KR20230010873A - A Graphene Enhanced Ultra Lightweight Polyurethane Rigid Composite Panel Manufacturing Method and A Graphene Enhanced Ultra Lightweight Polyurethane Rigid Composite Panel thereby - Google Patents

Abstract

The present invention relates to a graphene-enhanced ultralightweight rigid urethane foam composite panel for a building, which forms exterior walls, interior walls, and roofs of a building, wherein the panel is made lighter to allow construction to be performed faster than existing building construction methods, save construction costs, and shorten a construction period. In addition, the panel creates a semi-structural effect by increasing the strength of a panel installation frame and increases the effectiveness of insulation to reduce energy consumption for heating and cooling caused by seasonal temperature differences, thereby enhancing the functionality of the building. In addition, energy consumption is reduced to decrease the generation of carbon dioxide (CO_2), thereby allowing carbon emissions rights to be secured to create eco-friendly buildings. The panel is a lightweight panel that saves installation labor costs by approximately 25 to 30% in constructing a wall body, compared to the current construction costs of existing methods, and allows a dry construction method that saves construction period and labor costs by reducing 7-8 processes such as interior and exterior wall construction and roof construction to 2-3 processes, thereby eliminating restrictions of seasons or climate.

Description

A Graphene Enhanced Ultra Lightweight Polyurethane Rigid Composite Panel Manufacturing Method and A Graphene Enhanced Ultra Lightweight Polyurethane Rigid Composite Panel thereby}

The present invention relates to a method for manufacturing a graphene-reinforced ultra-lightweight polyurethane composite panel for construction and a graphene-reinforced ultra-lightweight composite panel using the same. It is faster than the existing method of construction, and reduces construction costs and shortens the construction period. In addition, by increasing the strength of the panel installation frame, it creates a semi-structural effect, and by increasing the insulation effect, it reduces energy consumption for cooling and heating due to seasonal temperature differences, thereby enhancing the functionality of the building and reducing CO2 generation by reducing energy consumption. Through this, it is possible to secure carbon credits and create eco-friendly buildings.

Therefore, the graphene-reinforced ultra-lightweight polyurethane composite panel for construction can reduce the structural cost of the existing method by increasing the strength, shorten the process, reduce the construction cost by reducing the weight of the panel, and save energy by insulation, and can drastically save heating and cooling costs. there is. In addition, a method for manufacturing graphene-reinforced ultra-lightweight rigid foamed urethane composite panels for construction that can build buildings with maximum economic and aesthetic effects by saving labor costs by minimizing the process and period of panel assembly, connection, and construction, and graphene reinforcement using the same It relates to ultra-lightweight rigid foamed urethane composite panels.

Method for manufacturing a graphene-reinforced ultra-lightweight polyurethane composite panel for construction and a graphene-reinforced ultra-lightweight polyurethane composite panel using the same according to the present invention is a finishing material on the front side, a core in the middle, and a finishing material on the back side or a preliminary finishing material for finishing such as gypsum board is installed, and the core is a graphene-reinforced ultra-light urethane composite panel made integrally by foaming hard foam urethane. On the front, finishing materials such as stone, tile, fiberboard, etc., and preliminary finishing materials for finishing, such as PVC foam board, gypsum board , cement board, magnesium board, etc. are installed, and the same type of material as the front side can be installed for the finishing material on the back side, and the core is foamed with reinforced ultra-lightweight foamed urethane containing graphene to form a high-strength lightweight insulation core. do. Inside the core, a FRP mesh made of paper or PVC, or a circular or prismatic pipe or box is embedded to form a structure within the core to adjust the strength by structural calculation. In addition, it is possible to produce and construct a hollow panel in which an electric facility line can be buried by using the inner space of the pipe in the core and the connecting pipe of the panel connection part.

This graphene-reinforced ultra-lightweight foamed urethane composite panel for construction is a panel that is installed by installing metal runners on the top and bottom to fix the top and bottom. In addition, it can be used as a wall panel for a freezer warehouse, a refrigerated warehouse, or a clean room, and the final finishing material is attached and completely finished during panel production to be constructed in a short process.

In addition, by omitting the front and rear finishing materials and installing and producing only the preliminary finishing materials on both sides of the core, it can be used for basic walls, such as partition walls or moisture barriers and other walls.

Domestic Patent No. 10-0655890, "Drywall system using panel-type studs and its construction method", Registered Patent No. 10-1078219 "Steel panel for drywall and drywall using the same", Registered Utility Model No. 20- Similar shape to No. 0469785 "Drywall insulation structure", Patent No. 10-1190249 "One-touch fastening structure of drywall stud" and Patent No. 10-1898730 "Drywall panel and drywall construction method using the same" There is something described as

However, most of these registered patents and utility models are drywall systems in which gypsum boards are installed on metal studs, and are vulnerable to moisture and waterproofing, have weak strength, have low sound insulation performance, and have little insulation effect. Therefore, most of these systems are installed on the inner walls of buildings, and gypsum boards are usually installed in two layers due to their low strength. Or install multiple layers according to the design of the building. Therefore, the process is complicated, and in places where insulation is required, an insulation material must be installed between the metal studs and then a gypsum board must be installed thereon. This method causes thermal bridging.

In general, these drywalls are not suitable for use in schools, public buildings, and houses due to their low strength, and are mainly used in commercial or public buildings. Others still use wet walls (concrete walls, brick walls), and there is no improvement in construction period and construction cost.

Republic of Korea Patent Registration No. 10-0655890 Republic of Korea Patent Registration No. 10-1078219 Republic of Korea Registered Utility Model No. 20-0469785 Republic of Korea Patent Registration No. 10-1190249 Republic of Korea Patent Registration No. 10-1898730

The present invention has been devised in consideration of and solving the above-mentioned conventional problems, the present invention requires about 7 to 8 processes in order to complete the exterior and interior walls and roofs of buildings, but 4 processes Finished at the factory, 1-2 processes are increased in strength of the panel itself, omitted or shortened, then panelized, and assembled on site with 2-3 processes to assemble wall panels, which finishes construction such as exterior and interior walls. Its purpose is to provide manufacturing production, its process, and panels using it.

The present invention for achieving the above object relates to a method for manufacturing a graphene-reinforced ultra-lightweight polyurethane foam composite panel for construction and a graphene-reinforced ultra-lightweight polyurethane foam composite panel using the same, which is related to rapid construction of buildings when the panel is used as an exterior wall material. It has the characteristics of a structure with increased strength and strength, and can be manufactured as an economical prefabricated panel for construction as an insulated panel for saving energy for heating and cooling. Therefore, in the conventional example, various panels installed on the outer wall, inner wall, and roof of a building have been assembled and combined in various ways according to their material or use. However, since all of these are installed through various processes to meet the design conditions and installation conditions of the exterior and interior walls, there were many problems such as thermal bridge, airtightness, and panel installation method.

The graphene-reinforced ultra-lightweight polyurethane foam composite panel for construction according to the present invention has the advantage of being able to make walls suitable for most buildings, as well as providing an economical and environmentally friendly product.

In addition, when the graphene-reinforced ultra-lightweight rigid polyurethane foam composite panel for construction according to the present invention is installed on the inner wall, it can be used as a non-bearing wall for drywall, and has the following advantages by supplementing the previous problems.

1. It is possible to form a wall by arranging the panels by reinforcing the hard foamed urethane core with graphene without installing metal studs, which are the frames to form the dry wall. (Graphene reinforcement function)

2. Windows, doors and other openings can be reinforced by installing metal stud frames to complete the wall.

3. Hard foam urethane, the core of this panel, has a closed cell structure and is very resistant to moisture and waterproofing. Moisture and water are not permeable. (Hard foam urethane effect)

4. The insulation effect of the core of this panel is about 1.8 times greater than that of Styrofoam with 0.038w/mk because the thermal conductivity is 0.019~0.022w/mk. (Efficacy of hard foamed urethane)

5. This panel is made of semi-incombustible insulation composite material, so unlike flammable materials, there is little risk of fire.

6. The weight of the inner wall panel is approximately 15kg/m2 (in case of thickness of 100mm), so the weight of the building is reduced and the life of the building is extended, and the weight of the structure is reduced to save the construction cost. (For reference, the weight of concrete is 100mm is approximately 100kg/m2 or more. It is about 15% of the weight of the concrete wall.)

7. The weight reduction and process reduction of this panel reduce the workability from 7-8 steps to 2-3 steps, so the installation labor cost is reduced by more than 30% and the construction period is shortened by that much.

Compared to the existing construction cost, this panel is an ultra-lightweight panel for wall construction, which can save installation labor costs by approximately 25% to 30%, and reduces 7-8 processes such as interior and exterior wall construction and roof construction to 2-3 processes. It is a dry construction method that can save construction period and labor cost, and is not subject to seasonal and climatic restrictions.

1 is a schematic production flow chart for producing a hard foamed urethane material and graphene to be stirred in the core of a graphene-reinforced ultra-lightweight polyurethane composite panel according to the present invention by a physical method.
Figure 2a is a schematic flow chart explaining the production process of the graphene-reinforced ultra-lightweight rigid polyurethane foam composite panel according to the present invention.
Figure 2b is a schematic diagram explaining the production process of the graphene-reinforced ultra-lightweight rigid polyurethane foam composite panel according to the present invention.
Figure 3 is a view schematically showing a graphene-reinforced ultra-lightweight polyurethane foam composite panel for construction according to the present invention, (a) is a view schematically showing an elevation view, (b) is a cut of line AA shown in (a) elevation view It is a schematic representation of a cross-sectional view.
4 is an installation view of a graphene-reinforced ultra-lightweight polyurethane foam composite panel for construction according to the present invention, (a) is an elevation view, and (b) is a cross-sectional view.
Figure 5 shows the test report issued by requesting the Korea Testing and Recognition Organization KTR Korea Testing & Research Institute for polyurethane insulation (insulation).

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Here, detailed descriptions of well-known functions and configurations that may obscure the gist of the present invention will be omitted. For the same reason, in the accompanying drawings, some components are exaggerated, omitted, or schematically illustrated.

In addition, the content described through the embodiments described below is only one embodiment for carrying out the present invention, and is not limited to the content of the embodiments described below, and terms or words used in this specification and claims It should not be construed as being limited to ordinary or dictionary meanings, and the inventors themselves conform to the technical spirit of the present invention based on the principle that the concept of terms can be properly defined in order to explain the invention in the best way. should be interpreted in terms of meaning and concept.

In addition, it should be understood that it will be apparent to those skilled in the art that other modifications based on the technical idea of the present invention other than the embodiments disclosed herein can be implemented.

1 is a schematic production flow chart for producing a hard foamed urethane material and graphene to be stirred in the core of a graphene-reinforced ultra-lightweight polyurethane composite panel according to the present invention by a physical method.

As shown in FIG. 1, graphene production is performed by distilling graphene raw materials through a regeneration distillation, passing through an extraction device and pumping device that extracts and transfers graphene, drying through a drying device, and then through a grinding device. The particle size is pulverized to about 20 ~ 50μm, and produced through a collecting device that collects the finished graphene. However, there are existing methods for producing graphene, such as chemical vapor deposition (CVD), epitaxial method using a silicon carbide insulator, and chemical method using a reducing agent, and it can also be obtained using these methods.

Figure 2a shows a schematic flow chart explaining the production process of the graphene-reinforced ultra-lightweight rigid polyurethane foam composite panel according to the present invention, Figure 2b is a schematic flow chart of the production process of the graphene-reinforced ultra-lightweight rigid polyurethane foam composite panel according to the present invention represents a drawing.

As shown in Figures 2a and 2b, in the method for manufacturing a graphene-reinforced ultra-lightweight polyurethane foam composite panel according to the present invention, the front finish material 4 is placed on the press base mold 1 in the press (not shown) in the base direction. laying down and installing the press left side mold 2 and the press right side mold 2 'to the left and right, respectively (S1);

Preparing a two-component rigid polyurethane foam (S2);

Stirring graphene having a particle size of 20 to 50 μm in a weight ratio of 1 to 10% in 1 solution of the prepared two-component rigid polyurethane foam according to conditions (S3);

stirring a second solution of hard foamed urethane in the same amount as the first solution of hard foamed urethane in a solution in which graphene and first solution of hard foamed urethane are stirred (S4);

Graphene, hard foamed urethane solution 1 and hard foamed urethane solution 2 are stirred, and the press base mold (1) is placed on the press, and the front finishing material (4) is installed on the press, and the press left side mold (2) and Step of pouring into the mold in which the right side mold 2' of the press is installed (S5);

Installing the backside finishing material 5 on the press top plate mold 3 (S6);

Closing and setting the press top plate mold 3 with the backside finishing material 5 installed thereon (S7);

Including the step of curing the mold by applying heat at 80 to 150 ° C. according to the situation (S8), the graphene-reinforced ultra-lightweight rigid polyurethane foam composite panel according to the present invention is completely manufactured.

The particle size of the graphene stirred in the production of the core of the graphene-reinforced ultra-lightweight polyurethane composite panel is about 20 to 50 μm, and the compressive strength reaches about 1.5 times as it is stirred at 1 to 10% by weight or more in the rigid polyurethane foam. Adjust the amount of graphene until

In general, the strength of rigid polyurethane foam is 10 to 15 N/cm2 in compressive strength and 20 to 30 N/cm2 in flexural strength when the density is 40 to 45 kg/m3 according to the KS M 3809 method. If the strength of rigid polyurethane foam is too weak to form a panel with the urethane insulation itself, a frame is formed with metal studs or square pipes and then completely embedded in the rigid polyurethane core to produce panels. However, the present invention overcomes these disadvantages by increasing the strength by using the strength enhancement characteristics of graphene to produce a wall panel itself.

Another method for manufacturing a graphene-reinforced ultra-lightweight rigid polyurethane foam composite panel according to the present invention is the method for manufacturing a graphene-reinforced ultra-lightweight polyurethane composite panel (steps (S1) to (S8)), the steps ( S1), that is, in a press (not shown), the front finishing material (4) is laid down in the direction of the base on the press base mold (1), and the press left side mold (2) and the press right side mold (2 ') are installed left and right After step (S1), the step of installing a hollow pipe 6 such as paper or FRP mesh or PVC round or angular pipe to enter the core on the installed front finishing material 4 on a spacer (not shown) By further configuration, the graphene-reinforced ultra-lightweight rigid polyurethane foam composite panel according to the present invention can be completely manufactured.

Figure 3 is a view schematically showing a graphene-reinforced ultra-lightweight polyurethane foam composite panel for construction according to the present invention, (a) is a view schematically showing an elevation view, (b) is a cut of line A-A shown in (a) elevation view It is a schematic representation of a cross-sectional view.

As shown in FIG. 3, the size of the graphene-reinforced ultra-lightweight polyurethane foam composite panel 100 can be made up to a thickness of 1.2m x 7.0m x 200mm depending on the size of the mold, especially the front and back finishes (4, 5). For the face material, finishing materials (tile, fiber cement board, PVC foam board, solid surface acrylic, metal, wood, etc.) or semi-finishing materials (gypsum board, magnesium board, cement board, etc.) can be installed. It is pin-reinforced graphene-reinforced ultra-light rigid polyurethane foam, and hollow pipes (6) such as round or square PVC pipes can be installed inside the core by structural calculation depending on the location and location of installation and attachment. The hollow pipe (6) can be replaced with FRP mesh or used together. In addition, when installed as a simple partition panel, the graphene-reinforced ultra-lightweight polyurethane core material itself can be manufactured and installed as a panel without front and back face plates and without pipes or meshes inserted into the core.

Figure 4 is a schematic installation view of the graphene-reinforced ultra-lightweight polyurethane foam composite panel for construction according to the present invention, (a) is an elevation view, (b) is a cross-sectional view.

As shown in FIG. 4, when the graphene-reinforced ultra-lightweight rigid foamed urethane composite panel 100 is installed as a wall between the slabs 10, metal channels (runners) 11 to make the thickness of the panel above and below the panel and install after cutting the panel to the height of the wall. The left and right side joints of the panels are connected and installed with construction glue, and the left and right top and bottom sides where the panels meet are made with intaglio joints, embossed joints, or flat joints and use wooden slats, steel pipes, etc. as connecting materials. and install it The joint of the square material (angle pipe (panel connection frame)) 13 such as steel or PVC is also used as a connecting material, but it is also used as an electrical wiring pipe connected to the electrical wiring and outlet box 12 or a pipe for embedment of facility piping pipe. used

This core panel without a face plate, that is, the graphene-reinforced ultra-lightweight foamed urethane composite panel (100), weighs about 4 to 4.5 kg/m2 in the case of a 100 mm thickness, and when the face plate is installed, it depends on the face plate, but approximately 15 to 20 kg /m2. For reference, concrete weighs more than 100 kg/m2 when it is 100 mm thick, and the graphene-reinforced ultra-lightweight rigid foam urethane composite panel 100 according to the present invention is lighter than the inner and outer wall panels currently using concrete, so it has good workability and shortens the construction period. And it is possible to reduce labor costs by about 25% to 30%.

Graphene stirred with hard foamed urethane to enhance the strength of this panel core is graphene produced by a physical production method, and application specifications are shown in Table 1 below. (Agitated graphene specification for improving graphene rigid polyurethane core strength)

Item unit Specification figures Carbon Content 99.5% or higher Ash less than 0.5% Bulk Density g/cm3 0.01~0.10 Moisture % less than 2% Particle Size ㎛ 15 to 25 Sheet Thickness ㎛ less than 10 Element Content Copper (Cu) ppm less than 150 Zinc (Zn) ppm less than 150 Iron (Fe) ppm less than 150 Cobalt (Co) ppm less than 150 Nickel (Ni) ppm less than 150

The graphene stirred in the panel core has a particle size of about 20 to 50 μm and is stirred in 0.1 to 10% (part by weight) of rigid foamed urethane to adjust the weight of graphene until the compressive shear strength increases by about 1.5 times. .

In general, the strength of rigid polyurethane foam is 10 to 15 N/cm2 in compressive strength and 20 to 30 N/cm2 in flexural strength when the density is 40 to 45 kg/m3 according to the KS M 3809 method. When the strength increases to this value, it can be considered that the strength at which the panel itself can form a non-bearing wall is reached.

As shown in Figure 5, looking at the test report issued by requesting the Korea Test Accreditation Organization KTR Korea Testing & Research Institute for polyurethane insulation (insulation), the test result tested by the KS M 3809 method, the thermal conductivity (average temperature ( 20±5) ℃) is 0.021 W/mk, flexural strength is 26 N/cm3, compressive strength is 14 N/cm2, and water absorption is 1.4 g/100 cm2.

If the required strength is not enough, FRP mesh or hollow pipes are installed inside the core to increase the strength of the panel, enabling it to function as a non-bearing wall.

In addition, the thermal conductivity of this panel is 0.019 ~ 0.022W/mk, which is about 70 times greater than that of concrete, which is about 1.6W/mk. When using a panel, it is the same as the result of using a thickness of 180 mm or more of Styro pole, so it is an eco-friendly material that reduces global warming by reducing CO2 generation because it saves power used for heating and cooling used in the current building and reduces the amount of raw materials used for power production. Through this, it can contribute to securing carbon credits and play a role in preserving the natural environment.

The graphene-reinforced ultra-lightweight polyurethane foam composite panel according to the present invention can be changed in material or dimensions according to the use of the building, and such changes fall within the scope of the present invention.

1: press base mold
2: press left side mold 2': press right side mold
3: press top plate mold
4: front finish material 5: back finish material
6: hollow pipe
7: Core (graphene-reinforced ultra-lightweight hard foam urethane)
10: slave
11: Metal Channel (Runner)
12: electrical outlet box
13: Each pipe (panel connection frame)
100: graphene-reinforced ultra-light rigid polyurethane composite panel

Claims (4)

Laying and installing the front finishing material on the press base mold in the base direction in the press and installing the press left side mold and the press right side mold to the left and right, respectively;
Preparing a two-component rigid polyurethane foam;
Stirring graphene having a particle size of 20 to 50 μm in a weight ratio of 1 to 10% in 1 solution of the prepared two-component rigid polyurethane foam according to conditions;
stirring a second solution of hard foamed urethane in the same amount as the first solution of hard foamed urethane in a solution in which graphene and first solution of hard foamed urethane are stirred;
A solution in which graphene, rigid foamed urethane 1 solution and rigid foamed urethane 2 solution are stirred is poured into a press base mold on a press, a front finishing material is installed on it, and a press left side mold and a press right side mold are installed on each of the left and right sides. Putting in and putting in;
Installing a backside finishing material on the press top plate mold;
Closing and setting the press upper plate mold on which the backside finishing material is installed;
A method for manufacturing a graphene-reinforced ultra-lightweight rigid polyurethane composite panel comprising the step of curing the mold by applying heat at 80 to 150 ° C depending on the situation. According to claim 1,
After the step of laying the front finishing material on the press base mold in the press base direction and installing the press left side mold and the press right side mold left and right, paper or FRP Mesh or PVC round or square pipe to enter the core on the installed front finishing material A method for manufacturing a graphene-reinforced ultra-lightweight rigid foamed urethane composite panel, characterized in that it further comprises the step of installing the same hollow pipe on a spacer. According to claim 1,
The amount of graphene stirred in the core production of graphene-reinforced ultra-lightweight polyurethane foam composite panel is to adjust the amount of graphene until the compressive strength reaches 1.5 times while stirring 1 to 10% by weight or more in hard foam polyurethane. Method for manufacturing graphene-reinforced ultra-lightweight rigid foamed urethane composite panel A graphene-reinforced ultra-lightweight rigid polyurethane foam composite panel manufactured by the method of manufacturing the graphene-reinforced ultra-lightweight polyurethane composite panel according to any one of claims 1 to 3.

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