KR20190054879A - The manufacturing method of semi-inflammable interior panel and the interior panel manufactured by the method - Google Patents

Abstract

The present invention relates to a semi-incombustible building interior material including cotton fibers and, more specifically, to a method for manufacturing a semi-incombustible building interior material and a semi-incombustible building interior material manufactured thereby, wherein the method comprises the following steps of: obtaining mushy cotton fibers by beating-polishing cotton fibers; forming a mushy board composition by mixing the mushy cotton fibers with expansion vermiculite or porous mineral granules of perlite; obtaining fiber boards through a dehydration process; drying the fiber boards by immersing a flame-resisting solution in the fiber boards; and performing a molding process.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a semi-fireproof interior material and a semi-fireproof interior material,

The present invention relates to a quasi-fireproof construction interior material containing natural mineral granules and cotton fibers, which is environmentally friendly and is a building finish material for wallpaper or plywood substitute which does not ignite in case of fire and does not generate toxic gas.

In addition, the present invention is capable of embossing and various patterns and colors on the surface of the board, and is also thin and light in weight, so that the interior material construction is convenient.

The construction interior material is a material that combines the finishing and decorating of the inner surface of the structure that constitutes the space of the building. Many of them are made of sheet material (sheet material) to form the surface, and various kinds of materials such as durability, texture It is required to meet the required performance, typically wall linings, floors and ceilings.

Recently, there is a growing need for fire-retardant interior materials as the awareness of fire is increasing. This is because the conventional building interior materials are mostly made of organic compounds, and toxic gases are emitted due to flammable substances during the fire.

In general, there are gypsum board, magnesium board, CRC board, wood board and calcium board as materials which are equivalent to semi-fireproof (flame retardant grade 2). However, these materials can not be used as final finishing materials because their surfaces are not beautiful. As a result of using the surface materials having different physical properties such as polypropylene, HPL, deco film, PET film, and the like, the flame retardancy problem of the surface material is caused.

Most of the surface materials are difficult to produce with flame retardant materials. In case of HPL, it is manufactured by impregnating the shape paper with melamine resin.

In general, semi-fireproof ceiling materials can be classified into ceiling materials including smc ceiling materials and inorganic fibers, which are largely thermosetting resin ceiling materials, depending on the raw materials. smc ceiling materials are widely used as ceiling materials such as toilets requiring waterproofing and ceiling materials containing inorganic fibers are products of mineral wool and glass wool products containing inorganic fibers, There is a combined Tex product. The mineral wool products are made of ceramic fibers made of artificial mineral fibers and the glass wool products are made of glass raw materials such as silica sand and wave glass.

In addition, there is a floor interior material and a wall interior material. These are generally formed as a hard panel. Recently, due to the occurrence of fire due to building fire, interest in the fireproof or semi-fireproof interior material of buildings is increasing.

Semi-incombustible lining materials are advantageous when fire occurs because they are usually non-combustible materials because they contain inorganic fibers or minerals. However, it is difficult to diversify designs and expensive manufacturing costs because they must be manufactured by a felt manufacturing technique. Above all, there is a disadvantage that it is not good for the respiratory system due to the mineral dust generated in the interior material, and it is disadvantageous in that it is difficult to construct due to heavy weight of the product and weak in shock.

Recently, attempts have been made for a sound absorbing panel using pearlite or vermiculite, but this also has various disadvantages.

That is, Patent Document 1 discloses a panel manufacturing method using soda silicate and expanded vermiculite. The invention disclosed in Patent Document 1 relates to a method of manufacturing a panel using soda silicate and expanded vermiculite, comprising a spraying step of uniformly spraying a liquid silicate of the same weight as the expanded vermiculite to the expanded vermiculite using a pressure atomizer, A molding process in which expandable vermiculite spray-coated with liquid sodium silicate is injected into the mold at a thickness exceeding 0-40% of a desired thickness and press-molded to a desired thickness; And a drying process in which the substrate is irradiated with ultraviolet light at a wavelength of -3000 MHz and 500-1500 W to provide a uniform light intensity from the inside to the outside of the panel and a relatively light weight due to the porosity of the expanded vermiculite.

Also, Patent Document 2 discloses a method of manufacturing a non-combustible sound absorbing material that can be used as an interior material. The invention disclosed in Patent Document 2 is characterized in that a first mixing step of mixing the first inorganic binder and the expanded vermiculite at a weight ratio of 1: 1, a drying step of drying the mixture through the first mixing step, 1) mixing a mixture of 60 to 80 parts by weight of expanded vermiculite coated with an inorganic binder and 20 to 40 parts by weight of a second inorganic binder, a forming step of compression-molding the mixture through the second mixing step, And a processing step of processing the surface of the compression-molded mixture. The present invention also provides a method of manufacturing a non-combustible sound absorbing material.

However, since the sound absorbing material and the panel disclosed in Patent Documents 1 and 2 are manufactured by pressurizing after the expanded vermiculite is put into a mold together with an inorganic binder, the automation of production is limited and the production cost is high. In addition, since a small impact can be easily broken because it is combined with an inorganic binder, a dangerous situation can occur due to falling of the interior material when an earthquake occurs. In addition, it is difficult to produce a variety of designs and colors due to the irregular appearance of the gemstones themselves.

In addition, since the conventional panels have a high manufacturing cost, the cost of construction is increased. As a result, the building owners hesitate to replace the building interior material despite the risk of fire in the building, and as a result, the damage caused by the fire can not be prevented.

1. Korean Patent No. 10-0895213 2. Domestic Registration No. 10-1133931

The present invention aims to provide a semi-fireproof construction interior material which is resistant to flames and does not emit toxic gases, and a construction interior material by the manufacturing method.

It is another object of the present invention to provide a semi-fireproof construction interior material which is remarkably low in manufacturing cost and light in weight, easy to construct, and resistant to impact when manufacturing a fireproof building interior material.

In order to solve the above problems,

The present invention relates to a method for producing a cotton fiber material, comprising the steps of: finely cutting a cotton fiber material and then grinding the cotton fiber material together with water in a water tank provided with a beater,

Adding at least one of natural mineral granules having a specific gravity of at least one of the expanded vermiculite and the pearlite to the cotton fiber material, and obtaining a mixed composition in a puddle state;

A step of obtaining a plate material by discharging the mixed composition containing water in a superheated state onto a mesh, and dewatering the plate material;

And a step of impregnating the dewatered sheet with a flame retardant and drying the sheet with a dryer.

However, since the expanded vermiculite has a sticky nature and is not well mixed with the cotton fiber material, it is preferable to use a mixture of pearlite and pearlite, , Diatomite, and diatomaceous earth granule are preferably added together to improve the hygroscopicity.

Preferably, the semi-fireproof construction interior material produced by the manufacturing process is finally cut into a suitable length and molded in a predetermined pattern.

Since the present invention is to produce an interior material using porous natural mineral granules of expanded vermiculite or perlite which are natural minerals, it not only has a nonflammability but also has flexibility because natural mineral granules are cohesively bonded by fine fiber of a cotton fiber, The nonwoven fabric can be produced in a mass-production mode and impregnated with liquid sodium silicate, so that the binding force and the incombustibility are increased.

Since the present invention can be mass-produced and the manufacturing cost is remarkably low, the interior materials of buildings using asbestos-containing interior materials can be replaced at low cost, and since it is a flexible interior material, And there is an advantage that it does not fall or break when an earthquake occurs and does not cause personal injury.

1 is a top view of a semi-fireproof construction interior material incorporating the cotton fiber according to the present invention
2 is a flow chart illustrating a method of manufacturing a semi-fireproof construction interior material comprising a cotton fiber according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method of manufacturing a semi-fireproof construction interior material including the cotton fiber according to the present invention will be described in detail with reference to the accompanying drawings.

<Examples>

(1) Acquiring a cotton fiber material in a beating state by beating polishing (S 100)

The cotton fiber material containing a large amount of cellulose was cut into a length of 40 mm, and then 3000 kg of water was filled in a water tank equipped with a beater, 150 kg of a cotton fiber material was put and polished by beating for 1 to 2 hours, And obtaining the ashes.

Commonly known cotton hairs contain 98% of celluloses and bast fibers of flax, hemp, flax, and jute contain about 70% cellulose do. The wood, which is the raw material of the pulp, contains about 40 to 50% of cellulose. Therefore, it is preferable to use a cotton fiber material containing a large amount of cellulose. Preferably, the cotton fiber utilizes waste cotton fibers which are generated as a by-product in the cotton product manufacturing process.

Since the chemical fiber is not made of cellulose, it can not be cohesively bonded with porous natural minerals such as expanded vermiculite or perlite granules because it is not loosened by water even by beating polishing.

Of course, although cellulose can be obtained from fibers or pulp other than cotton fibers, cotton fibers containing a large amount of high quality cellulose, which are not suitable for the production cost, are most preferable. The large amount of cellulose contained in the cotton fiber makes it possible to increase the effect of quasi-incombustibility. In particular, cotton fiber is an eco-friendly material that is a sustainable resource and harmless to the human body, because it can utilize a large amount of waste fiber that is used and abandoned in the industrial field or at home.

Of course, although it can be used as a raw material for pulp containing bast fibers such as flax, hemp, moss, jute and the like containing about 70% of cellulose or about 40-50% of cellulose, Is low.

(2) Porous Mineral Granule Loading and Mixing Process (S 200)

The expanded vermiculite can be introduced as the porous mineral into the above-mentioned cotton fiber material. In this case, 50 to 70 parts by weight of the expanded vermiculite may be included in 100 parts by weight of the cotton fiber material. When the expanded vermiculite is included in the range described above, it is excellent in adhesion to the cotton fiber material when mixed with the cotton fiber material of the non- Can be improved.

Expanded vermiculite is an inorganic material with excellent non-flammability, good heat insulation and light weight, so it is not precipitated in a tank tank but floated in water. It is mixed naturally with beaten polished cotton fiber in mixing process and has excellent adhesion with cotton fiber material. The nonflammability can be further improved. In other words, the cotton fiber material penetrates every corner of the pores of the expanded vermiculite and connects the expanded vermiculite together and at the same time.

The expanded vermiculite is crushed to a particle diameter of about 1 to 3 mm and calcined at 1000 to 1200 ° C to swell to swell to reduce the density and float in water.

As the expanded vermiculite tends to aggregate due to stickiness to each other, when pearlite is appropriately added in an amount of 30 to 50 parts by weight perlite, pearlite acts as a bridge to keep the spacing of the expanded vermiculite constant, give.

As a preferred embodiment, 90 to 110 kg of expanded vermiculite and 15 to 25 kg of pearlite are added and mixed, so that the microfibers of the cotton fiber material and the porous minerals are entangled with each other to be integrally bonded. That is, since the expanded vermiculite and pearlite are porous, the microfibers of the cotton fiber material floating on the water and floating on the water are inserted into the pores of the expanded vermiculite and the pearlite, and are tangled and strongly bonded together.

Although not included in the above examples, preferably, 5 to 10 kg of Il light and 3 kg of diatomaceous earth are sequentially added to allow the mineral to penetrate between the cotton fiber materials to be integrated with the cotton fiber material.

The diatomaceous earth is composed of silica (SiO ² ), which is an inorganic compound, and is a sediment formed by accumulation of diatomic algae, which is a monocyte algae, on the bottom of sea or lake. It has various performances such as deodorization, But also impart excellent flame retardancy.

In addition, since expanded graphite has a layered structure of graphite, when particles or small molecules are inserted between the layers and heat is applied, the particles are separated by a factor of several times as they are separated as an accordion. When beating, a small amount of 1 ~ 2kg of expanded graphite powder is put in close contact with the pores of the cotton fiber to form an integral body, so that it expands when it is fired and blocks oxygen and can have self-extinguishing function. The semi-flammability of the cotton fiber can be further improved. However, when an excessive amount is applied, the background color is displayed as black, which may cause a problem in painting.

(3) Sheet material obtaining process (S 300)

The porous fiber material mixed with the porous mineral is discharged onto a mesh containing water and is dehydrated to be made of a cotton fiber sheet.

The dehydration is performed by natural dehydration, a compression roller, or dehydrated through a pressure roller process so as to have a water content of 20 to 30%.

(4) Flame-Retardant Impregnation Process and Drying Process (S 400)

A step of impregnating the dewatered cotton sheet material with a flame retardant, drying the same with a hot air drier, and then obtaining a cotton sheet material. The impregnation of the flame retardant with the cotton fiber plate bonds the cotton fiber material with the porous mineral and improves the incombustibility.

The dewatered cotton sheet material is preferably dried at 180 DEG C by a hot-air drier following the impregnation of the flame retardant, and cut to a width of 1200 mm, a thickness of 4.5 mm, and a length of 2500 mm.

The flame retardant solution uses soluble silicate. From the economic standpoint, liquid sodium silicate is preferred. However, when only the sodium silicate is used as the flame retardant, the cotton fiber sheet tends to absorb moisture and become damp, so that at least one of colloidal silica, water-dispersed silica, or modified silicate is selected and mixed in addition to the liquid sodium silicate .

(5) Planar primary molding process (S 500)

The forming process, which is further performed after the drying process, is a process in which a surface of a sheet material is smoothed by applying a nonwoven fabric sheet material to a press and compressing it by applying pressure. Since heat and pressure are applied at this time, residual moisture and flame retardant liquid are dried.

The surface of the plate material subjected to the primary molding is coated with various colors in an aqueous paste and dried.

(6) Secondary molding process

The S 500 process may be completed, but the dried plate after the primary molding process and the coating process is placed on the mold frame with the coated side facing upward, and blister pressure molding is performed If you run it, you will be able to acquire a brilliant, three-dimensional building interior material.

The dried color coated plate material is pressed and formed in a mold so that a shape is formed on the plate material by pressing the colored plate material. Preferably, the construction interior material of the present invention is about 2 to 3 mm.

<Test Example>

1) Semi-incombustible test

The results of the tests described below are based on the results of the test conducted by the Institute for Disaster Prevention Testing, which is an accredited testing institute.

Test item sample number One 2 3 standard Quasi-fire
material Heat release rate Total calorific value 2.4 3.1 6.5 8MJ / m ² or less Time (s) in excess of ²⁰⁰ kW / m ² 0 0 0 10s or more Cracks, holes and melting through the specimen none none none Not to be gas
Hazard Mean behavioral downtime of rats 13 minutes
54 seconds 14 minutes
10 seconds 13 minutes
58 seconds More than 9 minutes

2) Whether or not asbestos is contained

Asbestos has not been detected at all as a result of the asbestos detection test of the product according to the above embodiment with respect to the harmfulness of the recent asbestos. It is based on the test results of Korea Institute of Construction & Living Environment Test, an accredited testing institute.

3) Mold resistance

 Aspergillus brasiliensis ATCC9642, Penicillium funiculosum ATCC 11797, Chaetomium globosum ATCC 6205, Trichoderma virans ATCC 9545, and Aureobasidium pullulans ATCC 15233 were cultured for 4 weeks in the experiment to test the fungus resistance of the product according to the above examples. No development of hyphae was recognized on the specimen inoculation. This is also based on the test results of Korea Institute of Construction & Living Environment Test.

4) Antibacterial test

 In the antibacterial test on the product according to the above example, 99.9% bacterial reduction rate of E. coli and P. aeruginosa was shown after 24 hours. This is also based on the test results of Korea Institute of Construction & Living Environment Test.

The surface fiber sheet including the porous mineral according to the present invention having such a manufacturing process is provided with an environmentally friendly material which is harmless to the human body and has a light and flexible nature so that not only excellent workability but also good semi-incombustibility, heat insulation, It is expected to open a new horizon of interior materials.

The specific embodiments of the present invention have been described above. It is to be understood, however, that the spirit and scope of the invention are not limited to these specific embodiments, but that various changes and modifications may be made without departing from the spirit of the invention, If you are a person, you will understand.

Therefore, it should be understood that the above-described embodiments are provided so that those skilled in the art can fully understand the scope of the present invention. Therefore, it should be understood that the embodiments are to be considered in all respects as illustrative and not restrictive, The invention is only defined by the scope of the claims.

100: semi-fireproof interior material according to the present invention
S 100: Process to polish a cotton material in a water tank to be weighed
S 200: Process of mixing porous natural mineral granules
S 300: Acquisition of cotton fiber sheet with mixed raw material
S 400: Flame retardant impregnation and drying process
S 500: Molding and coating process

Claims (4)

(A) forming a cotton fiber material in a pulp state by beating the cotton fiber material in a water tank equipped with a beater;
(B) adding at least one of expanded vermiculite and pearlite as a porous mineral granule to the surface cotton fiber material so as to be mixed with the cotton fiber material to form a mixed composition in a puddle state;
(C) discharging the mixed composition onto a mesh and dewatering the water to obtain a sheet material;
(D) impregnating the obtained sheet material with a flame retardant and drying the sheet material;
(E) forming and coating a pattern with a predetermined pattern;
A method of manufacturing a semi-fireproof interior material The method according to claim 1,
Characterized in that the flame retardant further comprises at least one of colloidal silica, water-dispersed silica and modified silicate in sodium silicate. The method according to claim 1 or 2,
A method for manufacturing a semi-fire-resistant construction interior material characterized by adding graphite in step (b) of introducing porous mineral to a cotton fiber material in a puddle state A semi-fireproof construction interior material manufactured by the manufacturing method according to any one of claims 1 to 4

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