phenol foam blocks 4 at the rim thereof to cover the rigid foamed urethane core 5 Consists of. Phenol foam is one of the materials having good thermal insulation effect and can be made lighter and harder to reduce the weight of the building and minimize the thickness of the wall. However, as described above, the phenol foam material itself has adhesion strength to hold the face plate and backboard, So that the adhesion strength of the core portion of the structural phenolic foam core composite insulation panel is compensated by using the phenol foam insulation core 2 which is a composite constitution of the hard foamed urethane core 5 simultaneously with the phenol foam block 4 .

The density of the material used for the phenolic foam insulation core 2 should be not less than 35 kg / m 3. The phenolic foam insulation core 2 is positioned between the panel flame retardant face 1 and the backboard 3 to function as a heat insulating material and a connecting material for connecting the flame retardant panel 1 to the backboard 3. Here, in order to connect the panel non-burned face plate 1 and the back board 3, the density of the phenol foam heat insulating core 2 should be 35 kg / m 3 or more, which is determined after calculating the wind pressure and the negative pressure in each region. However, the density of the hard foam urethane located at the center of the core should be 45 kg / ㎥ or more. The density of the rigid foamed urethane in the central portion of the core which adheres the panel flame retardant facings 1 and the backboard 3 to each other to maintain the strength of the panel is preferably about 45 kg / m3 to 60 kg / m3. The width and length of the insulation core 2 is about 900 mm × 600 mm and the thickness is usually about 55 mm (Jeju area), 80 mm (southern area) and 100 mm (central area) Do.

The backboard (3) attaches to the phenolic foam insulation core (2) of the panel, thereby connecting the entire panel to the structure of the building. The back board (3) uses non-combustible materials such as magnesium board and cement board. In addition, the magnesium board surface (back of the panel) located outside the panel is waterproof coated to prevent moisture damage. In addition, the inner plywood surface attached to the core of the back board 3 is not subjected to surface treatment in order to increase the bonding strength.

3 and 4 are views showing the combined structure of the building-made fire retardant composite phenol urethane panel. The fixing clip 6 for coupling the face plate 1, the phenol foam insulation core 2 and the back board 3 described above, And the structure of the clip hole 7 and the clip connecting line 8 for supporting the same is shown. As shown in Figs. 3 and 4, in order to support the attachment state of the face plate 1, the phenol foam heat insulating material core 2 and the back board 3, A clip hole 7 is formed, and the fixing clip 6 is fitted into the clip hole 7 to be engaged. The fixing clip 6 shown in Figs. 3 and 4 is shown in the form of a " c "or"? &Quot;, but may be modified into various forms according to the skill or application of the person skilled in the art. In order to prevent the fixing clip 6 from being peeled off, a clip connecting line 8 for connecting between the clip hole 7 and the fixing clip 6 is formed, You can support it firmly.

Fixing clamps 40 and 50 are used on the top, bottom, left and right sides of the back board 3 so as to be fixedly attached to the inner and outer wall structures or the pipes. The configuration of the stationary clamps 40 and 50 is shown in Figs. 5 and 6. Fig. The fixing clamps 40 and 50 are made of a galvanized steel sheet having a thickness of 2 mm, and a plurality of such fixing clamps 40 and 50 are used to attach the phenol foam core composite insulation panel to the inside / outside wall structure.

As shown in Fig. 5, the first fixed clamp 40 is divided into four sections by a galvanized steel plate or a stainless steel plate having a size of approximately 100 mm x 100 mm in width and length, thereby forming a mounting portion 41. The mounting portion 41 is cut into the inside of the plated steel sheet, and is bent to protrude into the "A" shape. It is preferable that the end portion of the mounting portion 41 is formed to be pointed so that the back board 3 can be inserted easily. In addition, some portions of the plated steel sheet are formed with engagement holes 43 for engagement with the inside / outside wall structure of the building.

The second fixing clamp 50 cuts the galvanized steel sheet as shown in FIG. 6 to form the mounting portion 51. Here, the groove 52 is a portion cut by cutting the mounting portion 51, and the mounting portion 51 is bent inward to protrude so as to be formed in a "C" shape. The end portion of the mounting portion 51 is also sharpened so as to facilitate insertion of the back board 3 and a coupling hole 53 for coupling with the inside / outside wall structure is also formed.

The fixing clamps 40 and 50 are formed with a plurality of engaging holes 43 and 53. The engaging holes 43 and 53 may be circular, elliptical or slit.

The first and second stationary clamps 40 and 50 can be used integrally as shown in the drawings of Figs. 5 and 6, or can be used by cutting as many portions as necessary depending on the intended use. For example, the first fixed clamp 40 shown in Fig. 5 may be cut in the lateral direction to be divided into two parts, or may be divided into four parts in the longitudinal direction. That is, one fixed clamp 40 can be divided into two or four as necessary. If it is divided into two or four, the necessary coupling ball is formed according to the purpose of use.

The second fixed clamp 50 shown in Fig. 6 is a clamp used when the panel is initially stuck with a clamp used at the lowermost end of the inner and outer walls of the building. The second fixed clamp 50 can also be divided into one or two.

Figs. 7 to 12 show the connection state between a building or a structure to be combined with a construction-retardant composite phenol urethane panel.

7 is a view showing an embodiment showing a state of connection between a building-made fire retardant composite phenol urethane panel and a structure of a building. Specifically, a panel on the outer wall of the building shows a detailed view of the building, It has been shown that the fixing clamp 40 of the present invention is attached to the back board 3 and the screws are fastened and attached to the structure of the building comprising the wooden stud 11, the metal stud 12 and the square pipe 13 .

8 is a basic detailed view showing the connection between the panel attached to the outer wall frame and the panel, and specifically showing a clearance operation between the construction-retarded composite phenol urethane panel. The clearance between the construction-retardant composite phenol urethane panel and the panel is filled in the order of the foam tape 23, the backup material 22 and the caulking 21 so that a waterproof effect can be expected. In addition, the screws installed on the back firmly hold this panel unlike the other panels.

FIG. 9 is a detailed view showing a part where the lower door sill of the window meets the panel, FIG. 10 is a detail view showing a connection part between the upper part of the window and the panel, FIG. 11 is a detail view showing the panel installation at the lower and lower ends of the building And FIG. 12 is a detailed view showing the connection between the corner panels attached to the concrete corner.

The structure of such a panel has the following advantages. First, the heat insulating material core (2) of the fire-retardant composite phenol urethane panel is formed by using the phenolic foam and the hard foaming urethane material, which are the most commonly used heat insulating materials, (Heat Bridge). Second, since there is no heat bridging phenomenon, there is no condensation phenomenon that can occur inside the wall due to the temperature difference, and various problems caused by moisture, various kinds of mold odors, and skin diseases that are harmful to the human body are eliminated. Third, Phenolic Foam and Rigid Foam Urethane are colorless and odorless eco-friendly materials. Fourth, the panel is easy to construct directly to the structure, and the process is shortened to shorten the air. The wall process of about 7 to 8 is reduced to about three processes, so that the air shortening and the construction cost are reduced. Fifth, it is an ultra light panel that weighs only 20% less than conventional brick wall or concrete wall. Sixth, the thermal conductivity of phenolic foam insulation core (2) is high (phenol foam 0019 ~ 0.021, hard foam urethane 0.021 ~ 0.022), which satisfies the insulation criterion required by the building method with minimum wall thickness. In other words, the thickness of the wall can be minimized to make a wide use space. Seventh, it is an eco-friendly building panel that reduces the generation of carbon dioxide by achieving the best energy saving effect.

Currently, most of the buildings are dry-bit finished on the outside of the building with thin plaster on the styrofoam. This external styrofoam is a fire-resistant material and there are many risks. Therefore, when the wall construction is performed using the panel of the present invention, there is no risk of fire because it is a fire-retardant panel.

The method for manufacturing the construction-retardant composite phenol urethane panel of the present invention is as follows.

1. As a mold-type method, a panel incombustible face plate (1) is placed under a mold of a square iron frame, the frame is sealed with a tape, and a fire-retardant phenol foam block is installed on the core frame. , The back board (3) is placed and pressed by a press to produce a panel after foam curing in the mold. This method requires curing for a certain period of time and must be fully cured to prevent deformation.

2. Alternatively, as a bonding method, after a prefabricated phenol foam heat insulating core 2 is placed on the edge of a panel face 1 coated with glue, a rigid foamed urethane block is provided at the center of the core, Place the painted backboard (3) on top of the insulation core (2) and apply force to make an integral composite insulation panel. After confirming that there is no deformation in the state where the curing is completely finished, the heat insulating material core 2 is adhered to the heat insulating material core 2 after applying the adhesive to the panel non-cohesive face material 1 and the back board 3.

The flame retardant composite phenol urethane panel manufactured by the above method has a width of about 900 mm and a length of about 600 mm and a thickness of 10 to 20 mm for the panel flame retardant material 1 and 55 to 100 mm for the heat insulating material core 2 Mm, and the back board 3 is 10 mm. The density of the heat insulating core 2 is approximately 35 kg / m 3 to 60 kg / m 3.

Specific details and features of panel manufacturing are as follows.

The fire-retardant composite phenol urethane panel of the present invention is a fire-retardant composite phenol urethane panel comprising a panel fire retardant face material (1) + phenol urethane heat insulating material core (2) + back board (3) In order to act as a wall panel of a building, connection of each member plays a most important role. Further, for the highest bonding strength, the fusion-re-release effect as in the case where the heat insulating material core 2 is foamed and adhered by using an adhesive agent of the same material as that of the heat insulating material core 2 can be seen.

This fire-retardant composite phenol urethane panel can be installed on the inner and outer wall structures of non-resistant walls as a fireproof panel, and the structure and panel are installed by fixing clamps 40 and 50 made of iron. In other words, the clamp is installed on the wooden stud 11 of the building, the metal stud 12 and the panel, and after the panel is fitted, screws are installed on the rear surface to integrally hold the panel and the structure.

The fixing clamps 40 and 50 are made of a galvanized steel sheet having a thickness of 2 mm and are provided with a panel on a metal stud 12 or a frame (square pipe) 13 having a square steel pipe structure. The stationary clamps 40, 50 can secure one, two, three or four panels in various ways. The fixed clamps 40 and 50 are fixed to the frame using a stud self-drilling screw (4.2 x 32 mm). The clamp spacing and the size of the openings are set by the structural calculation, The wall shall withstand the positive pressure negative pressure and direct load.

As shown in FIG. 12, the corner panel is manufactured by providing the latch 31 on the panel backboard 3 so as to manufacture the angular pipe 13 which is inserted into the latch 31 in accordance with the corner angle, And the latch 31 and the square pipe 13 are fixed by a self-screw, and both corner panels are connected. Corner panel installation in the field takes a lot of time to adjust up and down and left and right, but it is easy to install and firmly hold the corner panel through the above configuration.

13 and 14 are flowcharts showing the respective steps of the method for manufacturing the construction-retardant composite phenol urethane panel described above.

13 (a) to 13 (c), in the mold-type manufacturing method, first, molds 61 each having a rectangular shape are provided so as to oppose each other on a press base plate 60, The aluminum bar 62 for the joint is grooved and installed. This joint aluminum bar 62 is for providing a joint in the panel after removing the mold. The thickness of the aluminum bar is equal to the thickness of the joint between the panels.

In addition, when the size of the panel is large, it is also produced in one sheet without a joint.

Next, the outer surface of the panel incombustible face material 1 is installed toward the bottom of the base plate 60, and then masked so as to prevent the gap between the mold, the flame retardant panel 1 and the aluminum bar 62 from leaking out of the core material during the foaming. After sealing with tape, a plurality of phenol foam blocks 4 are arranged and poured into the urethane core solution.

After pouring the core solution, the back board 3, such as the size of the mold, is inserted as shown in Fig. 13 (c) within 3 to 10 minutes. The mold is closed with the press upper plate 63, the core is completely cured, the mold is removed after the press upper plate is removed, and the panel is completed.

Here, the urethane solution poured into the core is hardened after foaming to form a panel by integrating the phenol foam blocks of the face plate, the back board and the core rim.

14 (a) to 14 (b) is a bonding type manufacturing method. First, the back board 3 is placed on the conveyor 70 and moved to the press plate 71. A glue 80 is sprayed onto the back board 3 for 5 minutes before reaching the press plate 71 and the phenol foam block used in the phenol foam insulation core 2 is sprayed onto the back board 3 3) Place on top of the Edges. At the center of the core, a rigid foamed urethane block is installed to hold a phenolic foam block of face plate, backboard, and core rim. At this time, the adhesive adhered to the back board 3 adheres to the core, and the adhesive melts the core surface and is re-fusion-bonded. In the fusion re-release state, the above-described urethane solution is poured and foamed. It takes about 15 ~ 20 minutes to cure the core part. However, by using the urethane component of the same component, it is possible to shorten the panel production time and reduce the thickness error of the panel have. Be careful, however, if the force is not evenly applied at the top, the thickness may vary.

Next, after the adhesive 80 is applied to the rear face of the panel incombustible face plate 1 in the above-described manner, the face plate 1 is placed on the unfinished panel having the fire-proof thermal insulating material core board 2 on the back board 3 After loading, dry in the drying chamber. At this time, it is not favorable to apply any force on the panel fire retardant material, and it is not possible to obtain uniform thickness by applying the repulsive force.

1. Panel flame retardant 2. Phenol foam insulation core
3. Backboard 4. Phenol foam block
5. Rigid foam urethane core 6. Retaining clip
7. Clip hole 8. Clip connector
11. Wood studs 12. Metal studs
13. Square pipe 14. Metal runner
15. Concrete slab 21. Waterproof caulking
22. Backup material 23. Foam tape
31. Corner latch 32. Corner connection square pipe
33. Corner caulking 40, 50. Fixing clamp
41. 51. Mounting part 43, 53. Joining part

Claims (3)

At least one non-flammable face material,
A heat insulating material core comprising a hard foamed urethane core and a plurality of phenol foam blocks covering a rim portion of the hard foamed urethane core,
The backboards are joined together,
A plurality of fixing clamps for fixing and fixing to a building outer wall structure are used on upper, lower, left, and right sides of the back board,
The stationary clamp has a plurality of engaging portions each formed integrally with an "a" or a "" shaped engaging portion and has a plurality of engaging holes for engaging with an inner / outer wall structure,
A plurality of fixing clips for fixing the face material, the heat insulating material core and the back board are used,
Wherein a plurality of clip holes for supporting the fixing clip are formed on the face plate and the back board, and the fixing clip coupled to the clip hole is supported using a clip connecting line. The method according to claim 1,
Phenol Urethane panel with built-in fire-retardant property which is characterized by inserting backing material and caulking in gap between each building fire-retardant composite phenol urethane panel. A method for producing a phenolic urethane panel having a structure and a fire-
Providing a press base plate so as to face each other with a rectangular mold and providing an aluminum bar in the center of the base plate,
A step of closing the gap between the mold, the face plate and the aluminum bar with a masking tape so as not to cause leakage after installing the panel on the upper surface of the base plate,
Placing a plurality of phenol foam blocks in a core frame Edges and placing the urethane core solution on the face plate,
Placing the back board within 3 to 10 minutes after pouring the urethane core solution, sealing the mold with the press plate, waiting until the core is fully cured, and removing the mold after removing the press plate. A method for manufacturing a phenolic urethane panel having a composite structure.

Images