TWI477552B - 防火聚胺酯材料及防火結構 - Google Patents

防火聚胺酯材料及防火結構 Download PDF

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TWI477552B
TWI477552B TW101123323A TW101123323A TWI477552B TW I477552 B TWI477552 B TW I477552B TW 101123323 A TW101123323 A TW 101123323A TW 101123323 A TW101123323 A TW 101123323A TW I477552 B TWI477552 B TW I477552B
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agent
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Cheng Dar Liu
Che-I Kao
Buh Luen Chen
Yu Chi Wang
Ying Chang Su
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Priority to EP13810749.5A priority patent/EP2867331A4/en
Priority to CN201310265585.5A priority patent/CN103525074B/zh
Priority to PCT/US2013/048520 priority patent/WO2014004995A2/en
Priority to JP2015520557A priority patent/JP2015525812A/ja
Priority to US14/410,485 priority patent/US9650484B2/en
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Description

防火聚胺酯材料及防火結構
本發明係有關一種防火材料。特別是提供一種防火特性之聚胺酯材料及防火結構。
聚胺酯材料為一廣泛利用之聚合物材料，於日常生活食衣住行各方面幾乎皆可見其製品，尤其是發泡之聚胺酯更是其中一重要之材料，發泡聚胺酯可於模具內發泡，因而可製得所欲形狀之物品，例如做為建築物裝潢常見之線板、飾板或裝飾件，以取代耗時、耗力、成本高昂、且重量極重之石材或木材，為現今室內裝潢之一主力材料。
然而此等發泡聚胺酯材料當應用作為裝潢材料時，面臨防火消防上之一重大考驗，由於聚胺酯材料本身並不具有防火特性，當接觸到火源常快速著火熔融，並使災情擴大，因此改良發泡聚胺酯材料使其具有防火特性為此領域中之重大課題。
現今改善發泡聚胺酯材料之防火特性係為於聚胺酯材料中添加足量之防火粉體，例如氫氧化鋁、氮系防火成份如三聚氰氨，其遇熱釋放氮氣與氨氣降低可燃氣体濃度、磷系防火成份如聚磷酸銨，其遇熱後產生偏磷酸使有機物脫水、碳系防火成份如四羥基甲烷(Pentaery thritol)。然而此等成份之添加雖可明顯改善發泡聚胺酯材料之防火特性，但聚胺酯材料之發泡性卻同時大幅降 低，無法完全充滿發泡模具之模穴內之所有角落，因此無法製得精緻之表面細節。此外，發泡聚胺酯材料因前述防火成份之添加，亦使材料之整體重量增加，同時不利於室內裝潢之利用。
因此，本領域中亟需提出一可同時兼顧發泡聚胺酯材料之發泡性及改良重量之防火聚胺酯材料及防火結構，以利各應用領域之發展要求。
本發明併用防火無機粉體及中空結構，開發一可同時兼顧發泡聚胺酯材料之發泡性及改良重量之防火聚胺酯材料及防火結構，可因應聚胺酯材料各應用領域之發展要求。
因此，本發明係有關一種聚胺酯材料，其包含：發泡聚胺酯本體；防火無機粉體；及中空結構，其中該中空結構之密度係小於約0.1 g/cm3 ，且該中空結構之材料係選自由聚合物、玻璃及陶瓷所組成之群。
本發明另提供一種防火結構，其包含：一緻密層，其包含發泡聚胺酯；及一主體摻雜層，其包含發泡聚胺酯摻雜防火無機粉體及中空結構，其中該中空結構之密度係小於約0.1 g/cm3 ，且該中空結構之材料係選自由聚合物、玻璃及陶瓷所組成之群。
本發明係有關一種聚胺酯材料，其包含發泡聚胺酯本體、防火無機粉體及中空結構。該中空結構之密度係小於約0.1 g/cm3 ，且該中空結構之材料係選自由聚合物、玻璃及陶瓷所組成之群。
根據本發明之發泡聚胺酯本體係為聚胺酯材料之主體部分，其具體之發泡程度、發泡密度及/或泡沫大小係為視所應用之目的而定。本發明所屬技術領域中具通常知識者可依目的製得該發泡聚胺酯本體。該發泡聚胺酯本體之用量係可依所欲之防火性質、發泡性及材料之重量而定，於本發明之一較佳具體實施例中，該發泡聚胺酯本體之含量為約30%至約40%以重量計。
根據本發明之該防火無機粉體係為具防火阻燃效果之無機粉體，較佳地，該防火無機粉體細為可降低材料之熱總釋放量之粉體，於本發明之具體實施例中，防火無機粉體係選自由硼酸鋅、石墨、氫氧化鎂、氫氧化鋁、碳酸鈣、矽灰、黏土、多面體矽氧烷寡聚物(Polyhedral oligosilsesquioxane，POSS)、已膨脹之氧化石墨(Expanded graphene)及其混合物所組成之群。於本發明之較佳具體實施例中，該防火無機粉體係為遇熱可釋放結晶水之晶體，如氫氧化鎂或氫氧化鋁。於本發明之另一較佳具體實施例中，該防火無機粉體係為遇熱可釋放二氧化碳之晶體，如碳酸鈣或硼酸鋅。於本發明之再一較佳具體實施例中，該防火無機粉體係為遇熱可釋放二氧 化碳之粉體，如碳酸鈣、硼酸鋅或已膨脹之氧化石墨，其中已膨脹之氧化石墨為層狀之結構，其官能基經加熱後可釋放二氧化碳，而使各層間之距離增加，而可更進一步避免火源接觸發泡聚胺酯本體。於本發明之一更佳具體實施例中，該防火無機阻燃粉體係為氫氧化鋁。
該防火無機粉體之用量係可依所欲之防火性質、發泡性及材料之重量而定，於本發明之一較佳具體實施例中，該防火無機粉體之含量為約50%至約60%以重量計。
根據本發明之中空結構係指中心具有一空間之結構，其特徵在於該中空結構之密度係小於約0.1 g/cm3 ，因該中空結構之中心具有一空間，故其密度低，較佳地，該中空結構之密度係小於約0.05 g/cm3 ；更佳係小於約0.03 g/cm3 ；尤佳係自約0.05 g/cm3 至約0.03 g/cm3 。雖不願為理論所限制，但咸信該中空結構因其密度低，故可減輕材料之整體重量，且可使發泡聚胺酯本體之使用量減少，並可因發泡聚胺酯本體之使用量減少而使材料中有機成分降低，而減少材料之熱總釋放量，而達到防火之目的。另一方面，亦因該中空結構之密度低，於發泡時可先充滿模具之模穴，特別是精緻之表面細節部分，亦克服先前技術中因添加防火成份而使聚胺酯材料之發泡性大幅降低，無法完全充滿發泡模具之模穴內之所有角落之缺點。
根據本發明之該中空結構之材料係選自由聚合物、玻璃及陶瓷所組成之群，本發明所屬技術領域中具通常知 識者可將該等材料製得中心具有空間之中空結構。於本發明之一具體實施例中，該中空結構為聚合物材料，且係選自由發泡聚苯乙烯及發泡聚苯丙烯所組成之群。於本發明之另一具體實施例中，該中空結構為玻璃材料，經燃燒，玻璃高溫熔融產生膠結，亦可保護發泡聚胺酯本體不與火源接觸，進一步提升防火效果。
該中空材料之形狀及大小並無特殊限制，惟為搭配該聚胺酯材料之各項性質，該中空結構之粒徑較佳係小於約5 mm；更佳係為約1 mm至約5 mm。
該中空結構之用量係可依所欲之防火性質、發泡性及材料之重量而定，於本發明之一較佳具體實施例中，該中空結構之含量為約0.5%至約5%以重量計。
於本發明之一較佳具體實施例中，該聚胺酯材料可另包含其他防火成份，其具體實施例為氮系防火成份如三聚氰氨、磷系防火成份如聚磷酸銨、碳系防火成份如四羥基甲烷。
於本發明之一較佳具體實施例中，該聚胺酯材料更包含助劑，以增進該組合物之各式性質。該助劑之種類、成分及含量可依需要而定，例如為分散劑、隔熱劑、結構補強劑、黏結劑、界面活性劑、色料、染料、抗龜裂劑、防水劑、抗紫外線劑、抗菌劑、抗黴劑或成碳劑。
根據本發明之聚胺酯材料，可應用於各式發泡聚胺酯材料之領域，其較佳係應用於建築材料，更佳為應用於室內裝潢之建築材料，尤佳為應用於線板、飾板或裝飾件。
本發明另提供一種防火結構，其包含：一緻密層，其包含發泡聚胺酯；及一主體摻雜層，其包含發泡聚胺酯摻雜防火無機粉體及中空結構，其中該中空結構之密度係小於約0.1 g/cm3 ，且該中空結構之材料係選自由聚合物、玻璃及陶瓷所組成之群。
根據本發明之該防火結構係為由該聚胺酯材料所形成，因該中空結構之密度低，於發泡時摻雜發泡聚胺酯及防火無機粉體係可先充滿模具之模穴，而形成該主體摻雜層，較佳係位於該防火結構之表面，之後該發泡聚胺酯主體再行發泡於模穴內，因該發泡聚胺酯主體成份單純，故形成該緻密層。
根據本發明之中空結構可將熱總釋放量自約16 MJ/cm2 至約24 MJ/cm2 大幅降低至於約8 MJ/cm2 ，符合現今法規對防火材料之要求，且經燃燒測試時，其表面並不貫穿，可知該主體摻雜層可充份保護該緻密層不接觸火源，故該緻密層僅因高溫而熔融，而不起火燃燒，而為一優秀之防火結構。
茲以下列實例予以詳細說明本發明，唯並不意謂本發明僅侷限於此等實例所揭示之內容。
實例：
依下表1之成分配製防火組合物：
其中三聚氰氨係為氮源，遇熱釋放氮氣與氨氣降低可燃氣体濃度；聚磷酸銨係為脫水劑，遇熱後產生偏磷酸使有機物脫水；季戊四醇係為成碳劑，脫水後產生不燃碳化物；玻璃纖維未遇火前可補強材料結構，遇火燃燒後呈現熔融態增強炭化層強度；發泡劑亦可為正戊烷或者環戊烷，但成型後須在60℃烘箱靜置24 hr使殘留於材料內的發泡劑揮發。
其製造方法如下：
(a)取1 μm、8 μm、55 μm三種粒徑氫氧化鋁，重量分別為8.44 g、5.64 g以及16 g，再加入0.43 g三聚氰氨、2.26 g聚磷酸銨、0.14 g季戊四醇經由粉體攪拌機混合均勻備用。
(b)將0.27 g濕潤分散劑2280以及0.15 g之DisperBYK110加入5.74 g聚氨脂發泡A劑，攪拌後混入5 g發泡劑，並與16.5 g步驟(a)之混合粉體攪拌均勻。
(c)將步驟(a)剩餘之混合粉體與8.62 g聚氨脂發泡B劑以轉速1000 rpm之機械攪拌器攪拌2分鐘，加入步驟(b)之聚胺酯發泡A劑，並以1000 rpm之機械攪拌機攪拌30秒後加入1.06 g硼酸鋅以及1.06 g玻璃纖維持續攪拌30秒。
(d)將混合物倒入發泡模具中，控制材料密度約0.15至0.3 g/cm3 ，將模具維持40℃下熟化1小時，即可獲得防火結構。
將前述之防火結構以不同測試標準之測試結果示於表2。
表2所示為台灣耐燃一級(等同於國際標準ISO5660以及ASTM E1354)之試驗標準，以不同密度之試體塗覆於可發泡性聚苯乙烯(EPS)板上，其結果顯示之根據本發明之防火材料符合CNS14705耐燃一級規格。
上述實施例僅為說明本發明之原理及其功效，而非限制本發明。習於此技術之人士對上述實施例所做之修改及變化仍不違背本發明之精神。本發明之權利範圍應如後述之申請專利範圍所列。

Claims (10)

  1. 一種聚胺酯材料，其包含：發泡聚胺酯本體；防火無機粉體；及中空結構，其中該中空結構之密度係小於約0.1 g/cm3 ，且該中空結構之材料係選自由聚合物、玻璃及陶瓷所組成之群。
  2. 根據請求項1之聚胺酯材料，其中該防火無機粉體係選自由硼酸鋅、石墨、氫氧化鎂、氫氧化鋁、碳酸鈣、矽灰、黏土、多面體矽氧烷寡聚物(Polyhedral oligosilsesquioxane，POSS)、已膨脹之氧化石墨(Expanded graphene)及其混合物所組成之群。
  3. 根據請求項1之聚胺酯材料，其中該中空結構係選自由發泡聚苯乙烯及發泡聚苯丙烯所組成之群。
  4. 根據請求項1之聚胺酯材料，其中該中空結構之粒徑係小於約5 mm。
  5. 根據請求項1之聚胺酯材料，其另包含助劑，該助劑係選自由分散劑、隔熱劑、結構補強劑、黏結劑、界面活性劑、色料、染料、抗龜裂劑、防水劑、抗紫外線劑、抗菌劑及抗黴劑所組成之群。
  6. 一種防火結構，其包含：一緻密層，其包含發泡聚胺酯；及一主體摻雜層，其包含發泡聚胺酯摻雜防火無機粉體及中空結構，其中該中空結構之密度係小於約0.1 g/cm3 ，且該中空結構之材料係選自由聚合物、玻璃及陶瓷所組成之群。
  7. 根據請求項6之防火結構，其中該防火無機粉體係選自由硼酸鋅、石墨、氫氧化鎂、氫氧化鋁、碳酸鈣、矽灰、黏土、多面體矽氧烷寡聚物、已膨脹之氧化石墨及其混合物所組成之群。
  8. 根據請求項6之防火結構，其中該中空結構係選自由發泡聚苯乙烯及發泡聚苯丙烯所組成之群。
  9. 根據請求項6之防火結構，其中該中空結構之粒徑係小於約5 mm。
  10. 根據請求項6之防火結構，其另包含助劑，該助劑係選自由分散劑、隔熱劑、結構補強劑、黏結劑、界面活性劑、色料、染料、抗龜裂劑、防水劑、抗紫外線劑、抗菌劑、抗黴劑及成碳劑所組成之群。
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