KR20240023301A - A method for manufacturing a fireproof plate for a fire door and a method for manufacturing a fire door - Google Patents

Abstract

The present invention relates to a method of manufacturing a fire-resistant board for a fire door and a method of manufacturing a fire door using the same. More specifically, a method of manufacturing a fire-resistant board for a fire door that secures fire resistance, insulation, and condensation prevention performance while reducing manufacturing costs, and a fire door using the same. It is about manufacturing method. Accordingly, the present invention provides a method for manufacturing a fireproof board for a fire door, comprising the steps of mixing silica sol and sodium silicate and then stirring (s100); Adding acid to the stirred mixture and reacting (s200); Adding at least one metal powder selected from aluminum and zinc (s300); Adding vermiculite and perlite to the mixture containing the metal powder (s400); Adding glass fiber and cellulose fiber to the mixture and stirring (s500); Forming a plate body by spreading and drying the sol-state stirring body (s600); Impregnating the surface of the dried plate with a flame retardant and a thermosetting resin (s700); Hardening the plate by pressing and heating it in a mold of a certain shape (s800); The aim is to solve the above problems by providing a method of manufacturing a fire-resistant board for a fire door and a method of manufacturing a fire door using the same, which comprises a.

Description

Method for manufacturing a fireproof plate for a fire door and a method for manufacturing a fire door {A method for manufacturing a fireproof plate for a fire door and a method for manufacturing a fire door}

The present invention relates to a method of manufacturing a fire-resistant board for a fire door and a method of manufacturing a fire door, and more specifically, to a fire door and fire door assembly that reduces manufacturing costs while ensuring fire resistance, insulation, and condensation prevention performance.

As society's income level increases, the value of safety issues has increased, and in accordance with this trend, the demand for high-quality fire doors is also increasing. According to a recent media report, residents of 31 apartment complexes tested the performance of 173 fire doors, and as a result, 141 (82%) were judged to have failed. Accordingly, there is a need to develop fire doors that can protect the interior of the compartment and have high functionality.

As a government policy, the evacuation space helps ensure safety in that it prevents the spread of combustion to the upper floors in the event of a fire and is used as a survival space for evacuation. However, problems with the existing regulations that allow installation of non-insulated fire doors rather than insulated fire doors are highlighted. As a result, demands for thermal insulation performance standards have been constantly raised, and in fact, according to the Disaster Prevention Research Institute's mock-up test of the evacuation space, when a non-insulating fire door is installed, the temperature inside the compartment exceeds the safety standard (US NFPA code) of 60°C 10 minutes after a fire occurs. The excess was confirmed, and the temperature was shown to soar to 100℃ after 25 minutes and to a whopping 170℃ after 1 hour. Accordingly, the Ministry of Land, Infrastructure and Transport recently announced the “Rules on Standards for Building Evacuation, Fire Protection Structure, etc.” which strengthened the performance standards for fire doors installed in apartment evacuation spaces. Accordingly, from April 5, 2016, heat blocking performance requirements for apartment evacuation spaces were introduced. As it is mandatory to install fire doors that last longer than 30 minutes, demand is expected to increase significantly.

Conventional steel fire doors are known to be excellent in blocking flames, but due to the nature of the metal material, they have high thermal conductivity, which makes them vulnerable to heat insulation and condensation prevention. In addition, in the case of fire doors, they are located indoors inside apartments, which undermines the interior unity compared to wooden doors, so the need for heat-insulating wooden fire doors is emerging.

In the case of conventional wooden fire doors, it was common to construct wooden fire doors using needle-shaped fiber fillers such as glass fiber, glass wool, and mineral wool. In the past, the aggregate of wooden fire doors was made by impregnating flame retardant materials into solid wood or using general laminated veneer board (LVB) to construct the frame of the wooden door. In the case of raw wood, the possibility of deformation increases over time due to the nature of the wood, and in the case of general LVB, there was a disadvantage of not being able to secure flame retardant performance. Even in the adhesive applied to the wooden fire door, conventional organic adhesive components had the disadvantage of emitting toxic gases in case of fire and not maintaining adhesiveness at high temperatures.

Due to the nature of needle-shaped glass fibers used as materials for conventional fillers, they generate dust in the event of a fire, and when such dust is inhaled into the human body, it flows into the inside of the lungs and becomes lodged. If needle-shaped glass fibers become lodged inside the lungs, they are difficult to expel out of the body and can have a fatal adverse effect on the health of the lungs. In addition, there is concern that if a producer comes into contact with the skin when handling the above materials, the needle-shaped glass fibers may damage the skin tissue and expose the user to long-term pain.

As a conventional technology, KR1281366 'wooden fire door' uses wood and fire glass as interior door materials to prevent the fire glass from breaking and coming off in the event of a fire, and is a wood fire door that has excellent fire resistance and can be integrated into the interior. It has been done. Although the function and appearance of the above technology are excellent, heat-insulating glass is expensive and has limited supply and demand, so there are limits to commercialization.

KR1531357 'Wooden fire door using carbonized board' is a wooden fire door using carbonized board. The frame is made of cross-shaped wood, and the space formed between the frames is filled with incombustible material to ensure fire safety by using carbonized board and non-combustible board. Jinjin fire doors have been launched. According to the above technology, in order to secure fire prevention performance and rigidity, the thickness of the board had to be thick, which led to limitations in commercialization as a lightweight indoor door.

US9243444 B2 'Fire rated door' is a fire door made of fire-resistant composite fire-resistant material, and is a composite material containing 60-90% by weight of gypsum, 1.5-26% by weight of fiber, and 0.5-6% by weight of rheology modifier. A technology consisting of materials has been disclosed. Although the above technology is suitable for a fully automated manufacturing process, there is a problem in that the weight is not suitable for an indoor door due to the use of thick boards.

KR10-0918304 ‘Wooden fire door’ Announcement date September 18, 2009 KR1531357 ‘Wooden fire door using carbonized board’ Publication date April 15, 2015 US9243444 B2 ‘Fire rated door’

The goal of the present invention is to provide a wooden insulating fire door that protects people from fire and toxic gases at the entrance to a refuge compartment where people escape in the event of a fire. In the case of conventional wooden fire doors, there has been a problem of poor heat insulation performance due to the inability to fill airtightly. The present invention aims to improve these problems and provide wood fire door technology with price-competitive technology by improving aggregates, plates, adhesives, and internal fillers that are superior in fire prevention, heat insulation, flame retardancy, and insulation compared to conventional fire doors.

The present invention directly designs the frame, filler, external panel, and adhesive, and adjusts the composition ratio of each material to secure enhanced flame-blocking performance, heat-shielding performance, durability performance, insulation performance, smoke-blocking performance, and condensation reduction performance compared to conventional products. By adjusting and producing various samples, and reinforcing the manufacturing technology of each component through the data reflected through performance evaluation, the fire resistance performance, physical performance, insulation, and smoke-blocking performance are improved to be better than legal standards, making it highly functional and reducing manufacturing costs. We want to provide products.

The technical problem to be achieved by the present invention is not limited to the technical problem mentioned above, and other technical problems not mentioned can be clearly understood by those skilled in the art from the description below. There will be.

Accordingly, the present invention provides a method for manufacturing a fireproof board for a fire door, comprising the steps of mixing silica sol and sodium silicate and then stirring (s100); Adding acid to the stirred mixture and reacting (s200); Adding at least one metal powder selected from aluminum and zinc (s300); Adding vermiculite and perlite to the mixture containing the metal powder (s400); Adding glass fiber and cellulose fiber to the mixture and stirring (s500); Forming a plate body by spreading and drying the sol-state stirring body (s600); Impregnating the surface of the dried plate with a flame retardant and a thermosetting resin (s700); Hardening the plate by pressing and heating it in a mold of a certain shape (s800); The aim is to solve the above problems by providing a method of manufacturing a fire-resistant board for a fire door and a method of manufacturing a fire door using the same, which comprises a.

According to the present invention, it effectively minimizes human damage from flames, prevents secondary damage by improving the airtightness of internal fillers and suppressing toxic gas generation by inorganic adhesives, and also improves noise and condensation prevention capabilities by improving insulation. You can expect the desired effect. In addition, the performance of the fire door can be improved while the structure of the internal filler layer of the fire door can be simplified, thereby significantly reducing the manufacturing cost.

The present invention secures physical excellence and heat-insulating ability through the development of fillers, aggregates, exterior panels, and adhesives dedicated to wooden fire doors, and secures environmentally friendly elements according to recent consumer trends and quality performance and interior consistency above the standards according to the Ministry of Land, Infrastructure and Transport notification. Through this, we aim to provide a better life by satisfying the needs of consumers, improving their health by keeping them safe from substances harmful to the human body in daily life, and minimizing casualties due to disasters by making the evacuation space independent from the fire in the event of a fire.

The effects of the present invention are not limited to the effects described above, and should be understood to include all effects that can be inferred from the configuration of the invention described in the detailed description or claims of the present invention.

Figure 1 is a flowchart of a method for manufacturing a fireproof board for a fire door of the present invention.
Figure 2 is a schematic perspective view of the fireproof board for fire doors of the present invention.
Figure 3 is an exploded perspective view of the fire door of the present invention.
Figure 4 is an explanatory diagram explaining the manufacturing of the fire-resistant frame of the fire door of the present invention.
Figure 5 is a graph of test results of the fire door of the present invention.
Figure 6 is a table showing the test results of the fire door of the present invention.

Hereinafter, the present invention will be described with reference to the attached drawings. However, the present invention may be implemented in various different forms and, therefore, is not limited to the embodiments described herein. In order to clearly explain the present invention in the drawings, parts that are not related to the description are omitted, and similar parts are given similar reference numerals throughout the specification.

Throughout the specification, when a part is said to be "connected (connected, contacted, combined)" with another part, this means not only "directly connected" but also "indirectly connected" with another member in between. "Includes cases where it is. Additionally, when a part "includes" a certain component, this does not mean that other components are excluded, but that other components can be added, unless specifically stated to the contrary.

The terms used herein are only used to describe specific embodiments and are not intended to limit the invention. Singular expressions include plural expressions unless the context clearly dictates otherwise. In this specification, terms such as “comprise” or “have” are intended to indicate the presence of features, numbers, steps, operations, components, parts, or combinations thereof described in the specification, but are not intended to indicate the presence of one or more other features. It should be understood that this does not exclude in advance the possibility of the existence or addition of elements, numbers, steps, operations, components, parts, or combinations thereof.

Hereinafter, embodiments of the present invention will be described in detail with reference to the attached drawings.

Figure 1 is a flowchart of a method for manufacturing a fireproof board for a fire door of the present invention. As shown in Figure 1, the present invention relates to a method for manufacturing a fireproof board for a fire door,

Mixing silica sol and sodium silicate and then stirring (s100);

Adding acid to the stirred mixture and reacting (s200);

Adding at least one metal powder selected from aluminum and zinc (s300);

Adding vermiculite and perlite to the mixture containing the metal powder (s400);

Adding glass fiber and cellulose fiber to the mixture and stirring (s500);

Forming a plate body by spreading and drying the sol-state stirring body (s600);

Impregnating the surface of the dried plate with a flame retardant and a thermosetting resin (s700);

Hardening the plate by pressing and heating it in a mold of a certain shape (s800);

It provides a method of manufacturing a fire-resistant board for a fire door, comprising:

In the step of mixing the silica sol and sodium silicate and then stirring (s100), the mixing ratio of the silica sol and sodium silicate is preferably 6:4 to 4:6, and more preferably, the silica sol and sodium silicate are the same. It is mixed in proportion. Silica sol and sodium silicate serve as inorganic binders for fireproof boards and are important factors in non-combustible performance.

In the step (s200) of adding and reacting an acid to the stirred mixture, the acid is one or more acids selected from sulfuric acid, nitric acid, phosphoric acid, boric acid, and acetic acid, and the acid is added in an amount of 3-5w% of the total mass of the sodium silicate. It is desirable. As sodium silicate (Na2SO3), which is vulnerable to moisture, is added, the need to secure water resistance emerges. Accordingly, the present invention adds one or more acids selected from sulfuric acid, nitric acid, phosphoric acid, boric acid, and acetic acid. The above acid reacts with sodium silicate to produce an insoluble sodium salt. When sulfuric acid is added, sodium sulfate, an insoluble salt, is formed, and the reaction equation is as shown in Equation 1 below.

Equation 1) Na2O + H2SO4 -> Na2SO4 + H2O

The insoluble salt produced in this way forms an impermeable film when the silica sol aggregates, blocking moisture and ensuring water resistance.

In the step (s300) of adding at least one metal powder selected from aluminum and zinc, the inorganic binder sol is in a colloidal state of silica with a small particle size and has a low viscosity, so it may be excessively impregnated into the porous material. This may cause a decrease in the light weight, insulation performance, and thermal insulation performance of the porous material. Accordingly, the aluminum powder and zinc powder agglomerate silicon dioxide to form large-sized colloidal particles. Accordingly, excessive impregnation can be prevented and a highly viscous binder can be formed. Additionally, aluminum hydroxide (Al(OH)3), magnesium oxide (MgO), and aluminum oxide (Al2O3) may be added as needed.

In the step (s400) of adding vermiculite and perlite to the mixture containing the metal powder, the present invention provides a configuration in which fly ash, vermiculite, and perlite are added to the inorganic binder sol. The fly ash, vermiculite, and perlite are porous and foamable minerals that can achieve weight reduction by reducing the mass per volume and can be expected to improve fire resistance performance. However, since the perlite is a relatively expensive material, the manufacturing cost increases. Accordingly, in the step (s400) of adding vermiculite and perlite to the mixture containing the metal powder, 0.5 to 1.5 w% of calcium is added to the inorganic binder sol to improve overall strength, reduce weight, and improve fire resistance, thereby reducing the amount of pearlite added. It can be lowered. The calcium can be added in the form of calcium carbonate.

In the step of adding and stirring the glass fiber and cellulose fiber to the mixture (s500), it is preferable to add the glass fiber and cellulose fiber to 15-25w%, respectively. The glass fiber and cellulose fiber serve as glue between tissues and ensure sufficient durability. In the final product after drying, the addition ratio of the glass fiber and cellulose fiber is 25 to 35 w%, respectively.

In the step (s600) of forming a plate body by spreading and drying the sol-state agitator, the sol-state agitator is spread on the mesh structure and dried sufficiently to have a water content of about 20 to 30%. Drying temperature can be achieved at room temperature, but hot press can be applied to reduce manufacturing time.

In the step (s700) of impregnating the surface of the dried plate with a flame retardant and a thermosetting resin, the flame retardant resin includes ammonium phosphate, guanidine compound, benzisothiazolinone, and ethylene glycol ( It may be composed of one or more materials selected from ethylene glycol, and the thermosetting resin is preferably a phenol resin.

The step (s800) of curing the plate by pressing and heating it in a mold of a certain shape is preferably carried out for 25 to 30 minutes at a temperature of 190 to 210 ° C. and a pressure of 120 to 150 kgf / cm2. At this time, the optimal pressure to minimize surface smoothness and product deformation is 200°C, and if the temperature is lower or higher than the above temperature, the surface adhesion will decrease.

Figure 2 is a schematic perspective view of the fireproof board for fire doors of the present invention. The present invention provides a first inorganic fiber layer (110) made of inorganic fiber layers on both sides of the plate (120) after the step (s600) of forming a plate by spreading and drying the sol-state agitator as necessary. and the step (s650) of laminating the second inorganic fiber layer 130 may be applied. The first inorganic fiber layer 110 and the second inorganic fiber layer 130 are made of one or more materials selected from Cerakwool (ceramic insulating material), glass fiber, and rock wool. Accordingly, in the step (s700) of impregnating the surface of the dried plate with a flame retardant and a thermosetting resin, the flame retardant and a thermosetting resin are applied to the first inorganic fiber layer 110 and the second inorganic fiber layer 130. .

The present invention furthermore relates to a method of manufacturing a fire door,

Manufacturing a fireproof board 100 for a fire door by the method of any one of claims 1 to 7 (s10);

Cutting the edge of the fireproof board to make a square timber (s20);

Assembling the fire-resistant frame 200 with the square materials (s30); Inserting and combining the fire-resistant plate 100 into the fire-resistant frame 200 (s40);

Laminating external plates 300 on both sides of the fireproof plates 100 fastened to the fireproof frame 200 (s50);

It provides a method of manufacturing a fire door comprising:

Figure 3 is an exploded perspective view of the fire door of the present invention. According to the method of manufacturing a fire door as described above, the present invention includes a fire-resistant board (100) having heat dissipation and fire prevention performance; A fire-resistant frame 200 installed on the edge of the fire-resistant plate 100;

An external plate (300) covering the front and back surfaces of the fireproof plate (100);

It consists of:

The fireproof plate 100 includes a first inorganic fiber layer 110 made of inorganic fiber;

Internal filler layer 120 and second inorganic fiber layer 130;

A fire door constructed by lamination is provided.

The external plate 300 is applied with a fire-resistant finish, forms an exterior design and serves to block flames by directly facing the flame, and the internal filler layer blocks flame and heat during fire prevention and functions as insulation and condensation prevention. will be performed. Additionally, the fire resistant frame 200 has the function of maintaining the shape of the fire door in high temperature situations. Each of the above components may be bonded using an inorganic adhesive, and the inorganic adhesive may be a two-component flame retardant adhesive consisting of inorganic powder, flame retardant, non-halogen water-soluble resin, and hardener.

Conventional organic adhesives had the disadvantage of emitting toxic gases in case of fire and not maintaining adhesiveness at high temperatures.

In the case of such conventional adhesives, when exposed to high temperatures for a long period of time during the applicant's simulated firefighting test, adhesive strength was lost and fire spread into open gaps, causing a rapid decrease in flame blocking and blocking performance.

Accordingly, the present invention provides a two-part adhesive with a low viscosity of about 5,000 to 7,000 by mixing an amine-based curing agent with inorganic powder, flame retardant, and water-soluble resin instead of the existing urethane foam adhesive for wooden fire doors. The low-viscosity two-component adhesive secures high wettability, expands the convenience of the manufacturing process, and provides the effect of maintaining adhesive strength at high temperatures in the event of a fire. The inorganic adhesive is preferably a two-component adhesive containing at least one selected from the group consisting of aluminum hydroxide, copper oxide, zinc oxide, sodium silicate, mineral powder of methyl cellulose, melamine-based flame retardant, non-halogen water-soluble resin, and amine-based curing agent. According to the above configuration, the adhesive in the present invention has a low viscosity of about 5,000 to 7,000 to improve the wettability (fully wetted), thereby increasing the convenience of manufacturing, and as a post-process, hot press at 80 to 100 ° C. ) process provides a high-performance adhesive with a long-lasting flame retardant effect by bonding at high temperatures. In addition, the present invention goes further, and as a result of adding 6 to 7% (molar ratio) of potassium silicate and lithium silicate compared to the total content of the adhesive solids, boiling water resistance for 46 hours, salt water resistance (5% NaCl), acid resistance (5% H2SO4), It was confirmed that the alkali resistance (5% NaOH) properties were improved.

The fireproof plate 100 may be formed by stacking a first inorganic fiber layer 110 made of inorganic fiber, an internal filler layer 120, and a second inorganic fiber layer 130, and the first inorganic fiber layer 110 ) and the second inorganic fiber layer 130 is composed of one or more materials selected from Cerakwool (ceramic insulating material), glass fiber, and rock wool. The first inorganic fiber layer 110 and the second inorganic fiber layer 130 can be hardened by impregnating them with a flame retardant and a thermosetting resin such as a phenol resin and then heating and pressing them with a press. This configuration modifies the surface so that the outer plate 300 can be closely bonded in the future.

As described above, the internal filler layer 120 is composed of 25 to 35 w% of inorganic fiber, 25 to 35 w% of cellulose fiber, and 30 to 50 w% of inorganic binder sol. The composition of 25 to 35 w% of inorganic fiber and 25 to 35 w% of cellulose fiber is the optimal composition ratio to ensure fire resistance while maintaining a certain elasticity when cured after manufacturing.

Figure 4 is an explanatory diagram explaining the manufacturing of a fire-resistant frame. In the step (s20) of cutting the edge of the fireproof plate to make a square lumber and the step (s30) of assembling the fireproof frame 200 with the angle lumber, the fireproof plate (100) is cut into a bar shape, and then the cross-sectional direction The fireproof frame 200 is assembled by rotating the fireproof plate 100 to face 90 degrees with respect to the cross-sectional direction and joining it. According to the above configuration, the stress that distorts during heating can be distributed, and the effect of shortening the manufacturing time can be expected.

Figure 5 is a graph showing the test results of the fire door of the present invention, and Figure 6 is a table showing the test results of the fire door of the present invention. Figures 5 and 6 are the results of a test at the Korea Testing & Research Institute, and according to the above test results, the total heat release amount is 1.3 to 1.5 MJ/m2, which is only 17% of the judgment standard of 8 MJ/m2 or less. , the time for the heat release rate to continuously exceed 200kw/m2 was 0 seconds, satisfying the judgment standard of less than 10 seconds. In addition, there were no changes in the state of the test specimen such as cracks, holes, melting, or shrinkage after the test, and the average behavioral suspension time of the rats in the gas toxicity test was more than 14 minutes, which greatly exceeded the judgment standard of more than 9 minutes.

Accordingly, it was confirmed that the present invention satisfies the standards for semi-non-combustible materials of Ministry of Land, Infrastructure and Transport Notice No. 2022-84.

Although the present invention has been described with the accompanying drawings, this is only one example among various embodiments including the gist of the present invention, and is intended to enable those skilled in the art to easily implement the present invention. For this purpose, it is clear that the present invention is not limited to the embodiments described above. Therefore, the scope of protection of the present invention should be construed in accordance with the following claims, and all technical ideas within the equivalent scope by changes, substitutions, substitutions, etc. without departing from the gist of the present invention are the rights of the present invention. will be included in the scope. In addition, it should be clarified that some of the configurations in the drawings are provided in an exaggerated or reduced form than the actual figure for the purpose of explaining the configuration more clearly. In addition, the claim symbols are only for aiding understanding and do not mean that the shape and structure of the present invention is limited to the attached drawings.

1. Fire door
100: Fireproof board
110: First inorganic fiber layer
120: Internal filling layer
130: Second inorganic fiber layer
200: Fireproof frame
300: External plate

Claims (8)

In the method of manufacturing a fireproof board for a fire door,
Mixing silica sol and sodium silicate and then stirring (s100);
Adding acid to the stirred mixture and reacting (s200);
Adding at least one metal powder selected from aluminum and zinc (s300);
Adding vermiculite and perlite to the mixture containing the metal powder (s400);
Adding glass fiber and cellulose fiber to the mixture and stirring (s500);
Forming a plate body by spreading and drying the sol-state stirring body (s600);
Impregnating the surface of the dried plate with a flame retardant and a thermosetting resin (s700);
Hardening the plate by pressing and heating it in a mold of a certain shape (s800);
A method of manufacturing a fireproof board for a fire door, comprising:
According to paragraph 1,
In the step (s100) of mixing the silica sol and sodium silicate and then stirring, the mixing ratio of the silica sol and sodium silicate is 6:4 to 4:6.
According to paragraph 2,
In the step (s200) of adding and reacting an acid to the stirred mixture, the acid is one or more acids selected from sulfuric acid, nitric acid, phosphoric acid, boric acid, and acetic acid, and the acid is added in an amount of 3-5w% of the total mass of the sodium silicate. A method of manufacturing a fireproof board for a fire door, characterized in that.
According to paragraph 3,
A method of manufacturing a fireproof board for a fire door, characterized in that 0.5 to 1.5 w% of calcium is further added in the step (s400) of adding vermiculite and perlite to the mixture to which metal powder has been added.
According to paragraph 4,
In the step of adding glass fiber and cellulose fiber to the mixture and stirring (s500), the glass fiber and cellulose fiber are added to 15-25w%, respectively.
In number 5,
The step (s800) of curing the plate by pressing and heating it in a mold of a certain shape is performed for 25 to 30 minutes at a temperature of 190 to 210 ° C. and a pressure of 120 to 150 kgf / cm2. Manufacturing method.
According to clause 6,
After the step (s600) of forming a plate body by spreading and drying the sol-state stirring body,
Laminating a first inorganic fiber layer 110 and a second inorganic fiber layer 130 made of inorganic fiber layers on both sides of the plate body 120 (s650);
A method of manufacturing a fireproof board for a fire door, characterized in that further added.
In the manufacturing method of a fire door,
Manufacturing a fireproof board 100 for a fire door by the method of any one of claims 1 to 7 (s10);
Cutting the edge of the fireproof board to make a square timber (s20);
Assembling the fire-resistant frame 200 with the square materials (s30); Inserting and combining the fire-resistant plate 100 into the fire-resistant frame 200 (s40);
Laminating external plates 300 on both sides of the fireproof plates 100 fastened to the fireproof frame 200 (s50);
A method of manufacturing a fire door comprising: