KR20180131229A - Semi-incombustible fiber complex interior material and method of preparing the same - Google Patents

Abstract

The present invention relates to a semi-incombustible fiber complex interior material, which comprises a first layer, a honeycomb layer overlying the first layer, and a second layer overlying the honeycomb layer, wherein the first and second layers are fibrous sheet materials and at least one of the first and second layers is a semi-incombustible fibrous sheet material comprising cotton fibers, wherein the cotton fiber comprises 90 to 100 wt% of cellulose, and the present invention also relates to a manufacturing method thereof. One embodiment provides the semi-incombustible fiber complex interior material, which is environment-friendly, has semi-incombustible properties, and has dimensional stability, heat insulation properties, sound insulation properties, sound absorption properties and high hardness.

Description

FIELD OF THE INVENTION [0001] The present invention relates to a semi-incombustible fiber-reinforced composite material,

Quasi-nonflammable fiber-reinforced composite material and a method of manufacturing the same.

A gypsum board is the most commonly used material for architectural interior materials. These gypsum boards are produced by dividing into gypsum board and ceiling board. In the case of wall, it is sold as a semi-finished product and it is used by interior designers after the purchase, and in the case of ceiling material, it is shipped as a finished product and used in ceiling construction.

Also, mineral wool is used as a building interior material. Mineral wool is used as a ceiling material, but its strength is so weak that it is difficult to use it as a wall.

However, these interior materials are not satisfactory to consumers. Two types of gypsum board can be used: phosphorus gypsum gypsum and flue gas desulfurization gypsum. Radon is released due to uranium in phosphorus, which is the main material of phosphate gypsum. Especially, radon is the main cause of lung disease, Which is higher than the reference value. In addition, there is a report that, when made of mineral wool, fine fibers are accumulated in the lungs through the respiratory system for a long time due to the use of artificial mineral fibers, causing lung diseases.

Because the materials used for these walls and ceilings are heavily used, it is difficult to select eco-friendly materials due to the increase in construction costs. In addition, these interior materials can not be used for living spaces such as apartments and houses because they can not produce designs due to the characteristics of the materials of the products. In reality, imported goods having high prices occupy the market.

Korean Patent Publication No. 2013-0077548

One embodiment provides a quasi-nonflammable fiber-reinforced interior material that is environmentally friendly, semi-nonflammable, and has excellent dimensional stability, heat insulation, sound and sound absorption, and high hardness.

Another embodiment provides a method of manufacturing a quasi-incombustible fiber-reinforced composite material which is lightweight, easy to cut, and easily processed into various designs, thereby being excellent in productivity and productivity.

According to one embodiment, a first layer; A honeycomb layer positioned over the first layer; And a second layer overlying the honeycomb layer, wherein the first and second layers are fibrous sheet materials, at least one of the first and second layers is a semi-incombustible fibrous sheet material comprising cotton fibers, The cotton fiber provides a semi-incombustible fiber-embedded interior material comprising 90% to 100% by weight of cellulose.

The semi-incombustible fibrous sheet material may further comprise reinforcement fibers comprising bast fibers, pulp, synthetic fibers or a combination thereof, wherein the mixing ratio of the cotton fibers to the reinforcing fibers is in a weight ratio of 6: 4 to 9: 1 have.

The semi-incombustible fibrous sheet may further include 10 to 50 parts by weight of expanded graphite relative to 100 parts by weight of the cotton fiber.

The semi-incombustible fibrous sheet material may have a structure in which a plurality of flame retardant fibrous sheet materials are stacked and lapped together.

The plurality of flame retardant fibrous sheets may each be 0.5 mm to 3 mm.

The semi-incombustible fibrous sheet material may have a structure or a perforated structure in which a predetermined pattern is formed on at least one surface.

The quasi-incombustible fiber-reinforced panel material is approved as quasi-fireproof material as a result of the test according to the approval standard (KFIS 014) of the fireproof and semi-fireproof material of the interior decoration or the specification of the flame resistance test method of the interior material and structure of the building ) As a result of the test.

The first layer and the second layer may each have a thickness of from 2 mm to 20 mm.

The honeycomb layer may comprise a metal honeycomb, a semi-incombustible honeycomb composite, or a combination thereof.

Wherein the honeycomb layer is the semi-incombustible honeycomb composite, the semi-incombustible honeycomb composite comprises a first reinforcing material; A honeycomb core made of paper and positioned on an upper surface of the first reinforcing member; A coating layer positioned on top of the honeycomb core and comprising a subflammable coating composition; And a second reinforcing member located at the upper end of the coating layer and the same or different from the first reinforcing member.

Wherein the semi-incombustible coating composition comprises from 50% to 80% by weight of a soluble silicate; 10% to 30% by weight of expanded graphite; And 5% to 20% by weight of an inorganic material comprising aluminum hydroxide, magnesium hydroxide, ultracarb, diatomaceous earth, or a combination thereof.

The first reinforcing member and the second reinforcing member may each include glass fiber, glass paper, carbon fiber, nonwoven fabric, or a combination thereof.

In this case, the quasi-incombustible honeycomb composite is a quasi-nonflammable material approved as a result of the test according to the KFIS 014 of the fireproof and semi-fireproof materials of the interior decoration, or the specification of the flame resistance test method KS F2271) as a result of the test.

The thickness of the honeycomb layer may be 1.0 mm to 48.0 mm.

Wherein the honeycomb layer is adhered to the second layer and the first layer by a honeycomb bonding composition, respectively, and the honeycomb bonding composition comprises a binder including a urethane compound, an epoxy compound, an acrylic compound, 100 parts by weight of a resin; 20 to 60 parts by weight of expanded graphite relative to 100 parts by weight of the binder resin; And 1 to 20 parts by weight of an inorganic material comprising aluminum hydroxide, magnesium hydroxide, ultracarb, diatomaceous earth, or a combination thereof.

The thickness of the semi-incombustible fiber-reinforced composite material may be 10 mm to 200 mm.

The quasi-incombustible fiber-reinforced interiors have been approved as quasi-nonflammable materials as a result of tests in accordance with KFIS 014 for the standards of fireproof and semi-fireproof materials of indoor ornaments, F2271) as a result of the test.

The quasi-incombustible fiber-reinforced interiors may have a sound absorption coefficient of 0.6 to 1.0 at a frequency of 400 Hz to 1250 Hz as measured by the KS F 2805 reverberation method.

The quasi-incombustibble fiber-composite interiors may include a ceiling material, a wall material, or a combination thereof.

Another embodiment includes attaching a honeycomb layer to an upper surface of a first layer; And attaching a second layer to an upper surface of the honeycomb layer to form a laminate, wherein the first and second layers are fibrous sheets, and at least one of the first and second layers comprises a cotton fiber Wherein the surface fiber comprises 90% by weight to 100% by weight of cellulose. The present invention also provides a method for producing the semi-incombustible fiber-reinforced composite material.

The honeycomb layer may comprise a metal honeycomb, a semi-incombustible honeycomb composite, or a combination thereof.

Wherein the honeycomb layer is the semi-incombustible honeycomb composite, the semi-noncombustible honeycomb composite having a honeycomb core of paper attached to one surface of the first reinforcing material; Coating the attached honeycomb core with the sub-incombustible coating composition to form a coating layer; And attaching the second stiffener to an upper end of the coating layer.

Wherein the adhesion is performed by a honeycomb bonding composition, and the honeycomb bonding composition comprises 100 parts by weight of a binder resin comprising a urethane compound, an epoxy compound, an acrylic compound, or a combination thereof; 20 to 60 parts by weight of expanded graphite relative to 100 parts by weight of the binder resin; And 1 to 20 parts by weight of an inorganic material comprising aluminum hydroxide, magnesium hydroxide, ultracarb, diatomaceous earth, or a combination thereof.

The method may further include a step of painting or thermally transferring the surface of the laminated plate after the step of manufacturing the laminated plate.

The method for fabricating a semi-incombustible fibrous sheet material comprises the steps of forming a papermaking fiber sheet material through a papermaking process of putting a fiber material containing the cotton fiber into a papermaking composition, and impregnating the papermaking fiber sheet material into the impregnating composition, And forming a semi-incombustible fibrous sheet material by a laminating process in which a plurality of the flame-retardant fibrous sheet materials are prepared, and then a laminated adhesive composition is applied to one surface of the laminate and then laminated to each other.

Wherein said papermaking composition comprises 10 to 40 parts by weight of expanded graphite; 10 parts by weight to 40 parts by weight of a metal hydroxide comprising aluminum hydroxide, magnesium hydroxide, ultracarb or a combination thereof; 10 parts by weight to 40 parts by weight of a thermosetting resin; And 200 to 2000 parts by weight of water.

The impregnating composition is prepared by mixing 75 parts by weight to 95 parts by weight of a soluble silicate with respect to 100 parts by weight of the paper fiber sheet. From 20 parts by weight to 35 parts by weight of a metal hydroxide comprising aluminum hydroxide, magnesium hydroxide, ultracarb or a combination thereof; And 10 to 25 parts by weight of diatomaceous earth.

Wherein the rigid bonding composition comprises 100 parts by weight of a thermoplastic resin; 20 to 35 parts by weight of expanded graphite relative to 100 parts by weight of the thermoplastic resin; And 25 to 40 parts by weight of a metal hydroxide including aluminum hydroxide, magnesium hydroxide, ultracarb, or a combination thereof.

The flame-retardant fibrous sheet material formed through the impregnation process may be thermo-compression-molded before the laminating process.

The quasi-incombustible fiber-reinforced composite material according to one embodiment is not only applicable to waste cotton fibers, but also harmless to the human body and environmentally friendly, and has a flame-retardant second-order quasi-incombustibility. Furthermore, it is excellent in dimensional stability to prevent condensation, and is excellent in heat insulation, sound insulation and sound absorption. In addition, it is possible to realize various logos and various designs by a simple process, and thus it is a material having excellent productivity and productability. These quasi-incombustible fiber-reinforced interiors can be used both as ceiling materials and as wall materials.

1 is a perspective view of a semi-incombustible fiber-reinforced composite material according to one embodiment.
2 is a perspective view showing a quasi-incombustibble-fiber-interior material of another example.
Fig. 3 is a perspective view showing still another example of semi-incombustibble-fiber-interior material.
4 is a cross-sectional view taken along line AA in Fig.
5 is a schematic view showing a honeycomb core.

Hereinafter, embodiments of the present invention will be described in detail so that those skilled in the art can easily carry out the present invention. However, implementations may be implemented in various different forms and are not limited to the implementations described herein.

In the drawings, the thickness is enlarged to clearly represent the layers and regions. Like parts are designated with like reference numerals throughout the specification. It will be understood that when an element such as a layer, film, region, plate, or the like is referred to as being "on" or "on top of" another portion, Conversely, when a part is "directly over" another part, it means that there is no other part in the middle.

Hereinafter, a semi-incombustible fiber-reinforced composite material according to one embodiment will be described.

According to one embodiment, there is provided a quasi-incombustible fiber-reinforced interior material using a semi-incombustible fibrous sheet material. In this case, the semi-incombustible fibrous sheet material is obtained from a fibrous material containing cotton fibers. Specifically, the semi-nonflammable fibrous sheet material is obtained from a fibrous material obtained by using cotton fibers singly or a fibrous material obtained by mixing fibers such as bast fibers, pulp and synthetic fibers with cotton fibers. This semi-incombustible fiber board is obtained by using waste cotton fiber which is used in the industrial field or at home and it is obtained not only a low cost of production but also a low hardness, harmless to human body, , Wall materials, and the like.

Specifically, a quasi-incombustible fiber-interior material according to one embodiment will be described with reference to FIG.

1 is a perspective view of a semi-incombustible fiber-reinforced composite material according to one embodiment. 1, the semi-incombustible fiber-reinforced composite material 10 includes a first layer 20, a honeycomb layer 30 disposed on the first layer 20, and a honeycomb layer 30 disposed on the honeycomb layer 30. And a second layer (40). According to one embodiment, when the semi-incombustible fiber-reinforced composite material having the above structure is formed using the semi-incombustible fibrous sheet material, quasi-incombustibility of the flame retardant grade 2 is exhibited. In addition, unlike conventional interior materials, It is superior in sound absorption and can be used as a new material that can replace existing interior materials.

The first layer 20 and the second layer 40 are fibrous sheets. The fibrous sheet includes natural fibers including cotton fibers, bast fibers and the like; Synthetic fibers and the like; Or a combination thereof. At this time, at least one of the first layer 20 and the second layer 40 is a semi-incombustible fibrous sheet material including the cotton fiber among the fibrous sheet materials.

Cotton fiber is taken from the hair of the seed of a plant belonging to the family Malvaceae, and consists of almost pure cellulose only. Specifically, the cotton fiber may comprise 90% by weight to 100% by weight of cellulose, and may comprise, for example, 98% to 100% by weight of cellulose. Therefore, the cotton fiber is different from bast fibers such as flax, hemp, moss, jute and the like containing about 70% by weight of cellulose and is also distinguished from wood which is a raw material of pulp containing about 40 to 50% by weight of cellulose It is another material.

The quasi-incombustible fibrous sheet material including the cotton fiber can be obtained with high hardness, can reduce the production cost due to the utilization of the waste cotton fiber, is harmless to the human body and is environmentally friendly, thus being useful as a building interior material for ceiling materials and wall materials Can be used.

The semi-incombustible fibrous sheet material may further include reinforcing fibers in addition to the cotton fibers. The reinforcing fiber may include bast fiber, pulp, synthetic fiber, etc., alone or in combination of two or more. The synthetic fibers may include one or more of polyester, polypropylene, and the like. When the cotton fiber and the reinforcing fiber are both included, the blending ratio may be a weight ratio of 6: 4 to 9: 1, for example, a weight ratio of 7: 3 to 8: 2. When the quasi-incombustible fibrous sheet includes both the cotton fiber and the reinforcing fiber, if it is contained within the above-mentioned ratio range, not only the flame retardancy but also the high hardness plate can be obtained.

The semi-incombustible fibrous sheet may further include expanded graphite in addition to the cotton fiber. Expanded graphite is one of the components used for papermaking process, impregnating process and lapping process in the process of producing semi-incombustible fibrous sheet using cotton fiber, and is one of the constituents of semi-incombustible fibrous sheet. The expanded graphite may be contained in an amount of 10 parts by weight to 50 parts by weight, for example, 20 parts by weight to 40 parts by weight, based on 100 parts by weight of the cotton fiber. When the quasi-incombustible fibrous plate contains expanded graphite, specifically, when it is contained in the above-mentioned content range, quasi-incombustible of flame retardant grade 2 or flame retardancy close thereto can be secured.

The quasi-nonflammable fibrous sheet material may have a structure in which a plurality of flame retardant fibrous sheet materials 11 are laminated and lapped together. The number of flame retardant fibrous sheet materials 11 may be, for example, 2 to 6, 2 to 5, 2 to 4, and 2 to 3. The semi-incombustible fibrous plate is formed by bonding a plurality of flame retardant fibrous sheets to each other with a flame-retardant rigid bonding composition in a laminating process. A semi-incombustible fibrous sheet laminated with a plurality of flame- Semi-flammability can be ensured.

The thickness of the plurality of flame retardant fibrous sheets 11 may be 0.5 mm to 3 mm, respectively, and may be, for example, 0.5 mm to 2.5 mm, 1 mm to 2 mm. When the thickness of each of the flame retardant fibrous sheets is within the above range, not only the lamination processability is excellent but also semi-flammability of flame retardant grade 2 can be ensured.

The quasi-nonflammable fibrous sheet material may have a structure in which a predetermined pattern is formed on at least one surface, or a perforated structure. An example will be described with reference to FIG. 2, which is merely an example of a semi-incombustible fibrous sheet for the sake of understanding, but is not limited thereto. 2 is a perspective view showing a quasi-incombustibble-fiber-interior material of another example. 2, the semi-incombustible fiber-embedded composite material 10 includes a first layer 20, a honeycomb layer 30, and a second layer 40, wherein the first layer 20 And the second layer 40 may be inserted into a predetermined pattern 22 on one side. Such patterning can be performed during the thermo-compression molding of the flame-retardant fibrous sheet material that has been impregnated and dried before the laminating process in the manufacturing process of the semi-incombustible fibrous sheet material. Specifically, by attaching a metal mold that is carved in a desired shape to the top of a thermocompressor, various logos and patterns of various designs can be engraved at the same time as pressing without additional processing. In this way, it is possible to realize a design having a more natural and excellent aesthetic feeling by performing the pressing at the same time in the process of forming the semi-incombustible fiber board material without any additional process for processing. Accordingly, the semi-incombustible fiber composite material .

Semi-nonflammable fiber-reinforced plastics have been approved according to KFIS 014 for flame-retardant and semi-flammable materials of indoor ornaments. , It may be a flame retardant grade. According to KS F2271, flame retardant grade 1 is classified as nonflammable material, flame retardant grade 2 is classified as semi-combustible material, and flame retardant grade 3 is classified as flame retardant material. The quasi-incombustible fiber-reinforced composite material formed by laminating the quasi-incombustible fibrous sheet on both sides of the honeycomb layer is environment-friendly and semi-inflammable with flame-retardant grade 2, so that it can be used as a new material Can be utilized.

The thickness of each of the first layer 20 and the second layer 40 made of the semi-incombustible fibrous sheet material may be 2 mm to 20 mm, for example, 2 mm to 16 mm, 2 mm to 12 mm, 2 mm To 10 mm, from 2 mm to 8 mm, from 2 mm to 6 mm, from 4 mm to 6 mm. When the thickness of each of the first layer and the second layer is within the above range, there is no warpage of the plywood, high hardness and stable semi-incompatibility can be ensured, and in addition to the honeycomb layer, And a semi-nonflammable fiber-reinforced composite material excellent in sound absorption properties can be secured.

The method of manufacturing the semi-incombustible fiberboard will be described in detail in the method of manufacturing the semi-incombustible fiber-reinforced composite material to be described later.

The honeycomb layer 30 positioned between the first layer 20 and the second layer 40 may have a honeycomb-shaped cross-section of unit cells repeatedly joined together. In other words, columnar unit cells having a hexagonal cross section with open upper and lower portions may be repeatedly connected. When the honeycomb layer of the above-described type is introduced into a fibrous sheet material, specifically, a quasi-incombustible fibrous sheet material and formed into a composite structure like a panel shape, it has high hardness without warping or twisting, It is possible to minimize the heat loss due to the low thermal conductivity, and it is possible to secure excellent car sound and sound absorption due to the structure which not only facilitates alighting but also resonates with light weight.

The honeycomb layer 30 may comprise a metal honeycomb, a semi-incombustible honeycomb composite, or a combination thereof. Of these, the quasi-incombustible honeycomb composite is a new material formed to have quasi-incombustibility using a paper honeycomb, and the honeycomb layer 30 made of quasi-incombustible honeycomb composite has a quasi-incombustibility of flame retardant grade 2, , Wall materials, and so on.

The metal honeycomb may be made of at least one kind of metal such as aluminum, iron and the like. Specifically, the honeycomb may be made of aluminum having good heat transfer rate and easy processing.

Hereinafter, the case where the honeycomb layer 30 is made of a semi-incombustible honeycomb composite will be described with reference to FIGS. 3 and 4. FIG.

Fig. 3 is a perspective view showing a quasi-incombustible fiber-reinforced inner material according to still another example, and Fig. 4 is a sectional view taken along the line A-A in Fig.

3 and 4, the quasi-incombustible fiber-embedded interiors 10 include a first layer 20, a honeycomb layer 30, and a second layer 40, wherein the honeycomb layer 30 is a semi- Comb composite 31 as shown in FIG. The quasi-incombustible honeycomb composite 31 includes a first reinforcing material 32, a honeycomb core 34 made of paper located on the upper surface of the first reinforcing material 32, a coating layer (not shown) disposed on the upper end of the honeycomb core 34 36, and a second stiffener 38 positioned at the top of the coating layer 36.

The honeycomb core 34 will be described in detail with reference to FIG. 5 is a schematic view showing a honeycomb core. Referring to FIG. 5, the honeycomb core 34 includes a plurality of hexagonal cells. The height H of the honeycomb core may be 5 mm to 40 mm, and may be, for example, 8 mm to 30 mm. The thickness T of the body constituting the cell may be 0.1 mm to 1.0 mm, and may be, for example, 0.2 mm to 0.7 mm. The cell size S may also be between 5 mm and 20 mm, for example between 8 mm and 15 mm. When a quasi-incombustible honeycomb composite material is formed using honeycomb cores having a height, a thickness, and a size within the above range, it is possible to prevent dew condensation because of high hardness and dimensional stability, and to minimize heat loss due to low thermal conductivity , It is possible to secure an excellent car sound and sound absorption due to the structure which not only facilitates alighting but also causes resonance.

The coating layer 36 comprises a semi-incombustible coating composition as formed by coating the surface of the paper honeycomb core 34 with a semi-incombustible coating composition. Semi-nonflammable coating compositions include soluble silicates, expanded graphite, and their and other minerals. The coating layer 36 including the quasi-nonflammable coating composition is formed on the surface of the honeycomb core 34 made of paper, thereby ensuring semi-flammability of the flame retardant grade.

Each component of the quasi-nonflammable coating composition will be described below.

The soluble silicate refers to an aqueous solution of silica (SiO ₂ ) and an alkali metal, also called water glass. Examples of the alkali metal include sodium silicate (sodium silicate), potassium silicate (silicic acid silicate), lithium silicate and the like. The sodium silicate or potassium silicate is formed by melting silica with Na ₂ CO ₃ or K ₂ CO ₃ at 1100 ° C. to 1200 ° C. The glass thus produced is combined with high pressure steam to form a transparent, Becomes a viscous liquid. When such a soluble silicate is used, the flame retardancy of the semi-incombustible coating composition can be improved.

The soluble silicate may comprise from 50% to 80% by weight, such as from 60% to 80% by weight, based on the total weight of the semi-incombustible coating composition. When the amount of the soluble silicate is within the above range, the flame retardancy of the quasi-incombustible coating composition can be ensured and the dispersibility of the expanded graphite and the inorganic material can be increased to further improve the flame retardancy of the quasi-incombustible coating composition.

Expansion graphite has a layered structure of graphite, so when atoms or small molecules are inserted between the layers and heat is applied, the particles are expanded like an accordion and the particles are expanded several hundred times. This phenomenon of expanded graphite can improve the flame retardancy of quasi-incombustible coating compositions.

Expanded graphite may be in powder form. Specifically, the expanded graphite may have a particle size of 80 mesh to 300 mesh. When the expanded graphite has such a particle size range, the dispersibility in the semi-nonflammable coating composition can be improved.

Expanded graphite may be included in an amount of from 10% to 30% by weight, for example from 15% to 25% by weight, based on the total weight of the semi-flammable coating composition. The flame retardancy of the quasi-incombustible coating composition can be further improved when the expanded graphite is contained in the above-mentioned content range.

The mineral may include aluminum hydroxide, magnesium hydroxide, ultracarb, diatomaceous earth, or combinations thereof.

Aluminum hydroxide can increase the bonding strength by preventing hydrophobicity of paper and inducing hydrophilization. For example, aluminum hydroxide can enhance permeability to paper and enhance flame retardancy by using a domestic lanthanide cashew kh-8R nanoparticle powder.

UltraCab is the name of a special magnesium carbonate mineral brand that is a mixture of Huntite and Hydro Magnesite (hydrated magnesium carbonate) produced by LKAB Minerals Ltd. of Great Britain. UltraCab is not only cheap, but also excellent in heat resistance and flame retardancy.

The ultracav may be in powder form and may have a particle size of, for example, 100 mesh to 300 mesh. If the ultracav has the above range of particle size, the dispersibility in the semi-incombustible coating composition can be improved.

Diatomaceous earth is a sediment formed by accumulation of siliceous harmful of diatomic algae, which is a single-celled algae, on the sea or lake bottom, and is composed of silica (SiO ₂ ) component, which is mainly inorganic compound. Such a diatomaceous earth is an eco-friendly material and has various performance such as deodorization, heat insulation, humidity control, etc., and can impart excellent flame retardancy to a quasi-nonflammable coating composition.

The diatomaceous earth may be in the form of a powder, and may specifically have a particle size of 100 mesh to 500 mesh. When the diatomaceous earth has the above-mentioned particle size range, the dispersibility in the semi-incombustible coating composition can be improved to further improve the flame retardancy of the semi-incombustible coating composition.

These minerals may be included in an amount of 5 wt% to 20 wt%, for example 5 wt% to 15 wt%, based on the total weight of the semi-incombustible coating composition. The flame retardancy of the quasi-incombustible coating composition can be further improved when the inorganic matter is contained within the above-mentioned content range.

The semi-flammable coating composition may further comprise additives. The additive may include phosphates, borax, inorganic pigments, zinc, tin, vermiculite, perlite, loess, clay, scorching, or combinations thereof. The additive may be contained in an amount of 1 part by weight to 30 parts by weight, for example, 1 part by weight to 20 parts by weight, based on 100 parts by weight of the total amount of the semi-incombustible coating composition, that is, the soluble silicate, expanded graphite and inorganic material . The flame retardancy of the semi-incombustible coating composition can be further improved if the additive is included in the above range.

A coating layer 36 is formed on the surface of the honeycomb core 34. Specifically, the coating layer 36 may be formed so as to surround not only the upper end of the honeycomb core 34 but also the inner and outer surfaces of the body of the honeycomb core 34. In other words, the coating layer 36 may be formed on all surfaces of the body of the honeycomb core 34, in addition to the top of the honeycomb core 34 attached to the second stiffener 38, It is possible to stably obtain flame retardant grade 2 semi-flammability.

The thickness of the coating layer 36 may be from 0.05 mm to 1.50 mm, for example from 0.05 mm to 1.00 mm, from 0.1 mm to 1.00 mm, from 0.1 mm to 0.7 mm. When the thickness of the coating layer is within the above range, quasi-flammability of flame retardant grade 2 can be stably secured.

The first stiffener 32 is located on the bottom surface of the honeycomb core 34 and the second stiffener 38 is located on top of the coating layer 36.

The first stiffener 32 and the second stiffener 38 may be the same or different. Specifically, the first stiffener 32 and the second stiffener 38 may each comprise glass fiber, glass paper, carbon fiber, a nonwoven fabric, or a combination thereof. By attaching such a reinforcing material to both surfaces of the coated honeycomb core 34 to form a composite structure, the dimensional stability of the honeycomb layer 30 can be improved. In addition, when the honeycomb layer 30 is provided between the first layer 20 and the second layer 40 to form a composite panel structure, there is no warping or warping with high hardness, and condensation can be prevented.

The first stiffener 32 and the second stiffener 38 may each have a thickness of 0.1 mm to 1.0 mm and may have a thickness of 0.2 mm to 0.8 mm, for example. When the thicknesses of the first reinforcing material and the second reinforcing material are within the above ranges, excellent dimensional stability can be ensured, thereby realizing a semi-incombustible fiber-interior composite material capable of preventing condensation.

The attachment of the first stiffener 32 and the honeycomb core 34 and the attachment of the second stiffener 38 and the coating layer 36 may be accomplished by an adhesive composition. The adhesive composition is the same as the honeycomb adhesive composition described below, and therefore, a description thereof will be omitted here.

The quasi-incombustible honeycomb composite (31) has been approved as semi-fireproof material as a result of the test according to the approval standard (KFIS 014) of the fireproof and semi-fireproof material of the interior decoration or the standard of the flame resistance test method (KS F2271) as a result of the test. Accordingly, when the honeycomb layer made of the quasi-incombustible honeycomb composite is provided between the semi-incombustible fibrous plates to form a composite structure, environment-friendly and more stable quasi-incombustibility can be secured.

The thickness of the honeycomb layer 30 may be from 1.0 mm to 48.0 mm and may be, for example, from 5.0 mm to 48.0 mm, from 6.0 mm to 45.0 mm, from 6.0 mm to 40.0 mm. In the case where the honeycomb layer 30 is a semi-incombustible honeycomb composite 31 at this time, the thickness of the honeycomb layer 30 is determined by the thickness of the first reinforcing material, the height H of the honeycomb core, It is equal to the total thickness. When the thickness of the honeycomb layer is within the above range, not only stable semi-inflammability can be ensured but also excellent dimensional stability, heat insulation, sound insulation and sound absorption can be obtained at the same time.

One side of the honeycomb layer 30 adheres to the first layer 20 and the other side of the honeycomb layer 30 adheres to the second layer 40 and these attachments can each be performed by a honeycomb bonding composition have.

The honeycomb bonding composition may include a binder resin, expanded graphite, and an inorganic material.

The binder resin imparts an adhesive force for bonding the fibrous sheet material constituting the first layer and the second layer, specifically, the semi-incombustible fibrous sheet material and the honeycomb layer to each other.

The binder resin may include a urethane compound, an epoxy compound, an acrylic compound, or a combination thereof.

The urethane-based compound contains a urethane prepolymer synthesized from a polyol and a polyisocyanate as a main component, and any kind conventionally used in the art may be used for the purpose of imparting an adhesive force. Since the urethane compound has a strong adhesive force, it can be used more advantageously when it is bonded to a honeycomb layer made of a metal honeycomb.

The epoxy compound is exemplified by bisphenol A type resin, bisphenol F type resin, novolac resin and the like, and any type that is commonly used in the art may be used for the purpose of imparting adhesive strength. The epoxy-based compound may be more advantageously used when bonding to a honeycomb layer made of a semi-incombustible honeycomb composite.

The acrylic compound is a polymer synthesized from an acrylic monomer. Examples of the acrylic monomer include methyl (meth) acrylate, ethyl (meth) acrylate, isopropyl (meth) acrylate, n-butyl (meth) acrylate, isobutyl (Meth) acrylate, 2-ethylhexyl (meth) acrylate, hydroxypropyl (meth) acrylate, stearyl (meth) acrylate and hydroxybutyl (meth) acrylate. The acrylic compound can be more effectively used when bonding the honeycomb layer made of the semi-incombustible honeycomb composite.

Expanded graphite is the same as expanded graphite used in the quasi-nonflammable coating composition described above, so its explanation is omitted here. The expanded graphite may be contained in an amount of 20 to 60 parts by weight, for example, 30 to 50 parts by weight based on 100 parts by weight of the binder resin. When the expanded graphite is contained in the above content range, the flame retardancy of the honeycomb bonding composition can be further improved.

The inorganic material may include aluminum hydroxide, magnesium hydroxide, ultracarb, diatomaceous earth, or a combination thereof, and these inorganic materials are the same as the inorganic materials used in the quasi-nonflammable coating composition described above, so that the description thereof is omitted here. The inorganic material may be included in an amount of 1 part by weight to 20 parts by weight, for example, 5 parts by weight to 10 parts by weight, based on 100 parts by weight of the binder resin. When the inorganic material is contained in the above content range, the flame retardancy of the honeycomb bonding composition can be further improved.

When the honeycomb bonding composition having the above composition is used, not only the adhesion strength between the fibrous sheet material, specifically the quasi-incombustible fibrous sheet material and the honeycomb layer, but also the flame retardancy is improved, the semi-incombustible fiber- .

The thickness of the semi-incombustible fiber-reinforced composite material 10 formed by laminating the honeycomb layer 30 between the first layer 20 and the second layer 40 may be 10 mm to 200 mm, for example, 10 mm 10 mm to 100 mm, 10 mm to 70 mm, 10 mm to 50 mm, 15 mm to 40 mm, 20 mm to 30 mm. When the thickness of the quasi-nonflammable fiber-reinforced composite material 10 is within the above range, not only the hardness is high but also the room insulation, sound insulation and sound absorption are excellent.

The quasi-incombustible fiber-reinforced interiors (10) have been approved according to the criteria of fireproof and semi-fireproof materials for interior decoration (KFIS 014) (KS F2271) as a result of the test. The semi-incombustible fiber-reinforced composite material is eco-friendly and semi-inflammable with flame retardant grade 2, so that it can be used as a new material that can replace conventional building materials such as ceiling materials.

The quasi-incombustible fiber-reinforced composite material 10 may have a sound absorption coefficient of 0.6 to 1.0 at a frequency of 400 Hz to 1250 Hz as a result of testing according to the KS F 2805 reverberation method, for example, 0.7 to 1.0, 0.7 to 0.9, 0.8 to 0.9. Such semi-incombustible fiber-reinforced composite material can be used as a new material that can replace conventional building materials such as ceiling materials by securing excellent sound insulation and sound absorption.

The semi-incombustible fiber-composite interiors described above can be used for ceiling materials, wall materials, or both.

Hereinafter, a method for manufacturing a semi-incombustible fiber-reinforced composite material according to another embodiment will be described.

The quasi-nonflammable fiber-reinforced composite material 10 comprises the steps of attaching a honeycomb layer 30 to an upper surface of a first layer 20 and then attaching a second layer 40 to an upper surface of the honeycomb layer 30 to form a laminate Lt; / RTI >

The adhesion of the honeycomb layer 30 between the first layer 20 and the second layer 40 can be performed by the honeycomb bonding composition described above.

The quasi-nonflammable fiber-reinforced composite material 10 may be manufactured by forming a laminate and then painting or thermally transferring the surface of the laminate. At this time, the painting may be performed with a composition including at least one of yellow soil, charcoal, diatomaceous earth, elvan,

The honeycomb layer 30 may comprise a metal honeycomb, a semi-incombustible honeycomb composite, or a combination thereof. Hereinafter, a method for producing a semi-incombustible honeycomb composite will be described.

The quasi-incombustible honeycomb composite 31 is obtained by attaching a honeycomb core 34 made of paper to one surface of a first reinforcing member 32 and then attaching the honeycomb core 34 attached to the first reinforcing member 32 to a semi-incombustible Coating a coating composition to form a coating layer 36, and then attaching a second reinforcing material 38 to the top of the coating layer 36.

The coating may be performed on the front side, including the upper end of the honeycomb core 34 attached to the first stiffener 32. In other words, not only the top of the honeycomb core 34 but also the inner and outer surfaces of the cell forming body can be coated. Such a coating can be carried out by a spray coating method, but is not limited thereto.

The attachment of the first stiffener 32 to the honeycomb core 34 and the attachment of the second stiffener 38 to the coating layer 36 may each be performed by an adhesive composition.

The description of the first reinforcing material, the honeycomb core, the semi-nonflammable coating composition, the second reinforcing material, and the adhesive composition in the above-mentioned manufacturing method has been described above, and thus the description thereof is omitted here.

The first layer 20 and the second layer 40 are fibrous sheet materials and at least one of the first layer 20 and the second layer 40 is a semi-incombustible fibrous sheet material comprising cotton fibers. Hereinafter, a method for producing a semi-incombustible fibrous sheet will be described.

A semi-incombustible fibrous sheet material is obtained by forming a fibrous sheet material through a papermaking process in which a fibrous material including a cotton fiber is put into a papermaking composition, forming a flame retardant fibrous sheet material through an impregnating process of putting a papermaking fibrous sheet material into a impregnating composition, And a step of forming a semi-incombustible fibrous sheet by a laminating process in which a plurality of flame-retardant fibrous sheets are prepared, and then a laminated adhesive composition is applied to each surface of the laminated sheet and laminated to each other.

Specifically, after preparing a fiber material containing a predetermined size of fiber, a fiber material may be polished first by a beating process before the papermaking process. The beating process is a process in which the prepared fiber material is pulverized into a fine powder form and then put into a water tank and polished for 2 to 3 hours.

Then, the ground fiber material is formed into a papermaking fiber sheet material through a papermaking process. The papermaking process refers to a process in which a fiber material sanded into a storage tank containing a papermaking composition is charged, stirred, and then discharged. Specifically, the fibrous material and the paper making composition are kneaded in a storage tank with a stirrer, then sucked by a down-pressure pump, discharged to a paper machine (dehydrator), and discharged to a conveying conveyor. Thereafter, the discharged material is dried by a microwave dryer to form a nonwoven fibrous sheet material having flame retardancy.

The papermaking composition may comprise expanded graphite, metal hydroxide, thermosetting resin and water.

Expanded graphite is identical to the description of expanded graphite used in the semi-nonflammable coating composition described above. The expanded graphite may be contained in the papermaking composition in an amount of 10 to 40 parts by weight, for example, 20 to 30 parts by weight based on 100 parts by weight of the fiber material. When the content of the expanded graphite exceeds 40 parts by weight, the pH of the fibrous material composition becomes high and the dispersibility deteriorates. When the expanded graphite is included in the above range, the flame retardancy of the grass composition is further improved, so that the grass fiber sheet dried after the papermaking process can ensure the flame retardancy close to that of the second flame retardant grade.

The metal hydroxide may include aluminum hydroxide, magnesium hydroxide, ultracarb, or a combination thereof. These can improve the flame retardancy of the paper making composition as an inorganic compound. The description of aluminum hydroxide and ultracav is also as described above. The metal hydroxide may be contained in the papermaking composition in an amount of 10 parts by weight to 40 parts by weight, for example, 10 parts by weight to 20 parts by weight, based on 100 parts by weight of the fiber material. If the content of the metal hydroxide exceeds 40 parts by weight, the pH of the paper making composition increases and the dispersibility deteriorates. When the metal hydroxide is included in the above content range, the flame retardancy of the grassland composition is further improved, and thus the grassland fiber sheet dried after the papermaking process can secure the flame retardancy close to that of the second flame retardant grade.

The thermosetting resin can help agglomerate and disperse the expanded graphite and metal hydroxide, which are inorganic compounds, in the papermaking composition. Particularly, expanded graphite causes dusting due to expansion phenomenon, and it can be agglomerated by a thermosetting resin, so that the expanded graphite can be used together in a paper composition.

Examples of the thermosetting resin include a melamine resin, a phenol resin, a urea resin, an epoxy resin and a polyester resin. These thermosetting resins may be used alone or in combination of two or more. Of these, for example, a melamine resin can be used. The thermosetting resin may be contained in the papermaking composition in an amount of 10 to 40 parts by weight, for example, 10 to 20 parts by weight based on 100 parts by weight of the fiber material. When the thermosetting resin is contained in the above-mentioned content range, the flame retardancy of the grass-like composition can be further improved. Accordingly, the grass fiberboard sheet dried after the papermaking process can ensure the flame retardancy close to the semi-fireproof of the flame retardant grade 2.

The water may be contained in the papermaking composition in an amount of 200 to 2000 parts by weight, for example, 500 to 1500 parts by weight, based on 100 parts by weight of the fiber material. When the water content is within the above range, the flame retardancy of the grass composition can be further improved. Accordingly, the grass fiberboard sheet dried after the papermaking process can ensure the flame retardancy close to the semi-fireproof of the flame retardant grade 2.

The grass composition may further comprise additives. The additive can include diatomaceous earth, phosphate, borax, zinc, stannic, vermiculite, perlite, loess, clay, scorching, or combinations thereof. Such an additive may be included in the papermaking composition in an amount of 1 part by weight to 30 parts by weight, for example, 5 to 30 parts by weight, based on 100 parts by weight of the fiber material, depending on the desired characteristics. Among the above additives, for example, diatomaceous earth and phosphates may be included, and when used together, the flame retardancy of the grassland composition can be further improved.

By performing the process of papermaking the fiber material including the cotton fiber using the papermaking composition, environment-friendly and excellent flame retardancy can be ensured.

The thickness of the papermaking fiber sheet formed through the papermaking process may be from 1.5 mm to 5 mm, for example, from 2 mm to 5 mm, from 3 mm to 5 mm, and from 4 mm to 5 mm. When the thickness of the paper fiber sheet is within the above range, excellent impregnation property can be secured in the next impregnation step.

Next, the paper fiber sheet is impregnated with the impregnating composition through an impregnation process to form a flame retardant fibrous sheet material.

The impregnating composition may include soluble silicates, metal hydroxides, and diatomaceous earth.

The soluble silicate is identical to the description of the soluble silicate used in the semi-nonflammable coating composition described above. The soluble silicate may be contained in the impregnating composition in an amount of 75 to 95 parts by weight, for example, 80 to 90 parts by weight based on 100 parts by weight of the paper fiber sheet. When the soluble silicate is contained in the above content range, the flame retardancy of the impregnating composition can be ensured and the dispersibility of the metal hydroxide, which is an inorganic compound, and the diatomaceous earth can be increased, and the flame retardancy of the impregnation composition can be further improved. Thus, the flame retardant fiber board formed by impregnating the impregnated composition and drying the flame retardant fiber sheet can ensure flame retardancy of flame retardant grade close to semi-fireproof.

The metal hydroxides are the same as the metal hydroxides used in the aforementioned papermaking compositions. The metal hydroxide may be included in the impregnation composition in an amount of 20 to 35 parts by weight, for example, 25 to 30 parts by weight, based on 100 parts by weight of the paper fiber sheet. If the content of the metal hydroxide is more than 35 parts by weight, the pH of the impregnation composition may be increased and the dispersibility may be lowered. When the metal hydroxide is included in the above-mentioned content range, the flame retardancy of the impregnating composition is further improved, so that the flame retardant fiber sheet formed by drying after the impregnation process can secure the flame retardancy close to that of the second flame retardant grade.

Diatomaceous earth can be referred to the description of the diatomaceous earth used in the semi-nonflammable coating composition described above. The diatomaceous earth may be included in the impregnation composition in an amount of 10 to 25 parts by weight, for example, 15 to 20 parts by weight, based on 100 parts by weight of the paper fiber sheet. If the content of the diatomaceous earth exceeds 25 parts by weight, the pH of the impregnating composition may be increased and the dispersibility may be lowered. When the diatomaceous earth is included in the above content range, the flame retardancy of the impregnating composition is further improved. Accordingly, the flame retardant fiber board formed by drying after the impregnation process can ensure flame retardancy close to semi-fireproofing of flame retardant grade 2.

The impregnating composition may further comprise additives. The additives may include expanded graphite, phosphates, borax, inorganic pigments, zinc, secondary tin, vermiculite, perlite, loess, clay, scorching, or combinations thereof. Such an additive may be contained in the impregnation composition in an amount of 1 part by weight to 30 parts by weight, for example, 1 part by weight to 20 parts by weight, based on 100 parts by weight of the papermaking fiber sheet according to the desired characteristics. The inorganic pigments of various colors may also be added to impart color to the grass fiber sheet. The inorganic pigment may be a known pigment according to a desired color. Specifically, the additive may be used by mixing diatomaceous earth and inorganic pigment in a weight ratio of 10: 1 to 10: 4, for example, 10: 2 to 10: 3.

The impregnating composition was sufficiently stirred in an agitator and then transferred to an impregnation tank. Then, the paper fiber sheet was poured into a impregnation tank, impregnated thoroughly through a compression guide roller installed in the impregnation tank, and then pressure was applied by a steel compression roller, The impregnation process can be carried out while reducing the length. At this time, the plurality of guide rollers may be installed so as to progress while applying pressure using a roller made of a negative angle and embossing so that the infiltration composition can penetrate well between the cellulose constituting the paper fiber sheet.

In addition, a stirring pump can be installed in the impregnation tank itself so that an inorganic material such as a metal hydroxide, diatomaceous earth or the like, which constitutes the impregnating composition, is not mixed with the soluble silicate and precipitated.

Impregnated and dried to form a flame retardant fibrous sheet material.

Subsequently, the dried flame retardant fiber sheet can be further subjected to thermo-compression molding before the lapping step. The thermocompression molding is a planar thermocompression molding, which can be carried out under high temperature and high pressure using a thermocompressor, thereby maintaining the smoothness and stability of the fiber.

Specifically, 150 ℃ to a temperature of 200 ℃, for example, 170 ℃ to a temperature of 180 ℃, and 100 kg / cm ² to 400 kg / cm ^2, for example, 120 kg / cm ² to 250 kg / cm ² For 30 seconds to 5 minutes, for example, 40 seconds to 3 minutes. Further, the molding can be carried out such that the thickness of the flame retardant fiber plate is 0.5 mm to 3 mm, for example, 1 mm to 2 mm. When the flame-retardant fibrous sheet is molded to the above-mentioned thickness range, a semi-incombustible fibrous sheet can be secured in the following lamination process.

In the step of thermo-compression molding, the flame-retardant fibrous sheet material can be thermo-compression-molded into a thin sheet and various patterns can be formed on the surface of the flame-retardant fibrous sheet material. Specifically, by attaching a metal mold that is carved in a desired shape to the top of a thermocompressor, the pattern can be inscribed simultaneously with the pressing without requiring a separate processing step. In this way, it is possible to realize a design having a more natural and excellent aesthetic feeling by performing the pressing at the same time in the process of forming the semi-incombustible fiber board material without any additional process for processing. Accordingly, the semi-incombustible fiber composite material .

Next, a plurality of flame-retardant fibrous sheet materials subjected to thermo-compression molding may be prepared and then joined together to form a semi-incombustible fibrous sheet material.

Since it is difficult to ensure semi-flammability of flame retardant grade 2 as a single-layered flame retardant fiber sheet before laminating process, laminating process is required to obtain quasi-incombustibility. The quasi-incombustibility is the result of having been certified as quasi-nonflammable material as a result of testing according to KFIS 014 for the standards of fireproof and semi-fireproof materials of interior ornaments, or the standard of flammability test method of building interior materials and structures (KS F2271) According to the test result, it means that flame retardant grade 2 is secured.

Specifically, the laminating process can be carried out by applying a laminating adhesive composition on each of a plurality of flame-retardant fiber plate materials by a hobbing method, and adhering one surface of each of the laminating adhesive compositions to each other. At this time, pressure can be applied by a gold press so that the laminate bonding composition is cured.

A plurality of flame retardant fibrous sheets may be prepared, and two or more flame retardant fibrous sheets may be prepared. For example, 2 to 6, 2 to 5, 2 to 4, and 2 to 3 are prepared. can do. Depending on the use of various building interior materials, the number of flame retardant fiberboards can be selected considering the final plate thickness.

The rigid bonding composition may include thermoplastic resins, expanded graphite, and metal hydroxides. Hereinafter, the constituent components of the rigid bonding composition will be described.

The thermoplastic resin is used as a binder resin in the joint adhesive composition and imparts an adhesive force. For example, the thermoplastic resin may be a vinyl acetate resin, an acrylic resin, a polyvinyl alcohol resin, a vinyl chloride resin, a polyvinyl acetal resin, Ester-based resins, polyamide-based resins, and polyethylene-based resins. Of these, for example, a vinyl acetate resin or an acrylic resin can be used.

As described above, expanded graphite can further improve the flame retardancy of the joint adhesive composition due to the expansion phenomenon due to the layered structure of graphite.

Expanded graphite may be included in the composition in an amount of 20 to 35 parts by weight, for example, 30 to 35 parts by weight based on 100 parts by weight of the thermoplastic resin. When the expanded graphite is contained in the above range, the adhesive strength is improved and the flame retardancy is improved. Thus, the semi-incombustible fibrous plate laminated can secure quasi-incombustibility of flame retardant grade 2.

The metal hydroxide may include aluminum hydroxide, magnesium hydroxide, ultracarb or a combination thereof as described above, and for example, ultracav may be used to enhance the effect of improving the flame retardancy.

The metal hydroxide may be contained in the joint adhesive composition in an amount of 25 to 40 parts by weight, for example, 30 to 40 parts by weight based on 100 parts by weight of the thermoplastic resin. When the metal hydroxide is included in the above content range, the adhesive strength is excellent and the flame retardancy is improved. Thus, the semi-incombustible fiber sheet laminated can secure quasi-incombustibility.

The rigid bonding composition may further comprise additives. The additive may include diatomaceous earth, a dispersant, or a combination thereof, for example, diatomaceous earth may be used. The additive may be contained in an amount of 1 part by weight to 20 parts by weight, for example, 5 to 20 parts by weight, based on 100 parts by weight of the thermoplastic resin, depending on the desired properties in the joint adhesive composition.

As described above, diatomaceous earth can be used as an eco-friendly material to impart various properties such as deodorization, heat insulation, and humidity control, as well as impart excellent flame retardancy to the joint adhesive composition. The diatomaceous earth may be used in an amount of 10 to 20 parts by weight based on 100 parts by weight of the thermoplastic resin, and the flame retardancy may be improved when the content is within the above range.

The dispersing agent can increase the dispersibility of metal hydroxide such as aluminum hydroxide in powder form by using an acrylic compound, a urethane compound, an amide compound or the like. The dispersant may be included in an amount of 5 parts by weight to 8 parts by weight based on 100 parts by weight of the thermoplastic resin. When the content of the dispersant is within the above range, the dispersibility of the joint adhesive composition can be improved.

The thickness of semi-nonflammable fibrous sheet formed through the laminating process is as mentioned above.

When bonding a plurality of flame retardant fiber plates in the laminating step, glass fiber mesh, glass paper, or a combination thereof may be included between the flame retardant fiber plates. In other words, a glass fiber mesh or a glass paper may be added between the flame retardant fiber plates to form a laminate. In this case, warping of the plywood does not occur and the impact hardness can be improved.

As described above, the quasi-incombustible fibrous plate produced by the above-described production method is eco-friendly and quasi-incombustible of flame retardant grade 2, and thus can be usefully used as an interior material for various building materials.

Hereinafter, specific embodiments of the present invention will be described. However, the embodiments described below are only intended to illustrate or explain the present invention, and thus the present invention should not be limited thereto. In addition, contents not described here can be inferred sufficiently technically if they are skilled in the art, and a description thereof will be omitted.

( Semi-incombustible  Fabrication of fiber board)

Manufacturing example  1-1

(1) Grassland Process

A cotton fiber containing 98% cellulose was prepared to have a length of 40 mm, and then pulverized into a fine powder form by putting it into a crusher. Then, 200 kg of pulverized cotton fiber was put into a water tank of 2000 kg of water and beating for 2 hours.

Subsequently, 10 parts by weight of expanded graphite, 20 parts by weight of ultracab (UltraCarb), 10 parts by weight of melamine resin (weight average molecular weight 5,000 g / mol), 10 parts by weight of diatomaceous earth (EP mineral yarn, celatom ), 10 parts by weight of ammonium phosphate, and 1000 parts by weight of water.

Then, the polished cotton fiber was put into a storage tank containing the paper making composition, kneaded by stirring with a stirrer (agitator), sucked by a down-pressure pump, discharged to a dehydrator, discharged into a conveying conveyor, and sent to a microwave dryer And dried at 180 DEG C to form a papermaking fiber sheet having a width of 1220 mm, a thickness of 4 mm and a length of 2440 mm.

(2) Impregnation process

80 parts by weight of soluble silicate (Yongil Chemical Co., liquid potassium silicate No. 4), 30 parts by weight of UltraCarb (UltraCarb) and 20 parts by weight of diatomaceous earth (celatom EP 20) were added to 100 parts by weight of the above- By weight were mixed to prepare an impregnation composition.

Subsequently, the impregnating composition was sufficiently agitated in a stirrer and then conveyed to an impregnation tank. Then, the paper fiber sheet was impregnated, and then primary dried by applying pressure to a steel compaction roller through a guide roller installed in the impregnation tank. Subsequently, the resultant was subjected to secondary drying with a microwave dryer (manufactured by Sun Company), followed by thermocompression molding at 180 DEG C and 250 kg / cm < ² > pressure for 3 minutes using a thermocompressor, To form a plate material.

(3) laminating process

100 parts by weight of an aqueous vinyl acetate resin (Young's Chemical Industries, Ltd.), 30 parts by weight of expanded graphite, 30 parts by weight of UltraCar (LKAB Minerals Co., Ltd., UltraCarb) and 100 parts by weight of diatomaceous earth (EP mineral, celatom ) Were mixed to prepare an adhesive composition.

Two pieces of the above flame retardant fibrous sheet materials were prepared, and then the above-mentioned adhesive composition was applied on each side by a hob machine and then pressed with a gold press (Daesung Machinery Co.) to laminate each other to produce a semi-incombustible fibrous sheet having a thickness of 2 mm.

Manufacturing example  1-2

Except that in Manufacturing Example 1-1, instead of the cotton fiber, polishing was carried out using a fiber material composed of 80% by weight of a cotton fiber containing 98% of cellulose and 20% by weight of polypropylene (weight average molecular weight of 100,000 g / mol) -1, a semi-incombustible fibrous sheet was prepared.

( Semi-incombustible Honeycomb  Manufacture of Composites)

Manufacturing example  2

100 parts by weight of an epoxy compound (about 100 parts by weight of binder resin) and 100 parts by weight of an ultracarb (LKAB Minerals Co., Ltd., UltraCarb) (binder resin 100 Parts by weight) were mixed to prepare an adhesive composition.

A semi-incombustible coating composition prepared by mixing 70% by weight of a soluble silicate (Yukin Chemical Co., liquid potassium silicate 4), 20% by weight of expanded graphite, and 10% by weight of UltraCarb (LKAB Minerals Co., UltraCarb) was prepared.

(Honjin Co., Ltd.) having a height of 8 mm, a cell size of 10 mm and a thickness of 0.4 mm was attached to one side of a glass paper having a thickness of 0.5 mm (Korea Paper Co., Ltd., Glass Paper (GP) , The entire surface of the honeycomb attached to the glass paper was coated with the semi-incombustible coating composition to form a coating layer having a thickness of 0.1 mm. Then, a glass paper having a thickness of 0.5 mm (manufactured by Korea Fibers Co., Paper (GP)) was adhered with the adhesive composition to prepare a semi-incombustible honeycomb composite having a thickness of 9.1 mm.

( Semi-incombustible  Fabrication of fiber-reinforced composite material)

Example  One

Two semi-incombustible fibrous sheets prepared in Preparation Example 1-1 were prepared, and the honeycomb bonding composition was applied to one surface of each of the semi-incombustible fibrous sheets, and then the two surfaces of the semi-incombustible honeycomb composites prepared in Production Example 2 To form a laminate having a thickness of 13.1 mm to produce a quasi-nonflammable fiber-interior material.

The honeycomb bonding composition was prepared by mixing 100 parts by weight of an epoxy compound (about X-4117), 40 parts by weight of expanded graphite (based on 100 parts by weight of a binder resin), and ultracarb (LKAB Minerals Co., 10 parts by weight (based on 100 parts by weight of binder resin).

Example  2

A semi-incombustible fiber-interior material was prepared in the same manner as in Example 1, except that the semi-incombustible fibrous sheet prepared in Preparation Example 1-2 was used in place of the semi-incombustible fibrous sheet prepared in Preparation Example 1-1.

Example  3

Two semi-incombustible fibrous sheets prepared in Preparation Example 1-1 were prepared, and then the honeycomb bonding composition used in Example 1 was applied to one surface of each semi-incombustible fibrous sheet material, A semi-incombustible fiber-reinforced composite material was prepared by laminating a 14 mm-thick laminate with both sides of Com (Dong Shin Co., Ltd.).

Comparative Example  One

The product of USG BORAL, EXITON ^TM , was used as an interior material.

The product comprises a mineral wool component, the thickness is 12 mm and the size is 300 mm x 600 mm.

Rating 1: Semi-incombustible  Flame retardancy measurement of fiber board

The flame retardancy was measured according to the standard of the flame retardancy test method (KS F2271) of the built-in material and structure of the building after the semi-incombustible fiber sheet prepared in Production Examples 1-1 and 1-2 was cut to a size of 100 mm . As a result of the measurement, in the case of Production Examples 1-1 and 1-2, it was confirmed to be flame retardant grade 2 corresponding to quasi-incombustibility.

In addition, the flame retardancy was measured according to the criteria (KFIS 014) of the flame-retardant and semi-flammable materials of the interior decoration after the semi-incombustible fiber sheet produced in Production Examples 1-1 and 1-2 was cut to a size of 100 mm Respectively. As a result of the measurement, in the case of Production Examples 1-1 and 1-2, it was confirmed to be flame retardant grade 2 corresponding to quasi-incombustibility.

These results show that semi-nonflammable fibrous sheets prepared by the method according to one embodiment using cotton fibers containing 90% by weight to 100% by weight of cellulose ensure semi-flammability of flame retardant grade 2.

Evaluation 2: Semi-incombustible Honeycomb  Flame retardancy measurement of composites

The flame retardancy of the semi-incombustible honeycomb composite prepared in Preparation Example 2 was measured at a size of 100 mm in width and 100 mm in accordance with the standard of the flame retardancy test method (KS F2271) of the interior materials and structures of the building. As a result of the measurement, in the case of Production Example 2, it was confirmed to be flame retardant grade 2 corresponding to quasi-incombustibility.

In addition, the semi-incombustible honeycomb composite produced in Production Example 2 was cut to a size of 100 mm in width and 100 mm in size, and the degree of flame retardancy was measured according to KFIS 014 of the fireproof and semi-fireproof materials of the interior decoration. As a result of the measurement, in the case of Production Example 2, it was confirmed to be flame retardant grade 2 corresponding to quasi-incombustibility.

These results indicate that quasi-incombustible honeycomb composites having a structure composed of a quasi-incombustible coating composition and a composite structure of reinforcing materials on both sides using a paper honeycomb have a quasi-incombustibility of flame retardant grade 2.

Rating 3: Semi-incombustible  Measurement of flame retardancy of fiber-reinforced composite materials

The flame retardancy was measured according to the standard (KS F2271) of the flame retardancy test method of the interior material and structure of the building after the semi-incombustible fiber-reinforced composite material prepared in Examples 1 to 3 was cut to a size of 100 mm in width and 100 mm in size. As a result of the measurement, in Examples 1 to 3, flame retardant grade 2 corresponding to quasi-incombustibility was confirmed.

In addition, the semi-incombustible fiber-reinforced composite materials prepared in Examples 1 to 3 were cut to a size of 100 mm in width and 100 mm in size, and then the degree of flame retardance was measured according to the criteria (KFIS 014) for incombustibility and semi-combustible materials in the interior decoration. As a result of the measurement, in Examples 1 to 3, flame retardant grade 2 corresponding to quasi-incombustibility was confirmed.

This result also shows that when the quasi-incombustible fiber-reinforced composite material is formed together with the honeycomb using the semi-incombustible fibrous sheet according to one embodiment, quasi-incombustibility of flame retardant grade 2 is secured.

Rating 4: Semi-incombustible  Sound absorption measurement of fiber-reinforced composite material

The absorbency values of the semi-incombustible fiber-reinforced composite material according to Examples 1 to 3 and the interior material of Comparative Example 1 were measured according to the KS F 2805 reverberation method and the absorption coefficient values according to frequency (Hz) are shown in Table 2 below. The measurement environment is shown in Table 1 below.

Temperature 23 ℃ Relative humidity 80% R.H. Reverberation room capacity 325 m ³ Reverberation chamber surface area 291.8 m ³ Specimen Size
(Width X length X thickness) 3500mm X 3000mm X 108mm

(Sound absorption coefficient value) Frequency (Hz) Example 1 Example 2 Example 3 Comparative Example 1 100 0.14 0.16 0.15 0.11 250 0.42 0.36 0.34 0.32 315 0.52 0.52 0.52 0.30 400 0.70 0.66 0.64 0.48 630 0.74 0.72 0.70 0.48 800 0.75 0.74 0.72 0.46 1000 0.73 0.70 0.67 0.36 1250 0.68 0.64 0.62 0.34 1600 0.52 0.52 0.50 0.30 2000 0.38 0.38 0.34 0.30 3150 0.30 0.29 0.26 0.30 4000 0.28 0.27 0.24 0.20 5000 0.24 0.19 0.12 0.12

Referring to Table 2, in Examples 1 to 3, the sound absorption coefficient at a frequency of 400 Hz to 1250 Hz has a value within a range of 0.6 to 1.0, while in the case of Comparative Example 1 which is a conventional interior material, Can not be reached to 0.6. According to one embodiment, when a quasi-incombustible fiber-reinforced composite material is formed using a semi-incombustible fibrous sheet material made of cotton fibers containing 90% by weight to 100% by weight of cellulose, the mineral wool corresponding to artificial mineral fibers Compared with the conventional interior material, it can be seen that the sound absorbing property is excellent.

Therefore, the semi-incombustible fiber-reinforced composite material according to one embodiment has high hardness and quasi-incombustibility of flame retardant grade 2, and is not only an environmentally friendly material harmless to human body as compared with conventional interior materials but also excellent in sound insulation, sound- It can be very useful as a new material that can replace existing interior materials.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments, but, on the contrary, And it goes without saying that the invention belongs to the scope of the invention.

10: Semi-nonflammable fiber composite material
11: Flame retardant fiber board
20: First layer
22: Glyph
30: honeycomb layer
31: semi-incombustible honeycomb composite
32: first reinforcing layer
34: honeycomb core
36: Coating layer
38: second reinforcing layer
40: Second layer

Claims (31)

A first layer;
A honeycomb layer positioned over the first layer; And
And a second layer overlying the honeycomb layer,
Wherein the first layer and the second layer are fibrous sheets and at least one of the first and second layers is a semi-incombustible fibrous sheet material comprising a cotton fiber,
Wherein the cotton fiber comprises 90% by weight to 100% by weight of cellulose.
The method of claim 1,
The semi-incombustible fibrous sheet further comprises reinforcing fibers comprising bast fibers, pulp, synthetic fibers or combinations thereof,
Wherein the mixing ratio of the cotton fiber to the reinforcing fiber is a weight ratio of 6: 4 to 9: 1.
The method of claim 1,
Wherein the semi-incombustible fibrous sheet material further comprises 10 to 50 parts by weight of expanded graphite per 100 parts by weight of the cotton fiber.
The method of claim 1,
Wherein the semi-incombustible fibrous sheet material has a structure in which a plurality of flame retardant fibrous sheet materials are laminated and lapped together.
5. The method of claim 4,
Wherein the plurality of flame retardant fibrous sheet materials are each 0.5 mm to 3 mm.
The method of claim 1,
Wherein the semi-incombustible fibrous sheet material has a structure having a predetermined pattern formed on at least one surface thereof or a perforated structure.
The method of claim 1,
The quasi-incombustible fiber-reinforced panel material is approved as quasi-fireproof material as a result of the test according to the approval standard (KFIS 014) of the fireproof and semi-fireproof material of the interior decoration or the specification of the flame resistance test method of the interior material and structure of the building ) As a result of the test according to the present invention.
The method of claim 1,
Wherein the first layer and the second layer each have a thickness of 2 mm to 20 mm.
The method of claim 1,
Wherein the honeycomb layer comprises a metal honeycomb, a semi-incombustible honeycomb composite, or a combination thereof.
The method of claim 9,
Wherein the honeycomb layer is the semi-incombustible honeycomb composite,
The semi-incombustible honeycomb composite
A first stiffener;
A honeycomb core made of paper and positioned on an upper surface of the first reinforcing member;
A coating layer positioned on top of the honeycomb core and comprising a subflammable coating composition; And
And a second reinforcing material located at an upper end of the coating layer and the same or different from the first reinforcing material.
11. The method of claim 10,
The quasi-incombustible coating composition comprises
50% to 80% by weight of a soluble silicate;
10% to 30% by weight of expanded graphite; And
From 5% to 20% by weight of an inorganic material comprising aluminum hydroxide, magnesium hydroxide, ultracarb, diatomaceous earth, or combinations thereof.
Semi - incombustible fiber composite.
11. The method of claim 10,
Wherein the first reinforcing material and the second reinforcing material each comprise glass fiber, glass paper, carbon fiber, nonwoven fabric or a combination thereof.
11. The method of claim 10,
The quasi-incombustible honeycomb composite is a quasi-nonflammable material approved as a result of the test according to KFIS 014 of the fireproof and semi-fireproof material of the interior decoration, or the specification of the flame resistance test method of the interior materials and structure of the building F2271) as a flame retardant grade 2, which is a semi-nonflammable fiber-reinforced composite material.
The method of claim 1,
Wherein the honeycomb layer has a thickness of 1.0 mm to 48.0 mm.
The method of claim 1,
Wherein the honeycomb layer is adhered to the second layer and the first layer by a honeycomb bonding composition,
The honeycomb bonding composition
100 parts by weight of a binder resin comprising a urethane compound, an epoxy compound, an acrylic compound, or a combination thereof;
With respect to 100 parts by weight of the binder resin,
20 to 60 parts by weight of expanded graphite; And
1 to 20 parts by weight of an inorganic material comprising aluminum hydroxide, magnesium hydroxide, ultracarb, diatomaceous earth, or a combination thereof.
Semi - incombustible fiber composite.
The method of claim 1,
Wherein the semi-incombustible fiber-reinforced composite material has a thickness of 10 mm to 200 mm.
The method of claim 1,
The quasi-incombustible fiber-reinforced interiors have been approved as quasi-nonflammable materials as a result of tests in accordance with KFIS 014 for the standards of fireproof and semi-fireproof materials of indoor ornaments, F2271) as a flame retardant grade 2, which is a semi-nonflammable fiber-reinforced composite material.
The method of claim 1,
The quasi-incombustible fiber-reinforced composite material is a quasi-nonflammable fiber-reinforced composite material having a sound absorption coefficient of 0.6 to 1.0 at a frequency of 400 Hz to 1250 Hz as a result of a test according to KS F 2805 reverberation method.
The method of claim 1,
The semi-incombustible fiber-reinforced composite material includes a ceiling material, a wall material, or a combination thereof.
Attaching a honeycomb layer to an upper surface of the first layer; And
And attaching a second layer to an upper surface of the honeycomb layer to form a laminate,
Wherein the first and second layers are fibrous sheets and at least one of the first and second layers is a semi-incombustible fibrous sheet material comprising cotton fibers,
Wherein the cotton fiber comprises 90% to 100% by weight of cellulose
(JP) METHOD FOR MANUFACTURING STANDARD FLAMMABLE FIBER INJECTION MATERIAL
20. The method of claim 20,
Wherein the honeycomb layer comprises a metal honeycomb, a semi-incombustible honeycomb composite, or a combination thereof.
22. The method of claim 21,
Wherein the honeycomb layer is the semi-incombustible honeycomb composite,
The semi-incombustible honeycomb composite
Attaching a honeycomb core made of paper to one surface of the first reinforcing member;
Coating the adhered honeycomb core with a semi-incombustible coating composition to form a coating layer; And
And attaching a second reinforcing material, which is the same as or different from the first reinforcing material, to the upper end of the coating layer.
The method of claim 22,
The quasi-incombustible coating composition comprises
50% to 80% by weight of a soluble silicate;
10% to 30% by weight of expanded graphite; And
From 5% to 20% by weight of an inorganic material comprising aluminum hydroxide, magnesium hydroxide, ultracarb, diatomaceous earth, or a combination thereof.
The method of claim 22,
Wherein the first reinforcing member and the second reinforcing member each comprise glass fiber, glass paper, carbon fiber, nonwoven fabric or a combination thereof.
20. The method of claim 20,
The attachment is performed by a honeycomb bonding composition,
The honeycomb bonding composition
100 parts by weight of a binder resin comprising a urethane compound, an epoxy compound, an acrylic compound, or a combination thereof;
With respect to 100 parts by weight of the binder resin,
20 to 60 parts by weight of expanded graphite; And
1 to 20 parts by weight of an inorganic material comprising aluminum hydroxide, magnesium hydroxide, ultracarb, diatomaceous earth, or a combination thereof.
(JP) METHOD FOR MANUFACTURING STANDARD FLAMMABLE FIBER INJECTION MATERIAL
20. The method of claim 20,
After forming the laminate,
A step of painting or thermally transferring the surface of the laminate
Further comprising the steps of:
20. The method of claim 20,
The method of manufacturing the semi-incombustible fibrous sheet material
Forming a papermaking fiber sheet material through a papermaking process of putting a fiber material containing the cotton fiber into a papermaking composition,
Forming a flame retardant fibrous sheet material by impregnating the paper fiber sheet into an impregnating composition, and
Forming a semi-incombustible fibrous sheet material by preparing a plurality of said flame-retardant fibrous sheet materials, applying a rigid bonding composition on each side, and laminating them together
(JP) METHOD FOR MANUFACTURING STANDARD FLAMMABLE FIBER INJECTION MATERIAL
28. The method of claim 27,
The grass-
With respect to 100 parts by weight of the fiber material,
10 to 40 parts by weight of expanded graphite;
10 parts by weight to 40 parts by weight of a metal hydroxide comprising aluminum hydroxide, magnesium hydroxide, ultracarb or a combination thereof;
10 parts by weight to 40 parts by weight of a thermosetting resin; And
200 parts by weight to 2000 parts by weight of water
(JP) METHOD FOR MANUFACTURING STANDARD FLAMMABLE FIBER INJECTION MATERIAL
28. The method of claim 27,
The impregnating composition comprises
With respect to 100 parts by weight of the above paper fiber sheet,
75 parts by weight to 95 parts by weight of a soluble silicate;
From 20 parts by weight to 35 parts by weight of a metal hydroxide comprising aluminum hydroxide, magnesium hydroxide, ultracarb or a combination thereof; And
10 to 25 parts by weight of diatomaceous earth
(JP) METHOD FOR MANUFACTURING STANDARD FLAMMABLE FIBER INJECTION MATERIAL
28. The method of claim 27,
The rigid bonding composition comprises
100 parts by weight of a thermoplastic resin;
With respect to 100 parts by weight of the thermoplastic resin,
20 to 35 parts by weight of expanded graphite; And
From 25 to 40 parts by weight of a metal hydroxide comprising aluminum hydroxide, magnesium hydroxide, ultracarb or a combination thereof.
(JP) METHOD FOR MANUFACTURING STANDARD FLAMMABLE FIBER INJECTION MATERIAL
28. The method of claim 27,
Prior to the lapping process,
And thermo-compression molding the flame-retardant fibrous sheet material formed through the impregnation process
(JP) METHOD FOR MANUFACTURING STANDARD FLAMMABLE FIBER INJECTION MATERIAL

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