KR20210001202A - Construction Insulation Material Foam - Google Patents

Abstract

The present invention relates to a foamed heat insulation material for construction, formed by melting, compressing and kneading a heat insulation material composition including a foamable polymer resin, UV-attenuating agent and a flame retardant in an extruder, followed by continuous foaming into a sheet-like shape. The heat insulation material composition includes a foamable polymer resin selected from polystyrene, polyvinyl chloride, chlorinated polyvinyl chloride, polyethylene, polypropylene, polycarbonate, polystyrene-co-butadiene, polyvinyl acetate-co-ethylene, modified rubber polymer, thermoplastic polymer blend and combinations thereof, and at least one selected from silica calcium carbonate and talc, as an inorganic nucleating agent for preventing degradation of the heat insulation performance of a foamed product. The heat insulation material can be obtained in an eco-friendly manner, since no HCFC (hydrochlorofluorocarbon) foaming agent and HCBD (hexachlorobutadiene) flame retardant are used, includes cells having a small size of 60-260 micrometers upon the foaming, and thus has compact cells with a smaller size as compared to the conventional foamed heat insulation materials to prevent degradation of heat insulation properties with the lapse of time and to provide improved durability. In addition, when the heat insulation material is subjected to lamination to increase the thickness thereof, it is possible to increase the thickness of the heat insulation material with no problem of conversion into open cells, and thus to improve the heat insulation performance.

Description

Construction Insulation Material Foam

The present invention relates to a foam insulation material for construction, and in particular, it is an alternative foaming gas composition that does not use a foaming agent and a flame retardant harmful to the environment and has a low gas diffusion. It relates to a foam insulation material for construction that is improved to ensure long-term insulation and flame retardant reliability of XPS required by the market while conforming to regulations.

In general, in a building, heat is transferred from inside and out, and air flows into and out of the building through the fine pores of concrete or brick forming the wall, and heat transfer occurs inside and outside the building through heat transfer. In order to increase insulation, flame retardancy, sound absorption and moisture-proof function by being attached between the inner wall or the outer wall and the finishing material, construction insulation materials are widely used.

Halogen flame retardants, which have been mainly used so far, have played a flame retardant role by trapping radicals in the gaseous phase, but the halogen gas generated at this time can have a fatal effect on facilities, etc. by corroding metals such as molds or wires, and is harmful to humans.

Accordingly, in accordance with international climate agreements and domestic environmental regulations, from 2020, HCFC (hydrofluorocarbon) foaming agents and HCBD (hexaalcohol butadiene) flame retardants cannot be used. In order to replace HCFC, which is a foaming agent, research is being conducted to replace HFC (fluorohydrocarbon), CO2, and HC (hydrocarbon).

As an example of such an insulating material, Korean Patent Publication No. 10-1676742 (registration date November 10, 2016) includes 100 parts by weight of polystyrene resin, 1 to 5 parts by weight of flame retardant, 03 to 4 parts by weight of nucleating agent, and carbon dioxide foaming agent 02 To 1 part by weight and 3 to 10 parts by weight of other blowing agents, and 02 to 1 parts by weight of a carbon dioxide blowing agent, and 3 to 10 parts by weight of hydrogen fluorocarbon (HCFC) or hydrogen fluorocarbon (HFC) type blowing agent. There is disclosed an extruded styrene foam which is put into a mold under an extrusion pressure and a first extrusion temperature condition and extruded under a second extrusion pressure and a second extrusion temperature condition.

However, in the case of the conventional extruded polystyrene (XPS) foam, there is a problem in that the long-term thermal insulation performance is deteriorated as the foaming gas is replaced in the air.

Domestic Patent Publication No. 10-1676742 (Registration Date November 10, 2016)

An object of the present invention is to solve the problems of the conventional XPS insulation material described above, to form a small and uniform cell size, and the closed cell is not destroyed by an inorganic flame retardant, so that insulation and gas barrier performance are improved, thereby improving long-term reliability, and waste reuse rate. It is to provide this improved construction foam insulation.

In order to achieve the above object, the foamed insulating material for construction according to the present invention is formed by continuously foaming a heat insulating material composition comprising a foamable polymer resin, a UV attenuator and a flame retardant in an extruder to form a plate shape by melting, compressing, and kneading. In the foam insulation for construction,

Selected from polystyrene, polyvinyl chloride, polyvinyl chloride chloride, polyethylene, polypropylene, polycarbonate, copolymers of styrene and butadiene, copolymers of vinyl acetate and ethylene, rubber modified polymers, thermoplastic polymer mixtures, and combinations thereof as insulation composition A foamable polymer resin,

1,1-(1-methylethylidene)bis[3,5-dibromo-4-(2,3-dibromopropoxy)benzene, 1,1!-(isopropylene)bis[3, 5-dibromo-4-(2,3-dibromo-2-methylpropoxy)benzene, a flame retardant comprising at least one selected from tetrabromobisphenol A bis, and

In order to prevent deterioration of the thermal insulation performance of the foam, it is characterized in that it contains at least one selected from calcium silica carbonate and talc talc as an inorganic nucleating agent.

In an extruder, the insulating material composition is made of HFC-series gas as the main foaming agent and pentane and butane as the auxiliary foaming agent, so that the cell size is 60 to 260 μm, and the inorganic tank is foamed to 100 parts by weight of the foamable polymer resin. It is preferable to contain 0.6 to 3.2 parts by weight of the nucleating agent.

Including 2 to 3.5 parts by weight of pentane and 1.5 to 2.3 parts by weight of pentane based on 100 parts by weight of the main foaming agent by using the HFC-based gas as the main foaming agent at 200 to 240°C in an extruder, and using butane and pentane as auxiliary foaming agents. While foaming, it is possible to form to have an increased thickness by laminating at least two sheets of heat-sealable insulating materials extruded into a plate shape of 50 to 70 mm thick.

The foam insulation for construction according to the present invention can be manufactured eco-friendly because it does not use HCFC (hydrofluorocarbon) foaming agent and HCBD (hexaalcohol butadiene) flame retardant, and the size of the cells at the time of foaming is 60-260㎛ small and uniform. It is formed and foamed into dense cells of a size smaller than the cell size of the conventional foamed insulating material, preventing degradation in insulation properties with the passage of use, improving durability, and solving the problem of deteriorating insulation properties due to long-term use. The insulation thickness of the closed cell can be increased through a thermal lamination process, so that the cell becomes open when the thickness of the conventional insulation material is increased, so that the insulation thickness can be increased without deteriorating the insulation properties, thereby improving energy saving efficiency.

Hereinafter, the present invention will be described in more detail by way of examples of the present invention.

The foam insulation for construction according to the present invention comprises a foamable polymer resin, an inorganic nucleating agent for improving the insulation performance in the foam, and a UV attenuating agent for preventing deterioration of the insulation performance generated when the foaming gas is replaced with air. The composition containing is melted, compressed, and kneaded in an extruder, and is continuously foamed into a plate shape.

The foamable polymer resin includes polyvinyl chloride, polyvinyl chloride chloride, polyethylene, polypropylene, polycarbonate, copolymers of styrene and butadiene, copolymers of vinyl acetate and ethylene, rubber modified polymers, thermoplastic polymer mixtures, and combinations thereof. It may comprise a composition selected from, and polystyrene is preferred.

With respect to 100 parts by weight of the foamable polymer resin, at least one selected from calcium silica carbonate and talc talc as the inorganic nucleating agent is 0.6 to 3.2 parts by weight, and the size of the cells during foaming is controlled by adjusting the content of the inorganic nucleating agent. It is preferable to make it small and uniformly formed in the range of 60 to 280 μm. By the inorganic nucleating agent, the size of the cells is small and uniformly formed to improve the thermal insulation performance, and the deterioration of the thermal insulation function due to the conventional cell bursting into an open cell is prevented.

3 to 12 parts by weight of a flame retardant, and 0.07 to 4.3 parts by weight of at least one selected from carbon black, graphite, and titanium dioxide (TiO 2) as an ultraviolet attenuator may be further included.

As the flame retardant, 1,1-(1-methylethylidene)bis[3,5-dibromo-4-(2,3-dibromopropoxy)benzene, 1,1!-(isopropylene) At least one selected from bis[3,5-dibromo-4-(2,3-dibromo-2-methylpropoxy)benzene and tetrabromobisphenol A bis is included.

The heat insulating material composition is extruded in a plate shape having a predetermined thickness, preferably 50 to 70 mm thick, while foaming using an HFC-based gas as the main foaming agent at 200 to 240°C in an extruder and using butane and pentane as auxiliary foaming agents. At least two of the molded insulating materials are heat-sealed and integrated to increase the thickness.

It is preferable to use including 2 to 3.5 parts by weight of pentane and 1.5 to 2.3 parts by weight of butane based on 100 parts by weight of the main foaming agent.

1,1-(1-methylethylidene)bis[3,5-dibromo-4-(2,3-dibromopropoxy)benzene 4.7 as a flame retardant per 1000 g of the foamable polystyrene resin according to the present invention. g, 5g, 1g, 2g, and 3g of talc as an inorganic nucleating agent were added to a composition containing 2.1g of carbon black as an ultraviolet attenuator, and uniformly mixed, and HGC for 100 parts by weight of HFC gas at 200°C in an extruder. gas; Insulation materials of Examples 1 to 4 were prepared under extrusion molding of a foam insulation material having a thickness of 100 mm by injecting a foaming gas in which the ratio of pentane:butane was 100:2:1.5.

Table 1 below shows the experimental results for the cell size and thermal insulation (initial thermal conductivity) for the content of the inorganic nucleating agent in Examples 1 to 4 above.

Content of inorganic nucleating agent in polymer resin (% by weight) Evaluation item unit Experiment result Example 1: 0.5 Cell size mm 0.303 Initial thermal conductivity W/m· 0.02883 Example 2: 1 Cell size mm 0.266 Initial thermal conductivity W/m· 0.02772 Example 3: 2 Cell size mm 0.241 Initial thermal conductivity W/m· 0.02743 Example 4; 3 Cell size mm 0.229 Initial thermal conductivity W/m· 0.02711

From Table 1 above, when the inorganic nucleating agent content is 0.5% by weight relative to the total insulating material composition including polystyrene, since the cell size becomes larger than 0.3mm, it is not preferable.When the inorganic nucleating agent is 3% by weight, the cell size is 0.229 and the thermal conductivity is also It is preferable because it decreases, but as the content of the inorganic nucleating agent increases, the cell size decreases, but when the content of the inorganic nucleating agent is increased, the cell formation is hindered during foaming, which is not preferable.

In Table 2 below, an XPS insulation material having a thickness of 100 mm was prepared according to Example 2 of the present invention to compare and evaluate a conventional XPS insulation material having a thickness of 100 mm that does not contain an inorganic nucleating agent and thermal insulation performance-effect change over time.

subject Evaluation item unit KS M 3808 standard Experiment result Comparative Example:
XPS 100 mm (conventional) Cell size mm - 0.303 Initial thermal conductivity W/m· 0.028 or less 0.02883 Long-term thermal conductivity (23 degrees 50% R.H. 91 days) W/m· 0.030 or less 0.03524 Invention:
XPS 100 mm (1% by weight of inorganic nucleating agent) Cell size mm - 0.266 Initial thermal conductivity W/m· 0.028 or less 0.02772 Long-term thermal conductivity (23 degrees 50% R.H. 91 days) W/m· 0.030 or less 0.02966

In Table 2 above, the 100 mm thick insulation produced by XPS molding without using an inorganic nucleating agent according to the existing method has a cell size of 0.303 mm, but the thermal conductivity is high to 0.03524, so it is expected that the insulation performance will deteriorate. As a result, when the inorganic nucleating agent content contains 1% by weight of the inorganic nucleating agent with respect to the total insulating material composition including polystyrene, the cell size is relatively very small, 0.266mm, and the thermal conductivity is also significantly reduced to 0.02966, compared to the comparative example. It was confirmed that the insulation properties were maintained.

As described above, thermally fused two sheets of foamed insulating material having a thickness of 100 mm prepared by containing an inorganic nucleating agent in a polystyrene resin according to the present invention can be greatly improved. The surfaces to be bonded to the two sheets of 100mm thick foam insulation are integrated by heating a metal plate at 190 to 210° C. by pressure bonding in a molten state and fusion bonding.

Accordingly, when the thickness of the conventional insulation material is increased, the cell becomes open, so that the insulation performance can be improved by laminating two sheets of insulation material without the problem of deteriorating insulation performance.

The outer surface of the foamed insulating material may be coated with a water-repellent, water-repellent synthetic rubber and an alkaline inorganic water-repellent water-repellent compound, and a waterproofing agent.

The foamed insulation according to the present invention, preferably the extruded foamed polystyrene insulation, has little water-absorbing property, so it is very suitable for construction of the foundation or basement of a building, and takes up space even if it is formed thinner than a styrofoam material of the same performance It can be used suitably as an insulation material for buildings as it has low thermal conductivity and has good insulation performance, and it is foamed into dense cells that are smaller than the cell size of conventional foam insulation materials to prevent deterioration in insulation properties with the passage of use and improve durability. do.

The present invention can be used in the manufacture of foam insulation for construction without the use of a HCFC (hydrofluorocarbon) foaming agent and an HCBD (hexaalcohol butadiene) flame retardant.

Claims (3)

In the foam insulation for construction formed by continuously foaming a heat insulating material composition comprising a foamable polymer resin, a UV attenuator and a flame retardant in an extruder to form a plate shape by melting, compressing, and kneading,
Selected from polystyrene, polyvinyl chloride, polyvinyl chloride chloride, polyethylene, polypropylene, polycarbonate, copolymers of styrene and butadiene, copolymers of vinyl acetate and ethylene, rubber modified polymers, thermoplastic polymer mixtures, and combinations thereof as insulation composition A foamable polymer resin,
1,1-(1-methylethylidene)bis[3,5-dibromo-4-(2,3-dibromopropoxy)benzene, 1,1!-(isopropylene)bis[3, A flame retardant comprising at least one selected from 5-dibromo-4-(2,3-dibromo-2-methylpropoxy)benzene and tetrabromobisphenol A bis,
Foam insulation for construction, characterized in that it contains at least one selected from calcium silicate and talc as an inorganic nucleating agent in order to prevent deterioration of the insulation performance of the foam.
The method of claim 1,
In an extruder, the insulating material composition is made of HFC-series gas as the main foaming agent and pentane and butane as the auxiliary foaming agent. Foam insulation for construction, characterized in that it contains 0.6 to 3.2 parts by weight of a nucleating agent.
The method according to claim 1 or 2
Including 2 to 3.5 parts by weight of pentane and 1.5 to 2.3 parts by weight of pentane based on 100 parts by weight of the main foaming agent by using the HFC-based gas as the main foaming agent at 200 to 240°C in the heat insulating material composition as auxiliary foaming agents Foam insulation for construction, characterized in that forming to have an increased thickness by laminating at least two sheets of heat-sealing, extruded into a 50-70mm thick plate shape while foaming.