KR20230001544A - Functoanl sheet, Functional board and method for manufacturing the same - Google Patents

Abstract

According to the present invention, provided are an interior sheet which can perform excellent deodorization performance and antibacterial performance while realizing flame retardancy and performing semi-incombustible performance, and can have excellent adhesion to an object to be bonded, an interior board including the same, or manufacturing method thereof. A functional sheet according to the present invention comprises lower nonwoven fabric, a photocatalyst layer, and upper nonwoven fabric in a sequential manner, wherein the photocatalyst layer includes activated carbon of which the surface is coated with a visible light active catalyst.

Description

Functional sheet, functional board including the same, and manufacturing method thereof

The present invention relates to a functional sheet, a functional board including the same, and a manufacturing method thereof.

Interior boards, a conventional interior finishing material for architecture, are available in various colors and colors on inorganic boards such as calcium silicate board, magnesium board, CFC (Cellulose Fiber Reinforced Cements) board, MDF (Medium Density Fiberboard), HDF (High Density Fiberboard), and vermiculite board. It has eco-friendly and semi-incombustible performance that does not require additional finishing work by attaching a textured interior sheet or interior film.

However, air pollution has become serious in modern society, and with the recent emergence of highly contagious viruses, the time spent in indoor spaces has increased. Accordingly, there is a demand for a functional board capable of improving the quality of indoor air.

On the other hand, deodorization performance is very important in making indoor air comfortable. Conventionally, the deodorization performance used a method of adsorbing harmful gases and the like to a material having adsorption properties such as activated carbon. In this case, as the activated carbon becomes saturated after a certain period of time, there may be a problem in that the adsorption property is no longer exhibited. At this time, if the filter for an air purifier or air conditioner has deodorizing performance, this problem can be easily solved by replacing the filter. Considering this, it is somewhat difficult to replace the finishing material itself. Accordingly, there is a need for a deodorizing board capable of being reproduced.

An object to be solved by the present invention is to provide an interior sheet having excellent deodorization performance and antibacterial performance while implementing flame retardancy and semi-incombustible performance, and having excellent adhesion to an adherend, an interior board including the same, or a manufacturing method thereof . The technical problems of the present invention are not limited to the technical problems mentioned above, and other technical problems not mentioned will be clearly understood by those skilled in the art from the following description.

Since the present invention can make various changes and have various embodiments, specific embodiments are illustrated in the drawings and described in detail. However, this is not intended to limit the present invention to specific embodiments, and should be understood to include all modifications, equivalents, and substitutes included in the spirit and scope of the present invention.

It will be appreciated that when an element such as a layer, region or substrate is referred to as being “on” another element, it may be directly on the other element or intervening elements may exist. .

In the present application, the term "nano" may refer to a size in a nanometer (nm) unit, for example, from 1 to 1,000 nm, but is not limited thereto. In addition, the term "nanoparticle" in this specification may mean a particle having an average particle diameter in nanometer (nm) units, for example, may mean a particle having an average particle diameter of 1 to 1,000 nm, but It is not limited.

Unless defined otherwise, all terms used herein, including technical or scientific terms, have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention belongs. Terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with the meaning in the context of the related art, and unless explicitly defined in this application, they should not be interpreted in an ideal or excessively formal meaning. don't

<Functional sheet>

In order to achieve the above technical problem, one embodiment of the present invention provides a functional sheet.

In one embodiment, the functional sheet according to the present invention may sequentially include a photocatalyst layer and an upper nonwoven fabric on one side of a lower nonwoven fabric, and the photocatalyst layer may include activated carbon and a visible light activated photocatalyst.

As will be described later, the functional sheet of the present invention can be manufactured by a thermal fusion method. In the thermal fusion method, after dispersing yarn for thermal fusion on the lower nonwoven fabric, sequentially disposing the coated activated carbon and the upper nonwoven fabric, And / or it may be manufactured by laminating them using pressure, and in this process, the heat-sealing yarn penetrates the photocatalyst layer, and the yarn and the active carbon coated with the visible light active photocatalyst may be mixed and present.

In one example, the functional sheet according to the present invention may have a thickness of 0.1 to 2 mm, 0.2 to 1.5 mm, 0.3 to 1 mm, or 0.4 to 0.8 mm.

Bottom non-woven fabric and top non-woven fabric

In the present invention, the nonwoven fabric may refer to a fabric shape in which fibers or yarns are bonded to each other by chemical action, mechanical action, or appropriate moisture and heat treatment without a woven fabric process such as spinning, weaving, or knitting.

In one example, the nonwoven fabric of the present invention is not limited thereto, but may be formed of fibers or yarns of a thermoplastic resin material, and the thermoplastic resin is, for example, polyester (PET), polypropylene (PP), polyethylene (PE) ), polyvinyl alcohol (PVA), polyamide (Polyamide), polyurethane (PU), and polyvinylidene chloride (PVDC).

In one example, the nonwoven fabric according to the present invention may be a blend of two or more types of fibers having different fineness (denier), for example, 60 to 95% by weight of yarn of 1 to 4 denier and 5 to 8 denier It may include 5 to 40% by weight of phosphorus yarn.

In one example, the lower nonwoven fabric may satisfy a basis weight of 45 g/m ² to 75 g/m ² , that is, a weight per unit area, and the basis weight of the lower nonwoven fabric is 47 g/m ² or more, 49 g/m ² or more, 50 g/m ² or more, 52 g/m ² or more, 54 g/m ² or more, 56 g/m ² or more, 58 g/m ² or more, or 60 g/m ² or more, and 73 g/m ² or less , 70 g/m ² or less, 68 g/m ² or less, 66 g/m ² or less, 64 g/m ² or less, or g/m ² or less. As will be described later, the functional sheet according to the present invention is formed by the thermal fusion method, and since the lower nonwoven fabric is formed by scattering the yarn for thermal fusion on the nonwoven fabric, the basis weight of the lower nonwoven fabric is the sum of the basis weight of the yarn for thermal fusion. it could be At this time, the yarn for heat welding is not limited thereto, but as an example, a yarn having 1 to 4 denier may be used.

In the past, a method using a separate adhesive was used to combine the upper and lower nonwoven fabrics and activated carbon in the functional sheet using the hot melt method, but in the case of the hot melt method, the adhesive applied on the activated carbon blocks the pores of the activated carbon, thereby preventing the pores of the activated carbon itself. Not only does the air permeability of the functional sheet itself decrease, but it is difficult to fully demonstrate the function of the material interposed between the nonwoven fabrics, and aesthetics deteriorate, such as poor appearance due to yellowing caused by the adhesive. can happen Accordingly, the present invention has solved the above problem by using a heat-sealing method by further including a yarn for heat-sealing separately.

On the other hand, as will be described later, an adhesive layer for bonding with the porous board can be formed on the lower surface of the lower nonwoven fabric, and since the lower nonwoven fabric satisfies the basis weight, excellent adhesion to the inorganic board can be obtained. In addition, since the adhesive forming the adhesive layer does not penetrate into the lower nonwoven fabric and does not cause a problem of blocking the pores of the coated activated carbon located between the nonwoven fabrics, the problem of deteriorating the deodorizing performance of the coated activated carbon itself may not be caused, It is possible to suppress a phenomenon in which the adhesive layer penetrates into the upper nonwoven fabric and the aesthetics of the functional board is deteriorated. Furthermore,

In addition, in one example, the basis weight of the lower nonwoven fabric may satisfy a range exceeding 1 times the basis weight of the upper nonwoven fabric, and more specifically, 1.1 times or more, 1.2 times or more, 1.3 times or more, 1.4 times or more, or 1.5 times or more. A range of twice or more and a range of less than two times may be satisfied. That is, the lower nonwoven fabric has a larger basis weight than the upper nonwoven fabric and is composed of a denser nonwoven fabric than the upper nonwoven fabric, so that excellent durability can be achieved by maintaining the sheet shape as well as securing excellent adhesiveness.

In one example, the top nonwoven fabric may have a basis weight of 10 g/m ² to 60 g/m ² , and as an example, the basis weight of the top nonwoven fabric is 13 g/m ² or more, 15 g/m ² or more, 17 g/m ² or more, 20 g/m ² or more, 23 g/m ² or more, 25 g/m ² or more, 27 g/m ² or more, 30 g/m ² or more, 32 g/m ² or more, 34 g /m ² or more, 36 g/m ² or more, 38 g/m ² or more, 60 g/m ² or less, 50 g/m ² or less, 45 g/m ² or less, or 43 g/m ² or less there is. By satisfying the basis weight of the upper nonwoven fabric, it is possible to suppress a problem in which the coated activated carbon included in the photocatalyst layer positioned between the upper nonwoven fabric and the lower nonwoven fabric is separated.

Furthermore, the functional sheet according to the present invention exhibits antibacterial properties by causing a photoactive reaction in the photocatalyst layer by a light source from the outside, and the light source must be able to reach the photocatalyst layer through the upper nonwoven fabric. Therefore, as mentioned above, by using a nonwoven fabric having a lower basis weight than the lower nonwoven fabric, it is possible to exhibit better antibacterial performance by securing light transmittance and air permeability.

In addition, the upper nonwoven fabric is a layer located on the outermost side of the functional sheet and functional board and is configured to be visually recognized by the user, and when using the upper nonwoven fabric satisfying the basis weight, a visible light active catalyst is coated between the nonwoven fabrics. Activated carbon can also be recognized by a user, and aesthetics such as a granite pattern can be exhibited by the color contrast between the nonwoven fabric layer and the activated carbon coated with the visible light active catalyst.

In addition, in one embodiment, the functional sheet may be antibacterially treated with an upper nonwoven fabric and a lower nonwoven fabric in order to secure antibacterial properties. The antibacterial treatment may use a conventionally known method, and the antibacterial treatment may be coated using an antibacterial agent.

The antimicrobial agent is not particularly limited as long as it can impart antimicrobial properties such as antiviral, antibacterial, and antifungal properties. Antimicrobial agents include, for example, antimicrobial metals, antimicrobial metal compounds or quaternary ammonium compounds, alkylpyrimidium, quaternary phosphonium, imidazole and derivatives thereof, acrylic compounds or methacrylic compounds and cationic organic antibacterial compounds without limitation. can be used As an example, the antimicrobial metal compound may include metal oxides, metal-containing ion exchange compounds, metal-containing zeolites, and the like. Although not limited thereto, as an example, the antibacterial agent is zinc oxide (ZnO), silver (Ag), silver (II) oxide (AgO), gold (Au), platinum (Pt), palladium (Pd), iridium (Ir) ), tin (Sn), antimony (Sb), bismuth (Bi), zinc (Zn), copper (Cu), copper oxide (II) (Cu ₂ O), cuprous oxide (Ⅰ) (Cu ₂ O), Titanium oxide (TiO ₂ ), aluminum oxide (Al ₂ O ₃ ), or magnesium oxide (MgO) may be included.

In one example, the antimicrobial agent may be coated at 0.1 to 1.5 wt%, 0.2 to 1.3 wt%, 0.3 to 1 wt%, or 0.4 to 0.7 wt%, respectively, based on the basis weight of the upper nonwoven fabric and/or the lower nonwoven fabric, and 80 to 300 nm , 100 to 280 nm, 120 to 260 nm, 140 to 240 nm, 160 to 220 nm or 180 to 210 nm may have a particle size range.

In the present specification, the particle size is measured using a laser diffraction particle size analyzer and may mean an average particle size (D ₅₀ ).

photocatalyst layer

The photocatalyst layer includes activated carbon and a visible light-activated photocatalyst, and may serve to remove harmful substances from indoor air. Specifically, the photocatalyst layer according to the present invention includes activated carbon coated with a visible light active catalyst on the surface, and can remove harmful substances by adsorbing harmful substances and fundamentally decomposing harmful substances through the photocatalytic composition. By using an indoor fluorescent light as a light source, the application range of the photocatalyst composition can be expanded. In addition, while conventional deodorizing filters require replacement of harmful substance trapping materials (eg, activated carbon) after use for a certain period of time, the functional sheet of the present invention can be used semi-permanently by regenerating deodorizing ability using visible light without such replacement.

In one example, the photocatalyst layer is 40 g/m ² to 120 g/m ² , 43 g/m ² to 115 g/m ² , 45 g/m ² to 110 g/m 2 of activated carbon coated with a visible light active catalyst. m ² , 47 g/m ² to 105 g/m ² , 50 g/m ² to 100 g/m ² , 53 g/m ² to 97 g/m ² , 55 g/m ² to 95 g/m ² , or 57 g/m ² to 93 g/m ² . The photocatalyst layer according to the present invention includes activated carbon coated with a visible light active catalyst in the basis weight, thereby exhibiting almost the same level of performance as coated activated carbon that is not attached to a sheet, but due to the volume occupied by the coated activated carbon, the upper nonwoven fabric and the lower nonwoven fabric By exhibiting excellent adhesion to the liver, it is possible to suppress the problem of detachment of the coated activated carbon.

Activated carbon is a porous carbon material containing fine pores having a nano or micro size, and has very high adsorbability by containing an adsorbent (multiple functional groups on the surface). The activated carbon is a very effective deodorizing material in terms of price and performance. The activated carbon is an adsorbent and can remove harmful gases through adsorbable sites (pores). In particular, it is possible to improve the removal performance for formaldehyde, toluene, and ammonia.

In one example, the functional activated carbon according to the present invention may be used in a powder state after being pulverized as the activated carbon and then passed through a sieve to be classified into a desired size. As an example, activated carbon may be selected to have a specific particle size as activated carbon or coated activated carbon using a sieving step, and only a combination of particles having a particle size within a specific range may be used. At this time, a sieve of a certain standard may be used for sieving, and the present invention may perform the sieving process more than once or twice. As an example, a process of excluding particles that do not pass through a mesh with large pores may be performed using a mesh of 10 mesh or more, 20 mesh or more, or 30 mesh or more and 40 mesh or less, and additionally, 90 mesh or less, 80 mesh Hereinafter, a process of excluding particles passing through the mesh with small pores may be performed using a mesh of 70 mesh or less or 60 mesh or less and 50 mesh or more. Here, mesh means a unit indicating the particle size of solids, and 30 mesh means the amount of powder passing through a sieve with 30 holes in a standard sieve of 1 inch in length and width, respectively. means size.

Specifically, activated carbon may be used in combination such that the particle size is distributed within a range of 150 μm to 700 μm. As an example, the lower limit of the particle size of the activated carbon is 160 μm or more, 170 μm or more, 180 μm or more, 190 μm or more, 200 μm or more, 210 μm or more, 220 μm or more, 230 μm or more, 240 μm or more, or 245 μm or more. 690 μm or less, 680 μm or less, 670 μm or less, 660 μm or less, 650 μm or less, 640 μm or less, 630 μm or less, 620 μm or less, 610 μm or less, or 605 μm or less. In addition, activated carbon that does not satisfy the above range, such as having a particle size smaller than the lower limit or exceeding the upper limit, may not be included.

More specifically, activated carbon having a particle size of 150 μm to 500 μm is 90% by number or more, 91% by number or more, 92% by number or more, 93% by number or more, 94% by number or more, 95% by number or more, compared to the total activated carbon 96 number% or more, and the upper limit of the activated carbon content having a particle size of 150 μm to 500 μm is not particularly limited, but may be 100 number% or less or 98 number% or less.

In addition, as an example, activated carbon having a particle size of 270 μm to 500 μm, 75% by number or more, 76% by number or more, 77% by number or more, 78% by number or more, 79% by number or more, 80% by number, compared to the total activated carbon It may contain more than 81% by number, more than 82% by number, or more than 83% by number, and may include less than 90% by number, less than 87% by number, or less than 85% by number. Here, the number % is the content rate of activated carbon having a specific size in the total activated carbon, expressed as a ratio by counting the number of particles of a specific size for a sample in a certain space using a particle size analyzer, for example. it could be

On the other hand, since activated carbon itself is an adsorbent, adsorption performance may decrease when adsorbable sites are saturated. Therefore, the present invention can provide activated carbon to which visible light active catalyst particles are attached so that the activated carbon is not saturated, and the activated carbon can be regenerated by decomposing the harmful gas adsorbed by the visible light active catalyst, and the gas adsorption performance of the activated carbon itself can be improved. can make it

The visible light active catalyst may be active with respect to visible light in a wavelength range of 380 nm to 780 nm, for example, may exhibit absorbance of about 20% with respect to visible light with a wavelength of approximately 400 nm and visible light with a wavelength of approximately 500 nm. It can exhibit about 10% absorbance for light rays. That is, in the visible light active catalyst, electrons and holes generated from energy obtained by absorbing visible light generate peroxide anions or hydroxyl radicals to decompose volatile organic compounds (VOCs) to clean and deodorize air. can be material.

Conventionally, UV-active photocatalysts such as titanium oxide have been mainly used as photocatalysts, and in the case of such UV-active photocatalysts, the efficiency of the photocatalyst is very low by indoor light sources, requiring a separate light source supply device for irradiating ultraviolet rays. However, the photocatalyst layer according to the present invention includes a visible light active catalyst, so that the photocatalyst can be activated not only by ultraviolet light but also by visible light, so that it can realize visible light activity performance. Therefore, the visible light active catalyst according to the present invention can exhibit a high level of photocatalytic efficiency indoors without a separate light source supply device.

The visible light active catalyst may be composite particles including platinum particles and tungsten oxide particles, and the composite particles may be formed in a form in which nano-sized platinum particles are supported on surfaces of the tungsten oxide particles.

In the present application, it is preferable to use particulate WO ₃ as the carrier, and the caustic tungsten oxide particles may be formed into spherical, plate-shaped or needle-shaped particles by, for example, a sol-gel method or a hydrothermal method. However, the shape is not limited. The tungsten oxide particles may have excellent visible light activating performance.

In one example, the average diameter of the tungsten oxide particles can be calculated by electron microscopic measurement such as SEM image analysis, and for example, the average diameter is about 30 nm to 1,500 nm, 70 nm to 1,400 nm, 100 nm to 1,300 nm. nm, 150 nm to 1,200 nm, 200 nm to 1,000 nm, 300 nm to 900 nm, 400 nm to 800 nm, or 500 nm to 700 nm may be used. If the average diameter of the tungsten oxide particles is too large beyond the range, it is impossible to form a stable coating solution when the photocatalyst powder is dispersed in a solvent. It may not be suitable for your process. If the diameter of the tungsten oxide particle is too small within the above range, it may be difficult to stably support the platinum particle.

The platinum particles may be supported on a carrier by photodeposition, but are not limited thereto, and may facilitate separation of electrons and holes from energy obtained by absorbing light.

In one example, the average diameter of the platinum particles may be 1 nm to 10 nm. In addition to platinum particles, noble metals that are not easily oxidized, such as ruthenium, rhodium, palladium, osmium, iridium, and gold, may be used as a material supported on the carrier.

As an example, platinum is 0.01 part by weight to 5 parts by weight, 0.03 parts by weight to 4.5 parts by weight, 0.05 parts by weight or 4 parts by weight, 0.07 parts by weight to 3.5 parts by weight, 0.1 parts by weight, relative to 100 parts by weight of tungsten oxide. to 3 parts by weight, 0.13 parts by weight to 2.5 parts by weight, or 0.15 parts by weight to 1.5 parts by weight. By controlling the content of these materials at a weight ratio within the above range, the tungsten oxide particles sufficiently generate electrons and holes by visible light while sufficiently preventing recombination of electrons and holes generated by the platinum particles, thereby effectively improving photocatalytic activation efficiency. there is.

When the content of the tungsten oxide particles exceeds the above content range, electrons and holes generated by visible light can easily recombine, and it is difficult to separate them, resulting in insufficient photocatalytic activity. When the content is less than the above range, the tungsten oxide particles The photocatalytic activity may be deteriorated because the number of electrons transferred from the particle is not sufficiently secured, and the photocatalytic performance may be deteriorated because the area exposed to light of the tungsten oxide particle is reduced.

In addition, the specific surface area of the tungsten oxide particles may be about 50 m 2 /g to about 500 m 2 /g. By having a high specific surface area within the above range, it can be effectively exposed to a light source such as visible light, and the porosity can be formed at an appropriate level to sufficiently support the platinum particles.

The visible light active catalyst may have a particle size of about 1 μm or less, specifically, about 0.2 μm to about 1 μm, for example, about 0.4 μm to about 0.5 μm. The particle size of the composite particles can be obtained by measuring an aqueous dispersion of about 4 wt% of the photocatalyst using a particle size analyzer (Beckman, LS 13 320). In addition, the maximum particle diameter of the photocatalyst particles is about 10 μm or less.

The visible light active catalyst may be included in an amount of 1 to 7 parts by weight, 1 to 6 parts by weight, 1 to 5 parts by weight, or 2 to 4 parts by weight based on 100 parts by weight of the activated carbon. The functional activated carbon according to the present invention may impart sufficient regeneration and durability to the activated carbon by including the visible light active catalyst in the above range.

Specifically, the visible light active catalyst includes porous metal oxide particles carrying a visible light activating metal, has absorption of visible light, and can exhibit excellent efficiency even in an indoor light source.

On the other hand, it is common to use a binder material to coat the visible light active catalyst on activated carbon, but the binder material may block pores in the substrate or be attached to the surface of the catalyst to cause a problem of lowering the surface activity for light. . Therefore, in the present invention, the visible light active catalyst is coated on the surface of the activated carbon without a separate binder in the photocatalyst layer, and thus, the surface area of the catalyst to light is not reduced, so the life of the product can be extended.

At the same time, since the visible light active catalyst is formed from a composition using an aqueous solvent, it is possible to effectively prevent the degradation of the surface activity of the catalyst, thereby extending the life of the product, and to prevent the reaction between the catalyst and the solvent, thereby providing uniform long-term stability. It has the advantage of realizing performance and excellent storage stability.

In one example, the functional sheet according to the present invention has an adhesive force of the lower nonwoven fabric to the inorganic board and an adhesive force of the lower nonwoven fabric to the calcium silicate board of 770 g/in or more, 800 g/in or more, or 830 g/in or more. , 850 g / in or more, 870 g / in or more, 900 g / in or more, 930 g / in or more, 950 g / in or more, 970 g / in or more, or 1,000 g / in or more, the upper limit is large It may be, but is not limited to, 2,000 g/in or less, 1500 g/in or less, or 1,200 g/in or less. The inorganic board is as described in the functional board below, where the adhesive strength is 180 ° peel test at a speed of 5 mm / s using a tensioner in a method according to KS T 1028: 2009 for the functional sheet is evaluated according to Although the inorganic board described later has a slightly weak adhesive strength due to the nature of the material, the functional sheet according to the present invention can exhibit excellent adhesive strength to the inorganic board by controlling the basis weight of the lower nonwoven fabric to the above specific range.

<Functional board>

In order to achieve the above technical problem, one embodiment of the present invention may provide a functional board, and the functional board according to the present invention is a porous inorganic board in which the aforementioned functional sheet is laminated, and can be used as an indoor or outdoor finishing material. . In this case, the porous inorganic board may have a structure in which the lower nonwoven fabric of the functional sheet is bonded, and the inorganic board, the lower nonwoven fabric, the photocatalyst layer, and the upper nonwoven fabric may be sequentially stacked.

In general, sheets or films can be directly attached to walls, etc. as a finishing material. However, since these sheets or films are very thin, there are construction problems such as problems with smoothness or problems with foreign substances being attached together when using adhesives in the field. can happen Therefore, when using the functional board according to the present invention, it can be easily applied for interior wall finishing by using a board to which the sheet or film is already attached to the porous inorganic board without directly attaching the sheet or film to the wall during construction. It can have advantages of easy construction and easy cutting in the field.

In one embodiment, the porous inorganic board includes pores as a porous material, and the porosity of the porous inorganic board may be 30 to 90%, 40 to 80%, 50 to 70%, or 60 to 65%. By having fine pores on the surface of the porous inorganic board, not only deodorizing performance, but also an excellent moisture absorption and desorption amount can exhibit excellent humidity control performance. In particular, unlike the existing ones, the functional board according to the present invention attaches a functional sheet having excellent air permeability as described above, rather than a conventional interior sheet or film such as a PVC film, on a porous inorganic board, so that gas and moisture particles can easily pass through the functional sheet, so that the moisture control performance of the porous inorganic board can be sufficiently exhibited.

In one example, the porous inorganic board may be, but is not limited to, a CRC board, gypsum board, calcium silicate board, magnesium board or vermiculite board. Preferably, the porous inorganic board may be a calcium silicate board that has been polished or not. In one example, the thickness of the porous inorganic board may be 1 mm to 10 mm, but it is not particularly limited and porous inorganic boards having various thicknesses may be used as needed.

Also, in one embodiment, the functional board may further include an adhesive layer, and the functional sheet may be laminated on the porous inorganic board via the adhesive layer.

In one example, the adhesive layer may be a non-solvent curable resin adhesive including one selected from the group consisting of urethane-based adhesives, epoxy-based adhesives, and combinations thereof, but is not limited thereto. For example, polyurethane reactive adhesives that cure by a urethane reaction may be used as the adhesive. For example, both moisture-curable adhesives and heat-curable adhesives may be used as the adhesive.

In addition, the adhesive may be a moisture curing type hot melt adhesive. The moisture-curable hot-melt adhesive includes a moisture-curable polyurethane-based hot-melt adhesive, a moisture-curable epoxy-based hot-melt adhesive, and the like, and may preferably be a moisture-curable hot-melt polyurethane adhesive. Moisture-curing hot-melt polyurethane adhesive has excellent processability because it can exhibit adhesiveness through heating and cooling, and contains -NCO groups at the ends, so after cooling and curing physically, -NCO groups in the adhesive layer meet and react with moisture in the air. By reacting with the active hydrogen compound on the bonding surface and chemically cross-linking, it is possible to impart improved adhesive strength, water resistance and solvent resistance to the adhesive layer. In one example, the adhesive may include a urethane-based resin or an epoxy-based resin having a weight average molecular weight of about 1,000 g/mol to about 1,000,000 g/mol or about 1,000 g/mol to about 50,000 g/mol.

In addition, the adhesive may be used by mixing a low molecular weight adhesive and a high molecular weight adhesive. As the low molecular weight adhesive, a urethane-based resin or an epoxy-based resin having a weight average molecular weight of about 1,000 g/mol to about 50,000 g/mol of the resin before curing may be used, and the high molecular weight adhesive may have a weight average molecular weight of the resin before curing of about Urethane-based resins or epoxy-based resins from 500,000 g/mol to about 1,000,000 g/mol may be used. By mixing a small amount of the high molecular weight adhesive with a large amount of the low molecular weight adhesive, the viscosity of the adhesive can be adjusted and durability can be improved.

In one example, the adhesive forming the adhesive layer may penetrate into the pores of the inorganic board to include an impregnation area. Since the inorganic board is a porous material, when an adhesive layer is formed by applying an adhesive to one surface of the inorganic board, the adhesive may penetrate part of the voids of the inorganic board. Specifically, an adhesive component of the adhesive layer may permeate from one surface of the inorganic board in a thickness direction to form an adhesive-impregnated region having a predetermined thickness. That is, the adhesive-impregnated region may be formed from one surface of the inorganic board to a penetration depth of the adhesive. Therefore, the thickness of the adhesive impregnated region is equal to the penetration depth of the adhesive starting from one side of the inorganic board. The thickness of the adhesive-impregnated region may be equal to or smaller than the thickness of the inorganic board, preferably less than the thickness of the inorganic board, and for example, the thickness of the adhesive-impregnated region is about 0.08% of the thickness of the inorganic board. to about 20% or 0.1 to 10%.

When the adhesive is applied on an inorganic board, it is necessary to adjust the viscosity so that an adhesive layer can be sufficiently formed. As an example, the adhesive may have a viscosity of 1,200 to 2,000 cps, 1,300 to 1,900 cps, or 1,400 to 1,800 cps at 130 °C, and the amount of the adhesive may be 75 to 90 g/m ² . That is, by using the adhesive having the above viscosity, it is possible to form an impregnated region into the inorganic board to ensure durability and to form an adhesive layer on the inorganic board to improve adhesion.

The adhesive layer has a thickness of about 5 μm to about 500 μm, specifically, about 5 μm to about 200 μm, by applying an adhesive that satisfies the viscosity at 50 to 200 g/m ² or 70 to 130 g/m ² . can have thickness. The adhesive layer having the above thickness range may realize adhesive strength with the inorganic board at or above a predetermined level.

As described above, the surface of the inorganic board may not be smooth because it has porosity. Therefore, the present invention suppresses the adhesive from permeating beyond the lower nonwoven fabric layer into the upper nonwoven fabric layer by using an adhesive having a specific viscosity as described above, and at the same time exhibits excellent adhesion between the porous inorganic board and the functional sheet, thereby improving aesthetics. It is possible to provide a functional board with durability and durability.

In one example, the functional board according to the present application may have a primary removal rate for formaldehyde of 85% or more, 88% or more, 89% or more, 90% or more, or 91% or more, and the upper limit is not particularly limited, but is 99% may be below. In addition, the functional board according to the present application may have a cumulative purification amount for formaldehyde of 120 ppm or more, 123 ppm or more, 125 ppm or more, 127 ppm or more, 130 ppm or more, 133 ppm or more, 135 ppm or more, or 137 ppm or more, , The upper limit is not particularly limited, but may be 200 ppm or less.

In addition, the functional board according to the present application may have a primary removal rate of toluene of 81% or more, 82% or more, 83% or more, 84% or more, or 85% or more, and the upper limit is not particularly limited, but may be 99% or less. In addition, the functional board according to the present application may have a cumulative purification amount for toluene of 106 ppm or more, 108 ppm or more, 110 ppm or more, 112 ppm or more, 114 ppm or more, 116 ppm or more, 118 ppm or more, or 120 ppm or more And, the upper limit is not particularly limited, but may be 200 ppm or less. In the measurement method, a functional board measuring 30 cm x 30 cm is placed in a chamber having a size of 1 m ³ , then a target gas having a concentration of 10 ppm is injected, and the functional board adsorbs and removes the gas for 2 hours in a closed environment. The first removal rate is evaluated by measuring the amount of FT-IR, and the measurement is repeated until the removal rate is 80% compared to the first removal rate using FT-IR. is indicated by

In one example, the antibacterial property based on the JIS Z 2801 antibacterial evaluation method for Escherichia coli may be 99% or more.

In one example, the functional board of the present invention may exhibit flame retardancy or quasi-incombustibility. In detail, the functional board according to the present invention may have a smoke density of 70 or less, 65 or less, 60 or less, 55 or less, or 52 or less according to ASTM E 662 (Heat Flux: 25 kW/m ² , Flaming mode), 45 degree burning test (according to Fire Agency Notification No. 2021-7, Article 7), after-flame time and remaining time of 0 seconds or less, carbonized area of 40 cm ² or less, 35 cm ² or less, 30 cm ² or less, or 28 cm ² or less and the carbonization length may be 10 cm or less, 8 cm or less, or 7 cm or less.

<Method of manufacturing functional sheet>

In order to achieve the above technical problem, one embodiment of the present invention provides a method for manufacturing a functional sheet.

The method for manufacturing a functional sheet according to the present invention includes preparing a lower nonwoven fabric, scattering activated carbon particles coated with visible light active catalyst particles on one side of the lower nonwoven fabric, and coating the surface of the lower nonwoven fabric with visible light active catalyst particles. It may include disposing an upper nonwoven fabric on the activated carbon particles, and laminating by a thermal fusion method.

Conventionally, a method using a separate adhesive was used to laminate the upper and lower nonwoven fabrics and activated carbon in a functional sheet using a hot melt method. However, in the case of the hot melt method, problems such as the adhesive applied on the activated carbon blocking the pores of the activated carbon itself may cause problems in that it is difficult to fully demonstrate the function of the material between the nonwoven fabrics, and the breathability of the functional sheet itself There is a risk of deterioration, and as well as a yellowing phenomenon caused by the adhesive, a problem of deterioration in aesthetics may occur.

Accordingly, the functional sheet according to the present invention has excellent air permeability and does not cause yellowing without causing a performance degradation problem of the functional material applied between nonwoven fabrics by laminating by thermal fusion method without using a separate adhesive. can

Here, the upper nonwoven fabric, the lower nonwoven fabric, and the activated carbon coated with the visible light active catalyst are the same as described above.

In this way, the heat-sealing method may include dispersing yarn for heat-sealing on the lower nonwoven fabric, sequentially disposing the coated activated carbon and the upper nonwoven fabric, and then laminating them using heat and pressure. In this process, the heat-sealing yarn penetrates the photocatalyst layer, and the yarn and the active carbon coated with the visible light active catalyst can exhibit a structure in which the yarn is mixed and mixed, and the coated activated carbon is stably attached between the upper and lower nonwoven fabrics by the structure to prevent separation. can do.

<Method of manufacturing functional board>

In order to achieve the above technical problem, one embodiment of the present invention provides a method for manufacturing a functional board.

The method of manufacturing a functional board according to the present invention may include preparing a porous inorganic board and attaching the aforementioned functional sheet to the porous inorganic board. At this time, the surface contacting the porous inorganic board is the lower surface of the lower nonwoven fabric of the functional sheet, and may be disposed in the order of porous inorganic board/lower nonwoven fabric/photocatalyst layer/upper nonwoven fabric.

As described above, the interior sheet according to the embodiments of the present invention can realize flame retardancy and semi-incombustible performance as it is used as an interior and exterior material, implement excellent deodorization performance and antibacterial performance, and have excellent adhesion to an adherend. The included interior board may also exhibit excellent aesthetics.

However, the effects of the present invention are not limited to the effects mentioned above, and other effects not mentioned will be clearly understood by those skilled in the art from the description below.

1 is a diagram illustrating a functional board according to an exemplary embodiment.

Hereinafter, preferred experimental examples are presented to aid understanding of the present invention. However, the following experimental examples are only for helping understanding of the present invention, and the present invention is not limited by the following experimental examples.

manufacturing example

A visible light active photocatalyst composition in which 2.5 wt% of tungsten oxide (WO ₃ ) particles were dispersed in 97.5 wt% of water was prepared. At this time, the tungsten oxide (WO ₃ ) particles had a particle diameter of about 600 nm. A support material, which is an aqueous solution of chloroplatinic acid (H ₂ PtCl ₆ ), was mixed with the tungsten oxide particle dispersion solution. Subsequently, visible light energy was irradiated for a certain period of time using a visible light irradiation device to perform a primary photoreaction, and then, visible light irradiation was blocked for about 2 minutes, methanol was added, and the same irradiation device as the primary photoreaction was used. Visible light activity of Pt-WO ₃ containing approximately 0.2 parts by weight of platinum based on 100 parts by weight of tungsten oxide Catalyst particles were prepared.

A coating solution was prepared by adding the visible light active catalyst according to the preparation example at a concentration of 20% to water and stirring for 30 minutes.

After putting 10kg of activated carbon sieved through a 30/60 mesh net into the coater, fix the jacket temperature of the coater to 100 degrees, and when the temperature of the activated carbon is stabilized, spray the coating liquid on the stirred activated carbon through the spray nozzle did After spraying the entire amount of the coating solution, samples of activated carbon are taken every 10 minutes to measure the moisture content, and when the moisture content of the activated carbon becomes the same as before coating, drying is terminated and sieved using a 30/60 mesh screen. Activated carbon 100 Compared to parts by weight, activated carbon coated with 3 parts by weight of the visible light catalyst was obtained. Here, the sieving process using the 30/60 mesh mesh means excluding particles that pass through the 60 mesh mesh while excluding particles that do not pass through the 30 mesh mesh.

Example 1

Two sheets of nonwoven fabric having a basis weight of 40 g/m ² treated with flame retardation were prepared by mixing a 2D-thick flame-retardant yarn and a 6D-thick flame-retardant yarn at a weight ratio of 80:20. One of the prepared nonwoven fabrics was used as a lower nonwoven fabric having a total basis weight of 60 g/m ² by dispersing a heat-sealing yarn having a basis weight of 20 g/m ² composed of yarns having a 2D thickness on the nonwoven fabric. The other one was used as an upper nonwoven fabric. The upper and lower nonwoven fabrics are coated by spray spraying using a 20 wt% ZnO slurry containing 20 g of zinc oxide (ZnO) having a particle size of about 200 nm in 80 g of water, respectively. 0.5 wt% coating of ZnO relative to the basis weight of the nonwoven fabric It was treated antibacterially.

Activated carbon particles coated with the visible light active catalyst according to Preparation Example were dispersed on the antibacterial lower nonwoven fabric to have a basis weight of 60 g/m ² . After disposing an antibacterial upper nonwoven fabric on activated carbon particles coated with a visible light active catalyst, heat was applied, and lamination was performed under pressure to obtain a functional sheet having a thickness of approximately 0.6 to 0.7 mm.

Next, a moisture-curable polyurethane adhesive of 1,500 cps was applied at about 100 g/m ² on a calcium silicate board having a thickness of 6 mm to form an adhesive layer having a thickness of about 50 μm, and the adhesive layer and the lower surface of the lower nonwoven fabric were bonded, , Cured at room temperature for 3 days to obtain a functional board according to Example 1. The viscosity of the adhesive was measured through Dynamic Shear using a Rheometer (TA, ARES G2).

Example 2

A functional board according to Example 2 was obtained in the same manner as in Example 1, except that the activated carbon particles coated with the visible light active catalyst had a basis weight of 90 g/m ² on the antibacterial lower nonwoven fabric.

Comparative Example 1

2D thick plain yarn and 6D thick flame retardant yarn are mixed at a weight ratio of 80:20 to prepare a flame retardant treated 60 g/m ² basis weight lower nonwoven fabric, and 2D thick plain yarn and 6D thick flame retardant yarn are 80:20 It was mixed at a weight ratio of 20 to prepare a flame retardant upper nonwoven fabric having a basis weight of 40 g/m ² . The upper and lower nonwoven fabrics were coated by spraying using a 20 wt% ZnO slurry containing 20 g of zinc oxide (ZnO) in 80 g of water, and antibacterially treated to coat 0.5 wt% of ZnO based on the basis weight of each nonwoven fabric.

Activated carbon particles coated with the visible light active catalyst according to Preparation Example were dispersed on the antibacterial lower nonwoven fabric to have a basis weight of 60 g/m ² . Next, hot melt was applied on top of the activated carbon particles coated with the visible light active catalyst, and then an antibacterial nonwoven fabric was attached to the top to obtain a functional sheet having a thickness of 0.6 to 0.7 mm.

Next, a moisture-curable polyurethane adhesive of 1,500 cps was applied on a 6 mm thick calcium silicate board at 130 ° C to form an adhesive layer, the adhesive layer and the lower surface of the lower nonwoven fabric were adhered, and cured at room temperature for 3 days to compare. A functional board according to Example 1 was obtained.

Comparative Example 2

Using the same method as Example 1, except that two sheets of 40 g / m ² basis weight nonwoven fabric made of only 2D thick plain yarn and not flame retardant were prepared, and antibacterial treatment was not performed using ZnO slurry. , to obtain a functional board according to Comparative Example 2.

Comparative Example 3

A heat-sealing yarn having a basis weight of 20 g/m ² consisting of a 2D thick yarn on a nonwoven fabric having a basis weight of 20 g/m ² which is flame retardant by mixing a 2D thick flame retardant yarn and a 6D thick flame retardant yarn at a weight ratio of 80:20 A functional board according to Comparative Example 3 was obtained in the same manner as in Example 1, except that was dispersed and used as a lower nonwoven fabric having a total basis weight of 40 g/m ² .

Comparative Example 4

A heat-sealing yarn having a basis weight of 20 g/m ² consisting of a 2D thick yarn on a nonwoven fabric having a basis weight of 60 g/m ² that is flame-retardant by mixing a 2D-thick flame-retardant yarn and a 6D-thick flame-retardant yarn at a weight ratio of 80:20 A functional board according to Comparative Example 4 was obtained in the same manner as in Example 1, except that was dispersed and used as a lower nonwoven fabric having a total basis weight of 80 g/m ² .

Comparative Example 5

A functional board according to Comparative Example 5 was obtained in the same manner as in Example 1, except that the activated carbon particles coated with the visible light active catalyst were dispersed on the antibacterial lower nonwoven fabric to have a basis weight of 30 g/m ² .

<Experimental example>

Cumulative purification amount evaluation

The cumulative amount of purification was evaluated using formaldehyde and toluene as follows.

After placing the functional board according to Example or Comparative Example with a width of 30 cm x 30 cm in a chamber having a size of 1 m ³ and then injecting a target gas with a concentration of 10 ppm, the functional board is adsorbed and removed for 2 hours in a closed environment. The first removal rate was evaluated by measuring the amount of gas to be. Then, after repeated measurements using FT-IR until the 80% removal rate compared to the 1st removal rate is shown, the cumulative purification amount (ppm) at the time of 80% is shown in Table 1, and Table 2 shows the 1st The removal (%) rate was summarized.

formaldehyde toluene Example 1 137.44 120.8 Comparative Example 1 118.61 105.1

formaldehyde toluene Example 1 91.5 85.5 Example 2 93.4 87.2 Comparative Example 1 84.3 80.7 Comparative Example 5 73.3 70.8

Referring to Table 2, in the case of the primary removal rate, Example 1 using the thermal fusion method was approximately 5% higher than Comparative Example 1 using the hot melt method, but in the case of the cumulative purification amount, Example 1 compared to Comparative Example 1. It was found to be about 15% higher than 1, indicating that the gap was even larger.

In addition, it can be seen that the functional board according to Comparative Example 5 has a lower deodorization efficiency than that of Example.

Adhesion evaluation

In accordance with KS T 1028: 2009, the 180 ° peel test was evaluated at a speed of 5 mm / s using a tensile machine using a peel to board method instead of 180 ° Peel to Steel, and the lower nonwoven fabric in the functional sheet according to the above examples and comparative examples Adhesion to the calcium silicate board was evaluated. The results are summarized in Table 3 below.

Example 1 Comparative Example 3 Comparative Example 4 Adhesion (g/in) 1,037 1,213 759

Referring to Table 2, in the case of Comparative Example 3, although the adhesive strength was higher than that of the examples, the adhesive used in the adhesive layer penetrated beyond the lower nonwoven fabric to the upper nonwoven fabric, so that stains could be confirmed with the naked eye, resulting in an aesthetic problem. It can be confirmed that it is not suitable for a functional board used as an indoor and outdoor exterior material.

In addition, in the case of Comparative Example 4, it can be confirmed that the adhesive layer does not sufficiently bind the lower nonwoven fabric, so that the yarn of the lower nonwoven fabric is peeled off.

antibacterial

For the functional sheets prepared in the above Examples or Comparative Examples, an antibacterial test according to JIS Z 2801 was performed against Escherichia coli, and the results of the antimicrobial evaluation are summarized in Table 4 below.

Example 1 Comparative Example 2 Antimicrobial (%) 99.2 14

flame retardant

For the functional board specimen according to the above embodiment having a size of 75 mm x 75 mm, in accordance with ASTM E 662 at a temperature of 20 ± 15 ° C and a humidity of 50 ± 30 % RH (Heat Flux: 25jW / m ² , Flaming mode) The smoke density was measured.

In addition, for the functional board specimen according to the embodiment of 190 mm x 220 mm in size, 20 ± 15 ° C temperature and 50 ± 30% R.H. A 45 degree combustion test was conducted under humidity conditions. The 45 degree combustion test can be measured at the Korea Flame Retardant Testing Institute in accordance with Article 7 of the Fire Administration Notification No. 2021-7. Specifically, the sample was tilted so that a 4.5 cm long flame came into contact with the surface of the functional board, and the carbonized length was measured by exposing to the flame for 1 minute to obtain the carbonized area. The carbonized area was measured by measuring the longest carbonized length among the horizontal and vertical lengths of the functional board in accordance with the flame retardant performance standards of KOFEIS 1001 and obtaining the ellipse area. In addition, after conducting a flammability test for 1 minute, the after-flame time was measured by measuring the time for which after-flame remains on the specimen. In addition, after conducting a flammability test for 1 minute, the remaining time was measured by measuring the time remaining on the specimen. The results are as shown in Table 2 below.

The smoke density and 45 degree combustion test results for the functional board according to Example 1 are summarized in Table 5 below.

Example 1 Smoke density (Dm(corr)) 51.9 45 degrees
Combustion Afterburn time (seconds) 0 Remaining time (seconds) 0 Carbon area (cm ² ) 26.9 Carbonization length (cm) 6.3

As can be seen in Table 5, it can be seen that the functional board according to the present invention has excellent flame retardant performance with a smoke density (Dm (corr) of 52 or less, which is significantly lower than the standard value of 400 or less. It can be seen that the after-flame time and the remaining time are 0 seconds, the carbonization area is approximately 27 cm ² or less, and the carbonization length is within 6.5 cm, which satisfies the standard value.

Although described with reference to the above embodiments, those skilled in the art will understand that the present invention can be variously modified and changed without departing from the spirit and scope of the present invention described in the claims below. You will be able to.

10: Weapon board
11: adhesive impregnated area
20: adhesive layer
30: functional sheet
100: functional board

Claims (20)

sequentially comprising a lower non-woven fabric, a photocatalyst layer and an upper non-woven fabric;
The photocatalyst layer includes activated carbon coated with a visible light active catalyst on the surface,
A functional sheet having an adhesion of 770 g / in or more to an inorganic board having a porosity of 30 to 90% of the lower nonwoven fabric. According to claim 1,
A functional sheet having a thickness in the range of 0.1 to 2 mm. According to claim 1,
The lower nonwoven fabric is a functional sheet that satisfies a basis weight of 45 g/m ² to 75 g/m ² . According to claim 1,
A functional sheet in which the basis weight of the lower nonwoven fabric exceeds 1 times the basis weight of the upper nonwoven fabric. According to claim 1,
The upper nonwoven fabric is a functional sheet that satisfies a basis weight of 10 g/m ² to 60 g/m ² . According to claim 1,
The upper non-woven fabric or the lower non-woven fabric is a functional sheet coated with an antimicrobial agent of 1 to 1.5 wt% based on basis weight. According to claim 6,
Antimicrobial agents include zinc oxide (ZnO), silver (Ag), silver (II) oxide (AgO), gold (Au), platinum (Pt), palladium (Pd), iridium (Ir), tin (Sn), and antimony (Sb). , bismuth (Bi), zinc (Zn), copper (Cu), copper (II) oxide (CuO), cuprous oxide (Ⅰ) (Cu ₂ O), titanium oxide (TiO ₂ ), aluminum oxide (Al ₂ O ₃ ) or a functional sheet containing magnesium oxide (MgO). According to claim 1,
The photocatalyst layer is a functional sheet comprising activated carbon coated with a visible light active catalyst at 40 g/m ² to 120 g/m ² . According to claim 1,
The activated carbon is a functional sheet having a particle size in the range of 150 μm to 700 μm. According to claim 1,
The activated carbon is a functional activated carbon containing at least 90% by weight of activated carbon having a particle size of 150 μm to 500 μm, based on the total amount of activated carbon. According to claim 1,
The visible light active catalyst is a functional activated carbon containing platinum particles and tungsten oxide particles. According to claim 11,
Wherein the visible light active catalyst comprises 0.01 to 5 parts by weight of platinum based on 100 parts by weight of tungsten oxide particles. According to claim 1,
The particle size of the visible light active catalyst is 1 μm or less functional activated carbon. According to claim 1,
The visible light active catalyst is functional activated carbon included in the range of 1 to 7 parts by weight relative to 100 parts by weight of activated carbon. An inorganic board and a functional board in which the functional sheet according to claim 1 is laminated on the inorganic board. According to claim 15,
The functional sheet is a functional board laminated on an inorganic board via an adhesive layer. 17. The method of claim 16,
The adhesive forming the adhesive layer is a functional board having a viscosity of 1,200 to 2,000 cps at 130 ° C. Scattering activated carbon coated with a visible light active catalyst on one side of the lower nonwoven fabric; disposing an upper nonwoven fabric on the activated carbon coated with the visible light active catalyst; and a method of manufacturing a functional sheet according to claim 1 comprising the step of laminating by a heat-sealing method. A method of manufacturing a functional board by attaching the functional sheet according to claim 1 onto an inorganic board. According to claim 19,
An adhesive layer is formed on the upper surface of the inorganic board using an adhesive having a viscosity of 1,200 to 2,000 cps at 130 ° C,
A method of manufacturing a functional board for attaching a functional sheet via the adhesive layer.

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