WO2005030671A1 - Incombustible composition, incombustible construction product using incombustible composition, and method of producing incombustible construction product - Google Patents

Incombustible composition, incombustible construction product using incombustible composition, and method of producing incombustible construction product Download PDF

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Publication number
WO2005030671A1
WO2005030671A1 PCT/KR2004/002447 KR2004002447W WO2005030671A1 WO 2005030671 A1 WO2005030671 A1 WO 2005030671A1 KR 2004002447 W KR2004002447 W KR 2004002447W WO 2005030671 A1 WO2005030671 A1 WO 2005030671A1
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Prior art keywords
bcombustible
fire
board
composition
constraction
Prior art date
Application number
PCT/KR2004/002447
Other languages
French (fr)
Inventor
Jun-Han Choi
Sang-Hoon Lee
Byung-Ick Yoon
Original Assignee
Jun-Han Choi
Sang-Hoon Lee
Byung-Ick Yoon
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Publication date
Priority to KR10-2003-0067416 priority Critical
Priority to KR10-2003-0067418 priority
Priority to KR1020030067416A priority patent/KR100635832B1/en
Priority to KR10-2003-0067417 priority
Priority to KR1020030067418A priority patent/KR100635810B1/en
Priority to KR1020030067417A priority patent/KR20050031196A/en
Application filed by Jun-Han Choi, Sang-Hoon Lee, Byung-Ick Yoon filed Critical Jun-Han Choi
Publication of WO2005030671A1 publication Critical patent/WO2005030671A1/en

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    • CCHEMISTRY; METALLURGY
    • C03GLASS; MINERAL OR SLAG WOOL
    • C03CCHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C13/00Fibre or filament compositions
    • C03C13/06Mineral fibres, e.g. slag wool, mineral wool, rock wool
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02Macromolecular compounds
    • C04B26/10Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/12Condensation polymers of aldehydes or ketones
    • C04B26/122Phenol-formaldehyde condensation polymers
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02Macromolecular compounds
    • C04B26/10Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/12Condensation polymers of aldehydes or ketones
    • C04B26/125Melamine-formaldehyde condensation polymers
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02Macromolecular compounds
    • C04B26/10Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/18Polyesters; Polycarbonates
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/24Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
    • C04B28/26Silicates of the alkali metals
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/18Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/20Oxides; Hydroxides
    • C08K3/22Oxides; Hydroxides of metals
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00Use of ingredients characterised by shape
    • C08K7/02Fibres or whiskers
    • C08K7/04Fibres or whiskers inorganic
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K21/00Fireproofing materials
    • C09K21/02Inorganic materials
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00034Physico-chemical characteristics of the mixtures
    • C04B2111/00129Extrudable mixtures
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20Resistance against chemical, physical or biological attack
    • C04B2111/28Fire resistance, i.e. materials resistant to accidental fires or high temperatures
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/91Use of waste materials as fillers for mortars or concrete

Abstract

Disclosed is an incombustible composition, an incombustible construction product using the incombustible composition, and a method of producing the incombustible construction product. The incombustible composition includes organic or inorganic fiber, fly ash or bottom ash, fire proofing agent, and curing fire-retardant resin. Additionally, the method includes mixing components, constituting the incombustible composition, with each other, and pressing the incombustible composition using a high pressure hot press, a roller press or an autoclave to give a predetermined shape to the incombustible composition. Therefore, the incombustible composition is advantageous in that it is environmentally- friendly because it contains waste materials, and that it has excellent hardness, strength, and water resistance. Other advantages are that its production costs are relatively low, and that it has excellent incombustibility, depending on the contents of the components constituting the incombustible composition.

Description

INCOMBUSTIBLE COMPOSITIO INCOMBUSTIBLE CONSTRUCTION PRODUCT USING INCOMBUSTIBLE COMPOSπiON. AND METHOD OF PRODUCING INCOMBUSTIBLE CONSTRUCTION PRODUCT
Technical Field The present invention pertains to an incombustible composition, an incombustible construction product using the incombustible composition, and a method of producing the incombustible constmction product. More particularly, the present invention relates to an incombustible composition, which is used as construction ftashing and interior materials, being safe from fire, to prevent a fire from spreading and to prevent toxic gases from being generated from the constmction finishing and interior materials when the constmction finishing and interior materials are on fire, an incombustible constmction product using the incombustible composition, and a method of producing the incombustible constmction product.
Background Art Up to now, MDF, plywood, a plaster board, and a wood-wool cement board have been used as representative constmction finishing and interior materials in domestic and overseas constmction fields. However, the above constraction materials have different physical properties and disadvantages. Accordingly, efforts have been made to develop various fire-retardant materials by properly controlling compositions of the components constituting the constmction materials so as to complement the constmction materials with each other. However, these efforts are disadvantageous in that the developed fire-retardant materials do not have sufficient physical properties required for constmction finishing and interior 125 materials, but have the few desired physical properties, and thus, the use of the fire- retardant materials is applied to limited fields. In order to better understand the background of the invention, a description will be given of conventional technologies regarding the constmction materials, below. Conventional developments of the fire-retardant materials are mostly focused on coating a fire-retardant pigment on or attaching a fire-retardant film to the MDF or plywood, having no fire-retardancy, while the amount of the fire-retardant pigment or the fire-retardant film is properly controlled, or on attaching a fire-retardant board or an incombustible steel or aluminum plate to the plaster board. The MDF or plywood is produced by pressing and shaping wood chips using an organic adhesive, and most widely used as the constmction finishing and interior materials. However, the MDF or plywood has no fire-retardancy, thereby catching fire easily. To avoid the above disadvantage, an inorganic adhesive maybe used instead of the organic adhesive. However, the MDF or plywood, produced using the inorganic adhesive, is disadvantageous in that layers constituting the MDF or plywood are easily separated from each other and the MDF or plywood is easily damaged, thereby reducing productivity of the MDF or plywood. Additionally, because only the adhesive is made of an inorganic material and the MDF or plywood mostly consists of the combustible wood chips, the MDF or plywood has not sufficient fire-retardant ability (incombustibility, quasi-incombustibility, and fire-retardancy). Hence, it is difficult to commercialize the MDF or plywood using an inorganic adhesive. As for the plaster board with fire-retardancy, technologies have been developed to attach the fire-retardant board to the plaster board and to attach the incombustible steel or aluminum plate to the plaster board. In this regard, the plaster board is disadvantageous in that a plaster, used as a main component of the plaster board, is relatively heavy, and it is impossible to process the plaster in order to use it as a constmction finishing material. However, a technology of a material capable of being used instead of the plaster, has not yet been developed, and thus, the plaster board is still used as construction finishing and interior materials, having the fire-retardancy. In addition, the wood-wool cement board has been used as the constmction finishing and interior materials. The wood-wool cement board is produced by mixing various substances with cement. Examples of the above substances may include relatively light paper particles, perlites, Styrofoam particles, vermiculites, bottom ash, and a mixture thereof, and various additives maybe added into the wool-wood cement board in accordance with the use of the wood-wool cement board. However, the wood-wool cement board is used as constmction exterior and ceiling materials rather than the constmction finishing and interior materials because the wood-wool cement board has slightly different physical properties from a cement board. In other words, the wood-wool cement board does not serve to radically modify physical properties of the cement board. Currently, an incombustible constmction finishing and interior material is developed, which is produced by pressing and shaping incombustible alumina powder (Al2O3). However, the incombustible constraction finishing and interior material, including the alumina powder, is more expensive than the MDF or plywood by ten times or more, and thus, it is only applied to special fields but scarcely used in general constmction f ishing and interior material. According to the existing Building Standards Act and Fire Services Act in Korea, a fbishing and interior material, used in buildings, must be incombustible, quasi- incombustible, or fire-retardant, and the buildings, larger than a predetermined scale, must include fire-proofing sections to prevent the fire from spreading and to shield persons from fire. As well a fire door, made of a material capable of enduring fire for 30 minutes or one hour must be installed at the fire-proofing sections. Furthermore, the legally regulated fimshing and interior material is evaluated as three categories according to the KS (Korean Standard) F2271 method (a fire-retardant performance test method for constmction materials): first-grade fire-retardancy (incombustible materials), second-grade fire-retardnacy (quasi-incombustible materials), and third-grade fire-retardancy (fire-retardant materials). Particularly, the fire door is evaluated as the first fire door, enduring fire for one hour, and the second fire door, endrαring fire for 30 minutes, according to the KS F2257 method, and it is stated in the Building Standards Act that only the fire door, having performances satisfying the above standards, may be used in the buildings. The Building Standards Acts of different countries may be slightly different from each other. However, all countries regulate the standards regarding the performances of the constmction fimshing and interior material, and the Building Standards Act of each country provides that only the materials, having the performances satisfying the above standards, may be applied to the buildings. The reason for this is that the use of the desirable constraction finishing and interior material contributes to preventing the fire from spreading and to shielding persons in the buildings from toxic gases occurring due to fire. However, most of the commercial constmction finishing and interior materials insufficiently satisfy the above standards, and do not sufficient physical properties required to be used as the constraction finishing and interior material even though they have ^combustibility, quasi-incombustibility, or fire-retardancy. Heretofore, the constraction finishing and interior materials with excellent performance have not yet been developed even though many studies have been conducted to develop the constmction finishing and interior materials, having incombustibility, quasi- incombustibility, or fire-retardancy. In detail, the MDF or plywood as described above is the most widely used as the constmction interior material because the MDF or plywood is inexpensive and lightweight, has excellent processability, and ease of its use in building constructing is ensured. However, the MDF or plywood has poor water-resistance, and no incombustibility, quasi-incombustibility, or fire-retardancy, thereby catching fire easily and accelerating the spread of the fire. Accordingly, the use of the MDF or plywood is limited by the existing Building Standards Act in Korea In addition, the plaster board is made of waste chemical gypsum, discharged from a fertilizer plant or a power plant, plaster and the like. The plaster board is inexpensive, and has excellent processability. Further, the ease of use in building constracting is ensured, and the plaster board has incombustibility, quasi-incombustibility, or fire-retardancy. Hence, the plaster board is used as a rφresentative constmction fbishbg and interior material with incombustibility, quasi-incombustibility, or fire-retardancy. However, the plaster board is problematic in that it is very weak against water, easily damaged due to its poor strength, and brings about pollution because a lot of dust is created when it is processed and most of the used plaster board cannot be regenerated. Furthermore, it is difficult to shape the plaster board in various designs and to apply the plaster board to various fields because papers are attached to a surface of the plaster board. As for the wood-wool cement board, it has excellent strength, water-resistance, and incombustibility, quasi-incombustibility, or fire-retardancy. However, the wood-wool cement board has poor processability, and is relatively heavy and easily damaged. As well ease of its use in building constracting is not ensured. Therefore, the wood-wool cement board is used as exterior wall materials or surface materials of the buildings, but scarcely used as the constmction finishing and interior materials.
Disclosure of the Invention Accordingly, the present invention has been made keeping in mind the above problems, such as the poor fire-retardancy of conventional constmction fbishing and bterior materials and difficulty b applybg the conventional constraction finishbg and bterior materials to various fields, occurring b the prior art, and an object of the present bvention is to provide an bcombustible composition, which mostly consists of waste materials, and which is envirønmentally-friendly and bexpensive. m this regard, the bcombustible /030671
composition has excellent hardness, strength, and water-resistance, and has fire-retardancy dependbg on contents of the components thereof - Another object of the present bvention is to provide a method of producbg an bcombustible constmction product, havbg all desirable physical properties, required for constmction material, as well as bcombustibility, us g an bcombustible composition. A further object of the present bvention is to provide an bcombustible constraction product, produced accordbg to the above method, which is used as constraction finishbg and bterior boards, bebg safe from fire, preventing fires from spreadbg and preventing toxic gases from bebg generated from the constraction finishbg and bterior boards when the constraction finishbg and bterior boards are on fire. hi order to accomplish the above object, the present bvention provides an bcombustible composition, bcludbg 1 to 80 wr% of organic or borganic fiber, 1 to 80 wt% of fly ash or bottom ash, 1 to 80 wt% of fire-proofing agent, and 1 to 30 wt% of curing fire- retardant resb. Alternatively, the bcombustible composition bcludes 1 to 80 wt% of organic or borganic fiber, 1 to 80 wt% of fly ash or bottom ash, 1 to 60 wt% of fire-retardant curing agent 1 to 80 wt% of fire-proofing agent, and 1 to 30 wt% of curing fire-retardant resb. In order to accomplish the above object, the present bvention provides a method of producbg an bcombustible constmction product, which bcludes ixbg 1 to 80 wt% of organic or borganic fiber, 1 to 80 wt% of fly ash or bottom ash, 1 to 80 wt% of fire-proofing agent, and 1 to 30 wt% of curing fire-retardant resb to produce the bcombustible composition, and pressbg the bcombustible composition usbg a high pressure hot press to give a predetermbed shape to the bcombustible composition. Alternatively, the method bcludes mixbg a fly ash or a bottom ash and a fire- proofing agent with each other; spraybg a fire-retardant curing agent onto a mixture, and addbg an organic or borganic fiber bto the mixture, contabbg the fire-retardant curing agent; extmdbg the resulting mixture usbg an extrusion system, drybg the extruded mixture b a drybg system, and shattering the dried mixture bto particles with a predetermbed size usbg a shattering device; and addbg a curing fire-retardant resb and the fire-proofing agent to the particles to form a paste, and pressbg the paste usbg a high pressure hot press to give a predetermbed shape to the paste. b order to accomplish the above object, the present bvention provides an bcombustible constraction product, produced according to such method, which is applied to a fire door, an bcombustible board, or a fire-resisting board. m order to accomplish the above object, the present bvention provides an additional bcombustible composition, bcludbg 1 to 80 wt% of organic or borganic fiber, 1 to 80 wt% of fly ash or bottom ash, 1 to 80 wt% of fire-proofing agent, and 1 to 60 wt% of fire-retardant curing agent. Furthermore, the present bvention provides a method of producbg an additional bcombustible constraction product, which bcludes providbg the bcombustible composition; mixbg an organic or borganic fiber, a fly ash or bottom ash, and a fire- proofing agent with each other usbg a mixer after bebg weighed, and spraybg a fire- retardant curing agent and water onto a mixture to form a paste; pressbg the paste usbg a roller press; and curing the pressed paste usbg a drier b which a temperature is controlled from 10 to 200 °C. As well, the present bvention provides an bcombustible constmction product, which is shaped as the core material of a board constituting an dumbum or steel plate complex board, the mab body and doors of a kitchen table, the mab bodies and doors of built-b furniture, furniture, lavatory partitions, partition walls, an access floor, an OA floor, a stair board, a reinforced floor, or a ceilbg finishbg material. In order to accomplish the above object, the present bvention provides an additional bcombustible composition for a fire door/wall, which bcludes 1 to 80 wt% of organic or borganic fiber, 1 to 80 wt% of fly ash or bottom ash, 1 to 80 wt% of fire-proofing agent, 1 to 30 wt% of curing fire-retardant resb, and 1 to 40 wt% of bcombustible hollow filler. Additionally, the present bvention provides a method of producbg an bcombustible fire door/wall. The method bcludes providing the bcombustible composition; mixbg a fly ash or bottom ash, a fire-proofing agent, and a curing fire-retardant resb with each other; addbg an organic or borganic fiber bto a mixture, shattering the rnixture contabbg the organic or borganic fiber, mixbg an bcombustible hollow body with the shattered rnixture by use of a mixer usbg air, pressbg the resulting mixture usbg a high pressure hot press to form a board or square timber; and constracting a frame of the fire door/wall usbg the board and/or square timber and embeddbg an bcombustible core material bto the fire door/wall.
Best Mode for Carrybg Out the bvention
An bcombustible composition accordbg to the present bvention bcludes 1 to 80 wt% of organic or borganic fiber (a), 1 to 80 wt% of fly ash or bottom ash (b), 1 to 80 wt% of fire-proofing agent (c), and 1 to 30 wt% of curing fire-retardant resb (d). m this regard, this bcombustible composition is produced accordbg to a dry compression shapbg process. Alternatively, the bcombustible composition accordbg to the present bvention may bclude 1 to 80 wt% of organic or borganic fiber (a), 1 to 80 wt% of fly ash or bottom ash (b), 1 to 80 wt% of fire-proofing agent (c), 1 to 30 wt% of curing fire-retardant resb (d), and 1 to 60 wt% of fire-retardant curing agent (e). At this time, this bcombustible composition is produced accordbg to a wet and dry compression shapbg process. b addition, the bcombustible composition of the present bvention may further bclude an bcombustible lightenbg agent (f), an additive, such as a curing acceleration bbder, a surfactant, and/or a coloring agent, and water. An bcombustible composition accordbg to the present bvention bcludes 1 to 80 wt% of organic or borganic fiber (a), 1 to 80 wt% of fly ash or bottom ash (b), 1 to 80 wt% of fire-proofing agent (c), and 1 to 60 wt% of fire-retardant curing agent (e). Additionally, the bcombustible composition of the present bvention may further bclude an bcombustible lightenbg agent (f), an additive, such as a curing acceleration bbder, a surfactant, and/or a coloring agent, and water. An bcombustible composition for a board and/or a square timber of a fire door/wall accordbg to the present bvention bcludes 1 to 80 wt% of organic or borganic fiber (a), 1 to 80 wt% of fly ash or bottom ash (b), 1 to 80 wt% of fire-proofing agent (c), 1 to 30 wt% of curing fire-retardant resb (d), and 1 to 40 wt% of bcombustible hollow filler (k). In addition, the bcombustible composition of the present bvention may further bclude an bcombustible lightenbg agent (f), and/or an additive, such as a curing acceleration bbder, a surfactant, and/or a coloring agent.
Accordbg to the present bvention, it is preferable that the bcombustible composition confabs 1 to 80 wt% of organic or borganic fiber (a). Examples of the organic fiber bclude paper fragments shattered bto fibroid materials, shattered wood fragments, waste fibers, rice bran, vegetable fibers, and a rnixture thereof, and the borganic fiber is exemplified by rock wool, glass wool basaltic wool, ceramic wool, and a mixture thereof, this regard, the above exemplified organic or borganic fibers contab some waste materials. The organic or borganic fiber (a) is added bto the bcombustible composition to enable the bcombustible constraction product, produced usbg the bcombustible composition, to have similar physical properties to MDF or plywood. Accordingly, the organic or borganic fiber (a) enables the bcombustible constraction product to be processed b various sizes, usbg a small knife (cut knife), and serves to bcrease the attachment force of the bcombustible constraction product to screws when the bcombustible constraction product is attached to a wall. When the content of the organic or borganic fiber (a) b the bcombustible composition is less than 1 wt%, the bcombustible constraction product has improved fire- retardancy, but poor processability and attachment force to the screws due to the relatively high hardness thereof. On the other hand, when the content of the organic or borganic fiber (a) b the bcombustible composition is more than 80 wt%, the strength of the bcombustible construction product is reduced to lower the dimensional stability of the bcombustible constraction product. Additionally, the fly ash or bottom ash (b) is used to secure sufficient surface strength and a smooth surface of the bcombustible constraction product. At this time, the density, and surface and compression strengths of the bcombustible constraction product may be controlled b accordance with the content of fly ash or bottom ash (b) b the bcombustible composition. fn the present specification, the term "fly ash" means a relatively lightweight ash portion of remabbg ash after the burnbg of coals used as a fuel b a steam power plant, the term "bottom ash" meanbg ash portion heavier than fly ash. Even though fly ash or bottom ash (b) have lighter specific gravity than the cement, fly ash or bottom ash (b) have relatively high specific gravity b comparison with other components constituting of the bcombustible construction product. Hence, when the fly ash or bottom ash (b) content of the bcombustible constraction product is relatively high, it is difficult to accomplish the lightenbg of the bcombustible constraction product, but it is possible to obtab a strong bcombustible constraction product havbg the improved strength. other words, when the content of the fly ash or bottom ash (b) b the bcombustible constmction product is less than 1 wt%, it is difficult to produce the smooth bcombustible constraction product havbg the desired hardness and surface effect. On the other hand, when the content of the fly ash or bottom ash (b) b the bcombustible constraction product is more than 80 wt%, the bcombustible constraction product is relatively high b terms of specific gravity and easily damaged by a relatively weak impact, and thus, it is not proper to use as a board or a square timber. The organic or borganic fiber (a) constituting the bcombustible constmction product may be made of combustible materials. Hence, the fire-proofing agent (c), such as calcium carbonate, sodium bicarbonate, sodium carbonate, other carbonates, or a rnixture thereof may be added bto the bcombustible composition to mbimize the combustion of the bcombustible constraction product or the occurrence of toxic gases when the bcombustible constmction product is on fire, thereby the bcombustible constmction product ensures the bcombustibility or quasi-bcombustibility. Furthermore, when the bcombustible constraction product, containbg the fire- proofing agent (c), is on fire at a temperature of 500 °C or higher, the fire-proofing agent (c) is decomposed to allow carbon dioxide (CO2) to flow out of the bcombustible constmction product, thereby extinguishbg the fire. Accordbgly, the bcombustible constraction product, containbg the three components, that is, the organic or borganic fiber (a), the fly ash or bottom ash (b), and the fire-proofing agent (c), is improved b terms of the fire- retardancy because of the fire-proofing agent (c). b other words, the quasi-incombustible constmction product is improved to the bcombustible constraction product, and the fire- retardant constmction product is improved to the quasi-bcombustible or bcombustible constraction product. At this time, it is preferable that the content of the fire-proofing agent (c) b the bcombustible composition is 1 to 80 wt%. When the content of the fire-proofing agent (c) b the bcombustible composition is less than 1 wt%, the bcombustible composition does not secure a sufficient fire-proofing agent effect. On the other hand, when the content of the fire-proofing agent (c) is more than 80 wt%, the strength of the bcombustible constraction product is reduced. However, the bcombustible composition, containbg only the above three components, that is, the organic or borganic fiber (a), the fly ash or bottom ash (b), and the fire-proofing agent (c), is disadvantageous b that it does not have desirable compression or tensile strengths required for construction material, is readily deformed when the bcombustible composition is cured, and cannot be easily attached to various finishbg materials even though it has bcombustibility. To avoid the above disadvantages, the curing fire-retardant resb (d), such as a phenol resin, a fire-retardant polyester resb, or a melambe resb, is added bto the bcombustible composition to enable the bcombustible construction product to have desired physical properties, required for constraction material, as well as bcombustibility. b this respect, it is preferable that a content of the curing fire-retardant resb (d) b the bcombustible composition is 1 to 30 wt%. When the content of the curing fire- retardant resb (d) is less than 1 wt%, it is impossible to conduct the curing of the bcombustible composition. On the other hand, when the content of the curing fire- retardant resb (d) is more than 30 wt%, the production costs of the bcombustible composition are undesirably bcreased while the curing efficiency of the bcombustible composition is no longer bcreased. The bcombustible composition, containbg the above four components, that is, the organic or borganic fiber (a), the fly ash or bottom ash (b), the fire-proofing agent (c), and the curing fire-retardant resb (d), is pressed bto a desired shape usbg a high pressure hot press, preferably a high pressure hot press equipped with a high frequency heater, to accomplish the bcombustible constraction product. addition, a fire-retardant curing agent (e), such as sodium silicate, potassium silicate, or a mixture thereof, may be selectively added bto the bcombustible composition b an amount of 1 to 60 wt% to further improve bcombustibility of the bcombustible composition, containbg the organic or borganic fiber (a). In this regard, strength and processability, or the fire-retardancy of a construction board, produced usbg the bcombustible composition, may be controlled b accordance with the content of the fire- retardant curing agent (e) b the bcombustible composition. When the content of the fire-retardant curing agent (e) b the bcombustible composition is less than 1 wt%, other components constituting the bcombustible composition are not sufficiently bound to each other to reduce strength and hardness of the mcombustible construction product, thereby hbdering the bcombustible constraction product from fulfuΕng its function. On the other hand, when the content of the fire- retardant curing agent (e) b the bcombustible composition is more than 60 wt%, the bcombustible constraction product may be easily deformed due to a non-uniform surface curing speed distribution thereof. However, both wet and dry processes must be utilized to produce the bcombustible constraction product usbg the fire-retardant curing agent (e). b detail, a wet process is conducted to provide characteristics of the fire-retardant curing agent (e) to the incombustible construction product, and a dry process is then conducted to enable the bcombustible construction product to have physical properties required for constraction material, b which the curing fire-retardant resb (d), such as the phenol resb, fire-retardant polyester resb, or melambe resin, is added bto the bcombustible constmction product, thereby accomplishbg the bcombustible constraction product, simultaneously havbg fire- retardancy and physical properties required for constraction material. Selectively, the bcombustible lightenbg agent (f) may be added bto the bcombustible composition to lighten the bcombustible constraction product. At this time, specific gravities of constraction finishbg and bterior materials may be controlled accordbg to the content of the bcombustible lightenbg agent (f) b the bcombustible composition. Examples of the bcombustible lightenbg agent (f) bclude fine perlite particles, fine vermicuHte particles, rockwool wastes, diatomites, zeolites, or a mixture thereof m this respect, the waste fine perlite particles or waste fine vermiculite particles may be used as the bcombustible lightenbg agent (f). The content of the bcombustible lightenbg agent (f) b the bcombustible constraction product may be 1 to 50 wt%. When the content of the bcombustible lightenbg agent (f) b the bcombustible composition is less than 1 wt%, the bcombustible lightenbg agent (f) does not affect the specific gravity of the bcombustible constraction product and not fulfill its function. On the other hand, when the content of the bcombustible lightenbg agent (f) is more than 50 wt%, the surface of the bcombustible constraction product becomes rough, the strength of the bcombustible constmction product is reduced, and other components constituting the bcombustible composition are not uniformly mixed with each other, leadbg to a non-uniform distribution of the components b the bcombustible composition. Furthermore, 1 to 10 wt% of curing acceleration bbder (g) may be selectively added bto the bcombustible composition to improve the productivity of the bcombustible constraction product and to minimize shrinkage and deformation of the bcombustible constraction product when the bcombustible constraction product is cured. At this time, the curing acceleration bbder (g) serves to enable the fire-retardant curing agent (e) to be quickly dried, m this respect, examples of the curing acceleration bbder (g) bclude magnesia, plaster, borganic or organic acid mixtures, calcium silicate, or a rnixture thereof. Further, the curing time of the bcombustible constraction product may be controlled accordbg to the content of the fire-retardant curing agent (e) b the bcombustible composition. As well, the surfactant (h) may be selectively added bto the bcombustible. composition to improve its adiabatic property, water resistance, and water repellence of the bcombustible construction product, and to promote the lightenbg of the bcombustible construction product, b this regard, the surfactant (h) may be exemplified by an alkylbenzene sulfonic acid-based surfactant, havbg relatively large surface tension, and functions to reduce resistance to water and water-absorptivity of the bcombustible construction product, thereby enablbg the shape of the bcombustible constraction product to be mabtabedb water. Furthermore, the surfactant (h) serves to bcrease the porosity of the bcombustible constraction product to form a plurality of air layers b the bcombustible construction product. Thereby, the surfactant (h) improves adiabatic property of the bcombustible constraction product and contributes to lightenbg the bcombustible constraction product. At this time, it is preferable that the content of the surfactant (h) b the bcombustible composition is 0.1 to 0.3 wt% because the strength of the bcombustible construction product maybe reduced accordbg to the content of the surfactant (h). Meanwhile, the components (a) and (b), constituting the bcombustible composition, have dark gray colors, and significantly affect the color of the entire bcombustible composition. If the color of the bcombustible composition is dark gray, the application of the bcombustible composition to various colors of construction finishbg and bterior materials is limited. Accordbgly, 1 to 10 wt% of white borganic coloring agent (i) may be added bto the bcombustible composition, this regard, the white borganic coloring agent (i) is resistant to the fire and conceals well the dark gray color of the bcombustible composition. Additionally, examples of the white borganic coloring agent (i) bclude titanium dioxide (TrQz). b conclusion, the white borganic coloring agent (i) enables the bcombustible composition to have the light gray color, thereby providbg ease of surface treatment of the bcombustible construction product, such as pabting and woodgrab coating of the bcombustible construction product. Particularly, red and yellow borganic coloring agents (j) may be added bto the bcombustible composition while bebg mixed b a predetermbed mixbg ratio to allow the surface color of the bcombustible constraction product to vary. At this time, a separate coloring process of the bcombustible constraction product may be omitted. As well, the bcombustible composition accordbg to the present bvention may further contab 1 to 60 wt% of water, b detail, water is further added bto the bcombustible composition so as to smoothly mix the fire-retardant curing agent with other components b case that the fire-retardant curing agent is mixed with other components constituting the bcombustible composition. When an amount of water added bto the bcombustible composition is less than 1 wt%, the mixbg of the fire-retardant curing agent with other components is not sufficiently conducted because the paste is thick. On the other hand, when the content of water b the bcombustible composition is more than 60 wt%, the drybg time of the paste is undesirably long. Meanwhile, the bcombustible hollow filler (k) may be added bto the bcombustible composition to improve the lightenbg, noise-absorbbg ability, adiabatic property, and fire-retardancy of the fire door/wall. At this time, the fire-retardancy of the fire door/wall may be controlled accordbg to a content of the bcombustible hollow filler (k) b the bcombustible composition. Examples of the bcombustible hollow filler (k) bclude a perlite hollow body, a fly ash hollow body, a ceramic hollow body, an borganic hollow body, such as a Sbirasu balloon, a silica balloon, an elvan balloon, and a mberal balloon, or a rnixture thereof. In this respect, it is preferable that the content of the bcombustible hollow filler (k) b the bcombustible composition is 1 to 40 wt%. When the content of the bcombustible hollow filler (k) is less than 1 wt%, the bcombustible composition does not secure a sufficient bcombustible hollow filler effect because the bcombustible hollow filler (k) does not affect specific gravity, noise-absorbbg ability, adiabatic property, and fire-retardancy of the bcombustible composition. On the other hand, when the content of the bcombustible hollow filler (k) is more than 40 wt%, the bcombustible composition has a rough surface and is reduced b terms of strength. The production of the bcombustible composition of the present bvention and bcombustible constraction product, produced usbg the bcombustible composition, are conducted accordbg to a dry compression shapbg process, or a wet and dry compression shapbg process, bcludbg a first wet process and a second dry process. Hereinafter, a detailed description will be given of the production of the bcombustible constraction product usbg the bcombustible composition accordbg to the present bvention, below. It is to be understood that modifications, regardbg the production of the bcombustible constraction product, will be apparent to those skilled b the art without dφarting from the spirit of the bvention <Production of a constraction bterior board accordbg to the dry compression shapbg process> A method of producbg the bcombustible constraction bterior board accordbg to the dry compression shapbg process bcludes rnixbg, shapbg and drybg stφs. The components (a), (b), (c), and (d), stored b a silo equipped with a measuring system, are fed bto a rnixbg compartment to be previously mixed with each other by use of a strong air current generated by a 30 to 50 horsφower compressor installed at a lower portion of the mixbg compartment. At this time, the components (f), (g), (h) and/or (i) may be selectively added bto the mixbg compartment through the silo. A first rnixbg stφ is conducted usbg a mixer, for example, a low-speed ribbon mixer. At this time, the first rnixbg stφ may be selectively conducted accordbg to a kbd of construction products. The first mixed components are then mixed with each other usbg a high-speed shattering mixer equipped with blades while uniformly shattering the components, and then pressed usbg a press, for example, a high pressure hot press of 500 to 3,000 tons to form boards. The boards thusly formed are layered to a predetermbed height and subjected to a spontaneous curing process to accomplish the bcombustible construction bterior board. With respect to this, the components, fed bto the press, may be pressed while reinforcement meshes (nets), made of a glass fiber, are spread on the upper and lower sides of the press to bcrease compression and tensile strengths of the constraction bterior board. <Production of an bcombustible constraction bterior square timber accordbg to the dry compression shapbg process> The constraction bterior square timber with excellent bcombustibility may be produced usbg a mold, correspondbg b size to a desired square timber, accordbg to a similar procedure to b the case of the constraction bterior board. Alternatively, the constraction bterior board may be properly cut usbg a saw to produce the square timber with a desired size. m this regard, alumbum, steel, acryl, or wood may be embedded, as a rebforcbg material with a shape of square timber or plate, b the constraction bterior square timber so as to improve compression and tensile strengths of the constraction bterior square timber. <Production of the bcombustible constmction bterior board accordbg to the wet and dry compression shapbg process The wet and dry compression shapbg process bcludes a first wet process and second dry process. In the first wet process, the fly ash or bottom ash (b) and the fire- proofing agent (c), havbg relatively low water-abso tivity, are mixed with each other usbg a mixer after bebg weighed by use of a measuring system, and the fire-retardant curing agent
(e) is sprayed onto a mixture to produce a uniformly mixed paste. After the organic or borganic fiber (a), havbg relatively high water-absorptivity, is added bto the paste and uniformly mixed with the paste, a predetermbed amount of component (e) and water are added bto the resulting paste, as desired. The wet-kneaded components are transmitted bto an extrusion system to be extruded to form noodle-like bodies so as to be quickly dried, and completely dried b a drybg device, equipped with a conveyor Ibe or a rotary Mb. The dried components are shattered bto particles with a desired size usbg a shattering device, and then stored b a storage tank until the second dry process is conducted. Subsequently, the particles, subjected to the first wet process to secure bcombustibility and the predetermbed degree of hardness, are mixed with the curing fire- retardant resb (d) to bcrease strength of the bcombustible composition, to prevent the bcombustible constraction bterior board from bebg deformed, and to attach finishbg materials to the constraction bterior board. Further, the component (c) is added bto the particles to compensate for insufficient bcombustibility of the component (d). Selectively, the components (g), (i), and/or (j) may be further added bto the particles. Furthermore, it is necessary to properly control the content of the component (f) so as to enable the constraction product to have desired specific gravity because the specific gravity of the bcombustible constraction product is changed accordbg to the use of the bcombustible constraction product. For example, when a constraction product, such as an access floor, has a density of 1.1 to 1.2 g/cuf, it is not necessary to add the component (f).bto the particles to control the specific gravity of the constraction product, the case of a typical constraction bterior board, it has the density of 0.7 to 0.9 g cnf, and thus, the component (c) must be added bto the particles so as to control the specific gravity of the typical constraction bterior board. Subsequently, the components, mixed so as to enable the constraction bterior board to have the desired specific gravity, are pressed usbg a high pressure hot press (500 to
3,000 tons) at 60 to 200 °C for 1 to 60 min to accomplish the bcombustible constraction bterior board. If a high pressure hot press with a high frequency heating function is used to press the bcombustible composition, the component (d) is quickly cured to significantly reduce pressbg time of the bcombustible composition. cidentally, the components, fed bto the press, may be pressed while reinforcement meshes (nets), made of a glass fiber, are spread on the upper and lower sides of the press to bcrease compression and tensile strengths of the constmction bterior board. <Production of the bcombustible constraction bterior square timber accordbg to the wet and dry compression shapbg process> The constraction bterior square timber with excellent bcombustibility may be produced accordbg to a similar procedure to b the case of the constmction bterior board. In this regard, alumbum, steeL acryl, or wood may be embedded, as a rebforcbg material with a shape of square timber or plate, b the constraction bterior square timber so as to improve compression and tensile strengths of the construction bterior square timber. Meanwhile, the constraction product, havbg excellent bcombustibility, of the present bvention has various characteristics accordbg to each process, b detail, the constraction product, produced accordbg to the dry compression shapbg process, has a smooth surface and excellent strength, and is not deformed nor shrunk during the curing process. However, the above constraction product accordbg to the dry compression shapbg process has poorer fire-retardancy than b the case of the wet and dry compression shapbg process. The constraction product accordbg to the present bvention, havbg excellent bcombustibility or fire-retardancy, and excellent physical properties, may be usefully applied to the followbg various fields. CD Wood fire door The fire door, produced usbg the bcombustible board and square timber accordbg to the present bvention, has many advantages, such as excellent fire-resisting and fire-proofing functions, excellent processability, and various finishbg functions, unlike a conventional steel fire door. Particularly, if the wood fire door accordbg to the present bvention is applied to the inner doors of tenement houses, such as apartment houses, the wood fire door functions to prevent a fire from spreadbg and to shield persons from toxic gases generated by fire when the houses are on fire, thereby securing improved residential environment. Firewall The use of the bcombustible fire wall, produced accordbg to the present bvention, leads to the reduction of the production costs and a load of the fire wall, and the reduction of a thickness of the fire wall (an average thickness of the typical fire wall is 200 rn/m), thereby bcreasbg the effective area of the fire wall. (E) Fire-resisting coating board When four sides of a steel member of the fire-resisting board are subjected to a finishbg process usbg the bcombustible constraction product accordbg to the present bvention, the covering of the steel member usbg the bcombustible constraction product and the finishbg of the fire-resisting board are simultaneously accomplished. ® bcombustible board The bcombustible board, produced usbg the bcombustible constraction product b accordance with the present bvention, overcomes the disadvantages of a conventional plaster board, has excellent bcombustibility and processability, supporting force of a screw, attachbg possibility of various finishbg material and is easily regenerated. Accordbgly, the above bcombustible board is useful as the constmction finishbg and bterior material. © Board When the bcombustible board accordbg to the present bvention is applied to a reinforced floor, an access floor, an OA floor, a stair board, a fire wall, a partition wall, a lavatory partition, a wall finishbg and bterior material, a ceilbg finishbg and bterior material, a built-b furniture, a kitchen table, a desk, a filbg cabbet, or a table, the above constraction finishbg and bterior products, bcludbg the bcombustible board, can have excellent bcombustibility and economic efficiency, and is efficiently tightened. Havbg generally described this bvention, a further understandbg can be obtabed by reference to examples and comparative examples which are provided hereb for the purposes of illustration only and are not btended to be limiting unless otherwise specified. Physical properties of samples accordbg to the examples and comparative examples are evaluated as follows. 1) bcombustibility, quasi-bcombustibility, and fire-retardancy: the samples are evaluated b three categories accordbg to a KS F2271 method (a fire-retardant performance test method for constraction materials): first-grade fire-retardancy (bcombustible materials), second-grade fire-retardnacy (quasi-bcombustible materials), and third-grade fire-retardancy (fire-retardant materials) 2) Specific gravity and density: The specific gravities and densities of the samples are measured accordbg to a KS L5316 method (test method of physical properties of plaster boards) 3) Fire resistance: The fire resistances of the samples are evaluated accordbg to a KSF3507 method (plaster boards) . 4) Submergence stability: The submergence stabilities of the samples are evaluated accordbg to the KS F3507 method (plaster boards) After the construction products were produced accordbg to the dry compression shapbg process and the wet and dry compression shapbg process, the fire-retardancy and physical properties of the constraction products, dφendbg on a kbd of the components constituting the constraction products, were evaluated, and the results were compared with each other. As for the bcombustibility, quasi-bcombustibility, or the fire-retardancy of each constraction product, which is considered as the most important factor to be accomplished b the present bvention, the construction products were evaluated b three categories accordbg to the KS F2271 method: first-grade fire-retardancy (bcombustible materials), second-grade fire-retardnacy (quasi-bcombustibϊe materials), or third-grade fire- retardancy (fire-retardant materials), b this regards, these evaluations were conducted accordbg to contents of components constituting the construction products and a kbd of the constraction products, and compared with each other. Furthermore, a weight per unit area of each constmction product was measured, and a weight change of the construction product accordbg to a mixbg ratio of the components was measured. Additionally, stability of each constraction product against fire was evaluated by use of fire resistance of the constraction product. Particularly, submergence stabilities of the constraction products were evaluated because it is required that most of the constmction finishbg and bterior materials have submergence stabilities, and the results were compared with each other.
EXAMPLES 1 TO 3
Components as described b the followbg Table 1 were fed bto a rnixbg compartment, and previously mixed with each other for ten rnbutes usbg a strong air current generated by a compressor, installed at a lower part of the mixbg compartment. At this time, the amount of each component was described b the followbg Table 1. The mab mixbg of the components was conducted usbg a low-speed ribbon mixer, or a high-speed shattering mixer. Subsequently, the mixed components were pressed usbg a high pressure hot press of 500 tons to form boards each havbg a thickness of 20 m/m and a size of 500 mm x 800 mm. The boards formed were then spontaneously cured for three days to create fire- retardant boards. Physical properties of the fire-retardant boards were evaluated accordbg to the above evaluation methods, and the results are described b the followbg Table 1.
TABLE 1
Physical properties of the incombustible construction product produced according to the dry compression shaping process
Figure imgf000024_0001
'(a): component (a), rock wool, 2(b): component (b), fly ash, 3(c): component (c), calcium carbonate, 4(d): component (d), phenol resin, 5(f): component (f), fine perlite particle, 6Shap.: shape of the construction product, 7Fire: fire-retardancy, 8Sp.: specific gravity/density 9Subm.: submergence stability b the example 1, the weight per unit area of the bcombustible board, produced accordbg to the dry compression shapbg process, was 0.8 to 1.2, and the fire-retardancy and fire resistance of such an bcombustible board were evaluated as the first-grade fire- retardancy (bcombustible). Furthermore, the submergence stability of such bcombustible board was excellent, and thus, a shape of the bcombustible board was mabtabed b water without bebg deformed.
EXAMPLES 4 TO 6
Fly ash and 7 wt% of fire-proofing agent, as described b the followbg Table 2, were fed through a measuring system bto a mixer, and then mixed with each other b the mixer for ten mbutes. At this time, 5 wt% of lightenbg agent was selectively added bto the mixer. Subsequently, a portion of fire-retardant curing agent was sprayed onto the mixture to form a uniformly mixed paste. After an organic or an borganic fiber, havbg relatively high water-abso tivity, was added bto the paste and then mixed with the paste for ten mbutes, the remabbg fire-retardant curing agent was added bto the paste, containbg the organic or borganic fiber, b conjunction with 10 wt% of water, m this respect, the total content of fire-retardant curing agent b the resulting paste was 15 wt%. The resulting paste was transmitted bto an extrusion system to be extruded to form noodle-like bodies, and completely dried b a drybg device, equipped with a conveyor fine, for 30 min. The dried bodies were shattered bto particles usbg a shattering device. Subsequently, 10 wt% of curing fire-retardant resb and 3 wt% of calcium carbonate were added bto the particles, and the resulting mixture was pressed usbg a high pressure hot press at about 150°C for about 30 min to form bcombustible boards each havbg a thickness of 20 m/m and a size of 500 mm x 800 mm. At this time, calcium carbonate was added bto the particles so as to compensate for insufficient bcombustibility of the curing fire-retardant resb. Physical properties of the bcombustible products were evaluated accordbg to the above evaluation methods, and the results are described b the followbg Table 2.
TABLE 2 Physical properties of the incombustible constructionproduct produced according to the wet and dry compression shaping process
Figure imgf000026_0001
'(a): component (a), shattered waste paper, 2(b): component (b), fly ash, 3(c): component (c), calcium carbonate, 4(d): component (d), phenol resin, 5(e): component (e), sodium silicate liquid containing 50% of solids, 6( ): component (f), fine perlite particle, 7Shap.: shape of the constructionproduct, ^ire: fire-retardancy, 9Sρ.: specific gravity/density 10Subm.: submergence stability "Fire res.: fire resistance
From the Table 2, it can be seen that higher content of fly ash b the bcombustible composition brings about higher specific gravity of the bcombustible construction product, and that higher content of shattered waste paper leads to lower fire-retardancy and fire resistance of the bcombustible constructionproduct.
COMPARATIVE EXAMPLES 1 TO 5
Physical properties of five commercial constraction finishbg and bterior products, bcludbg MDF/plywood, a typical plaster board, a fire-proofing plaster board, a slate board, and a wood-wool cement board, were evaluated accordbg to the above methods, and the results are described b the followbg Table 3. TABLE 3 Physical properties of commercial construction finishing and interior products
Figure imgf000027_0001
'(a): component (a), 2(b): component (b), 3(c): component (c), ''Fire: fire-retardancy, 5Sρ.: specific gravity/density 6Subm.: submergence stability 7Fire res.: fire resistance From the Table 3, it can be seen that the commercial constraction finishbg and bterior products have no fire-retardancy, second grade fire-retardancy, first grade fire- retardancy, first grade fire-retardancy, and first grade fire-retardancy for comparative examples 1 (MDF/plywood), 2 (typical plaster board), 3 (fire-proofing plaster board), 4 (slate board), and 5 (wood-wool cement board), respectively. Accordbgly, the typical and fire- proofing plaster boards have no problems b securing fire-safety, and the slate board and wood-wool cement board are most preferable to be used as a fire-proofing material. As shown b the Table 3, the products accordbg the comparative examples 4 and 5 each have the best bcombustibility. However, each of them have a poor weight per unit area, and thus, they are problematic b terms of makbg them lighter. Additionally, the plaster boards each have the poorest submergence stability. As results, MDF or plywood, widely used as the construction finishbg and bterior material, has no fire-retardancy, and thus, it is not suitable to be used as the constraction material b consideration of the Buildbg Standards Act and the Fire Services Act. Further, the use of the plaster board is lbiited accordbg to uses and positions of buildbgs. As for the slate board and wood-wool cement board, they have a much higher weight per unit area than MDF and the plaster board, thereby the ease of use b buildbg constracting cannot be ensured. Meanwhile, when the examples are compared to the comparative examples, the boards accordbg to the examples 2 and 3 as described b the Table 1 each have the first- grade fire-retardancy, like the slate board and wood-wool cement board accordbg to the comparative examples 4 and 5 as described b the Table 3. As well the boards are bcombustible b terms of fire resistance. Furthermore, the weights per unit area of the boards accordbg to the examples 2 and 3 are 1.0 to 1.2, which are similar to those (1.0 to 1.4) of the slate board and wood-wool cement board accordbg to the comparative examples 4 and 5. The present bvention provides a method of producbg an bcombustible core material bterposed between constraction bterior boards with excellent bcombustibility to improve adiabatic and fire resisting properties of the constmction bterior boards. The method bcludes providbg the bcombustible composition; mixbg the organic or borganic fiber, fly ash or bottom ash, and fire-proofing agent with each other usbg a mixer after they are weighed, and spraybg water and a fire-retardant curing agent bto a mixture to form a paste; pressbg the paste usbg a roller press; and drybg and curing the pressed paste usbg a drier b which a temperature is controlled withb a range of 10 to 200 °C . The production of the bcombustible core material will be described below. <Production of a constraction bterior core material accordbg to a wet process> The organic or borganic fiber (a), fly ash or bottom ash (b), and fire-proofing agent (c), stored b a silo equipped with a measuring system, are fed bto a rnixbg compartment to be mixed with each other usbg a strong air current generated by a 30 to 50 horsepower compressor, installed at a lower portion of the mixbg compartment. At this time, the bcombustible lightenbg agent (f), curing acceleration bbder (f), and/or borganic coloring agent (h) and/or (i) may be selectively added bto the mixbg compartment through the silo. The mab mixbg of the above components is conducted usbg a mixer, and a predetermbed amount of water is fed through a water inlet, positioned at an upper part of the mixer, bto the mixbg compartment. After the completion of the feedbg of water bto the rnixbg compartment, the fire-retardant curing agent (e) is sprayed through a spray nozzle bto the mixbg compartment Subsequently, a diluted surfactant solution, produced by dissolving the surfactant (g) water, and air may be selectively fed bto a bubble generator to form bubbles, and the bubbles thusly formed are fed bto the rnixbg compartment. All of the components, fed bto the mixbg compartment, are mixed with each other for a predetermbed time to form a paste. The paste is shaped bto a core material with a predetermbed thickness usbg the roller press while it is moved on a conveyor. The core material is cured usbg, for example, the drier b which the temperature is controlled withb a range of 10 to 200 °C to accomplish the bcombustible core material. Accordbg to the present bvention, an autoclave curing device may be used and a high frequency heating function may be provided to the roller press, so as to quickly evaporate the fire-retardant curing agent (e) and water. The bcombustible core material, produced accordbg to the wet process, is very light, and is porous, havbg a plurality of air layers therein, thereby ensuring excellent adiabatic property. Therefore, the construction product accordbg to the present bvention has excellent bcombustibility or fire-retardancy, adiabatic property, . and physical properties. Additionally, b case the construction product is used as the core material of bcombustible bterior and exterior boards, constibtbg a fire door, a fire wall an alumbum or steel plate complex board, a mab body and doors of a kitchen table, mab bodies and doors of built-b furniture, fitrniture, a lavatory partition, a partition wall, an access floor, an OA floor, a stair board, a reinforced floor, and a ceilbg finishbg material, the above constraction bterior and exterior products, bcludbg the core materials, these items have excellent bcombustibility, adiabatic property, and economic efficiency, and are efficiently lightened.
EXAMPLES 7 TO 9 An organic or borganic fiber (a), a fly ash or bottom ash (b), and a fire-proofing agent (c), stored b a silo equipped with a measuring system, were fed bto a mixbg compartment to be mixed usbg a strong air current generated by a 30 to 50 horsepower compressor, installed at a lower portion of the rnixbg compartment. At this time, an bcombustible lightenbg agent (f) may be selectively added bto the mixbg compartment through the silo, and the above components were fed bto the rnixbg compartment b amounts as described b the followbg Table 4. The mab mixbg of the components was conducted usbg a mixer, and a predetermbed amount of water was fed through a water inlet, positioned at an upper part of the mixer, bto the mixbg compartment. After the completion of the feedbg of water bto the rnixbg compartment, a fire-retardant curing agent (e) was sprayed through a spray nozzle bto the mixbg compartment. All of the components, fed bto the mixbg compartment, were mixed with each other for ten mbutes to form a paste. The paste was shaped bto a core material with a thickness of 20 m/m usbg a roller press while it is moved on a conveyor. The core material was dried and cured usbg a drier at about 100°C for 12 hours to accomplish an bcombustible core product. EXAMPLE 10
An organic or borganic fiber (a), a fly ash or bottom ash (b), a fire-proofing agent (c), and an bcombustible lightenbg agent (f), stored b a silo equipped with a measuring system, were fed bto a rnixbg compartment to be mixed usbg a strong air current generated by a 30 to 50 horsepower compressor, installed at a lower portion of the mixbg compartment. At this time, the above components were fed bto the rnixbg compartment b amounts as described b the followbg Table 4. The mab mixbg of the components was conducted usbg a mixer, and a predetermbed amount of water was fed through a water inlet, positioned at an upper part of the mixer, bto the mixbg compartment. After the completion of the feedbg of the water bto the mixbg compartment, a fire-retardant curing agent (e) was sprayed through a spray nozzle bto the mixbg compartment. Subsequently, a diluted surfactant solution, produced by dissolvbg 20 g of surfactant (g) b 1,000 g of water, and air were fed bto a bubble generator to form bubbles, and the bubbles thusly formed were fed bto the rnixbg compartment. All of the components, fed bto the mixbg compartment, were mixed with each other for ten mbutes to form a paste. The paste was shaped bto a core material with a thickness of 20 m/m and a size of 500 mm x 800 mm usbg a roller press while it is moved on a conveyor. The core material was dried and cured usbg a drier at about 100 °C for 12 hours to accomplish an bcombustible core product. Physical properties of the bcombustible core products b the examples 1 to 4 were evaluated accordbg to the above evaluation methods, and the results are described b the followbg Table 4.
TABLE 4 Physical properties of the incombustible construction products produced according to the wet process
Figure imgf000032_0001
'(a): component (a), shatteredrockwool, 2(b): component (b), fly ash, 3(c): component (c), calcium carbonate, 4(e): component (e), sodium silicate liquid containing 50% of solids, 5(l): component (f), fine perlite particle, 6Sur.: surfactant 7Shaρ.: shape of the constructionproduct, ^ire: fire-retardancy, 9Sρ.: density/specific gravity 10Subm.: submergence stability uFire res.: fire resistance
From the Table 4, it can be seen that the bcombustible core products accordbg to the examples 7 to 9 are relatively lightweight, each have a weight per unit area of 0.4 to 0.7 and first-grade fire-retardancy. Additionally, the fire resistances of the bcombustible core products accordbg to the examples 7 to 9 are evaluated havbg bcombustibility, and thus, are useful as constraction finishbg and bterior core materials. the case of the example 10, the bcombustible core product is lightweight due to bubbles thereb and has excellent hardness at a surface thereof even though a content of the shattered rock wool is reduced and the content of fly ash bcreases. Furthermore, higher content of the fly ash b the bcombustible composition brings about a higher specific gravity of the bcombustible core product, and higher content of shattered rock wool b the bcombustible composition leads to lower submergence stability of the bcombustible core product. m the method of producbg the bcombustible board or square timber accordbg to the present bvention, the compression shapbg process bcludes a first rnixbg process and a second pressbg process, the first mixbg process, the fly ash or bottom ash (b), fire- proofing agent (c), and curing fire-retardant resb (d) are mixed with each other b a form of powder usbg a mixer after they are weighed with the use of a measuring system. Subsequently, the organic or borganic fiber (a) is added bto a rnixture. At this time, the bcombustible lightenbg agent (f) may be selectively added bto the mixture. The above components are mixed with each other usbg the mixer, for instance, a super mixer (Hensel) b which sharp blades revolves at a relatively high speed to uniformly shatter and mix the components, and the bcombustible hollow filler (k) is then added bto the mixture. At this time, it is preferable that the mixbg is conducted usbg air for a relatively short time to prevent the properly shattered component (a) from bebg agglomerated. The resulting mixture is stored b a storage tank until the second pressbg process starts. Meanwhile, it is necessary to properly control contents of the components of the resulting rnixture so as to enable the constraction product to have desired specific gravity because the specific gravity of the bcombustible constraction product is changed accordbg to the use of the bcombustible constraction product. For example, when a construction product, such as a square timber of a wood fire door/wall, has the density of 1.0 to 1.2 g/cπ , it is needed to bcrease the content of the component (b) b the bcombustible composition so as to improve the specific gravity and strength of the square timber. However, because it is most preferable that a typical construction bterior board has the density of 0.7 to 0.9 g/cπf, the contents of the components constituting the bcombustible composition may be properly controlled b such a way that the content of the component (b) is reduced and the content of the component (a) is bcreased. Subsequently, the components, mixed so as to enable the constraction product to have the desired specific gravity, are pressed usbg a high pressure hot press (500 to 3,000 tons) at 60 to 200 °C for 1 to 60 mm to accomplish the bcombustible construction board. If a high pressure hot press with a high frequency heating function is used to press the bcombustible composition, the component (d) is quickly cured to significantly reduce a pressbg time of the bcombustible composition. bcidentally, the components, fed bto the press, may be pressed while reinforcement meshes, made of a glass fiber, are spread on upper and lower sides of the press to bcrease the compression and tensile strengths of the bcombustible constmction board. Meanwhile, the square timber with excellent bcombustibility for the fire door/wall may be produced accordbg to a similar procedure to b the case of the bcombustible construction board. ' Alternatively, the square timber may be produced usbg the constraction bterior board. The constraction product, havbg excellent bcombustibility, of the present bvention has various characteristics accordbg to each process, m detail, the constraction product, produced accordbg to the compression shapbg process, has a smooth surface and excellent strength, and is not deformed nor shrank during the curing process. b this regard, alun±ium, steel, acryl, or wood may be embedded, as a rebforcbg material with a shape of square timber or plate, b the constraction square timber so as to improve compression and tensile strengths of the constraction square timber during the compression shapbg process. b the present bvention, the frame of the fire door/wall is constructed usbg the bcombustible board and/or square timber, and the bcombustible core material is then added bto the frame to produce the fire door/wall. b this regard, examples of the bcombustible core material bclude lightweight foam concrete, autoclaved lightweight concrete (AL , lightweight foam mberal board, lightweight foam glass board, bulk, blanket, or mat-shaped rock wool, basaltic wool, glass wool or ceramic wool. Furthermore, a method of producbg the bcombustible core material may bclude rnixbg 1 to 80 wt% of organic or borganic fiber, 1 to 80 wt% of fly ash or bottom ash, 1 to 80 wt% of ire-proofing agent, and 1 to 60 wt% of fire-retardant curing agent with each other to produce the bcombustible composition, and shapbg the bcombustible composition usbg a roller press or an autoclave. With respect to this, the bcombustible core material is disclosed b the specification filed by this applicator. Additionally, the frame constituting the fire door may be produced usbg the bcombustible board or square timber, or usbg a conventional steel or stainless steel. At this time, the use of the conventional steel or stainless steel during the production of the frame brings about no negative effects to the fire-retardancy of the fire door. Selectively, an bcombustible steel plate, a mberal board, a rock wool board, a silica board, a plaster board, a magnesium board, or an alumba board may be further attached to one or more sides of the fire door/wall, and MDF, plywood, natural patterned- wood, bterior film, an alumbum plate, or decorative paper may be further attached to one or more sides of the fire door/wall. EXAMPLES 11 TO 14
A fly ash or bottom ash (b), a fire-proofing agent (c), and a curing fire-retardant resb (d) were mixed with each other b a rnixbg ratio as described b the followbg Table 5 usbg a mixer after they were weighed with the use of a measuring system. Subsequently, an organic or borganic fiber (a) was added bto a mixture, and uniformly mixed with the mixture while the resulting mixture was shattered usbg a super mixer (Hensel). An bcombustible hollow filler (k) was then added bto the resulting mixture. At this time, the mixbg was conducted usbg air for ten mbutes to prevent the properly shattered component (a) from bebg agglomerated. The resulting composition was stored b a storage tank before a second pressbg process was conducted. The resulting composition was then pressed usbg a high pressure hot press (about 1000 tons) at about 150°C for about 30 mm to produce bcombustible boards, each havbg a thickness of 35 m/m and a size of 900 mm x 2100 mm. Physical properties of the bcombustible boards were evaluated accordbg to the above evaluation methods, and the results are described b the followbg Table 5.
TABLE 5 Physical properties of incombustible constacuonproduc s produced according to a compression shaping process
Figure imgf000036_0001
'(a): component (a), rock wool, 2(b): component (b), fly ash, 3(c): component (c), calcium carbonate, 4(d): component (d), phenol resin, 5(k): component (k), fly ash hollow body, 6Shap.: shape of the constructionproduct, 7Fire: fire-retardancy, sSp.: density/specific gravity 9Subrα: submergence stability
From the Table 5, it can be seen that higher content of the rock wool b the composition brings about lower specific gravities of the boards of the examples 11 and 12 and the square timbers of the examples 13 and 14, produced accordbg to the compression shapbg process. Furthermore, the fire-retardancies and fire resistances of the constraction products accordbg to the examples 1 to 4 are the same as each other.
COMPARATIVE EXAMPLES 6 TO 10 Physical properties of five commercial constraction finishbg and bterior products, bcludbg MDF/plywood, a typical plaster board, a fire-proofing plaster board, a slate board, and a wood-wool cement board, were evaluated accordbg to the above evaluation methods, and the results are described b the followbg Table 6.
TABLE 6 Physical properties of the commercial construction finishing and interior products
Figure imgf000037_0001
(a): component (a), 2(b): component (b), 3(c): component (c), ''Fire: fire-retardancy, 5Sρ.: density/specific gravity 6Subm: submergence stability 7Fire res.: fire resistance
From the Table 6, it can be seen that the commercial constraction finishbg and bterior products have no fire-retardancy, second grade fire-retardancy, first grade fire- retardancy, first grade fire-retardancy, and first grade fire-retardancy for comparative examples 6 (MDF/plywood), 7 (typical plaster board), 8 (fire-proofing plaster board), 9 (slate board), and 10 (wood-wool cement board), respectively. Accordbgly, the typical and fire- proofing plaster boards have no problems b securing a fire-safety, and the slate board and wood-wool cement board are most preferable to be used as a fire-proofing material. As shown b the Table 6, the products accordbg the comparative examples 9 and 10 each have the best bcombustibility- However, each of them have a weight per unit area of 1.0 to 1.4, and thus, they are problematic b terms of their tightenbg. Additionally, the plaster boards each have the poorest submergence stability. As results, MDF or plywood, widely used as the construction finishbg and bterior material, has no fire-retardancy, and thus, it is not suitable to be used as the constmction material b consideration of the Buildbg Standards Act and the Fire Services Act. Further, the use of the plaster board is limited accordbg to uses and positions of buildbgs. As for the slate board and wood-wool cement board, they have a lot higher weight per unit area than MDF and the plaster board, thereby ease of their use b constracting buildbgs cannot be ensured. A detailed description will be given of the comparison of the examples with the comparative examples, below. As described b the Table 5, b the examples 11 and 12, the weight per unit area of the bcombustible board, produced accordbg to the compression shapbg process, is 0.7 to 0.9, which is the similar to that of MDF of the comparative example 6 as described b the Table 6. Additionally, the fire-retardancy and fire resistance of such bcombustible board are similar to those of the fire-proofing plaster board of the comparative example 8. Furthermore, the submergence stabilities of the bcombustible boards of the examples 11 and 12 are excellent, and thus, a shape of each bcombustible board is stably mabtabed b water without bebg deformed. As well, the square timbers, produced accordbg to the compression shapbg process, of the examples 13 and 14 as described b the Table 5 each have the first-grade fire- retardancy, like the slate board and wood-wool cement board accordbg to the comparative examples 9 and 10 as described b the Table 6. m addition, the square timbers are bcombustible b terms of fire resistance. Furthermore, the weights per unit area of the square timbers accordbg to the examples 13 and 14 as described b the Table 5 are l.Oto 1.2, which are similar to those (1.0 to 1.4) of the slate board and wood-wool cement board accordbg to the comparative examples 9 and 10 as described b the Table 6.
EXPERIMENTAL EXAMPLE 1
A board of the example 11 as described b the Table 5, and a square timber of the example 13 were used to construct a frame of a fire door, a core material made of ceramic wool was embedded b the fire door, and plywood was attached to any one side of the fire door to accomplish the bcombustible fire door with a thickness of 35 m/m and a size of 900 mm x 2100 mm. The bcombustible fire door was tested for fire accordbg to KS F2257 b Korea bstibte of Constraction Technology, b this regard, the bcombustible fire door was subjected to a first-grade fire door test for 1 hour, and stood the fire test as described b the followbg Table 7.
TABLE 7 Physical properties of the incombustible fire door including the board, square timber, and core material
Figure imgf000039_0001
'(a): component (a), rock wool, 2(b): component (b), fly ash, 3(c): component (c), calcium carbonate, 4(d): component (d), phenol resin, 5(k): component (k), fly ash hollow body 6Ceram.: ceramic wool, 7Shap.: shape of the constructionproduct, ^ire: fire-retardancy, ^ire res.: fire resistance I0Subm.: submergence stability "Test: fire test (1 hour)
bdustrial Applicability
As described above, the present bvention provides an bcombustible composition used to produce an bcombustible/quasi-bcombustible/fire-retardant board or square timber, b this regard, 1 to 70 wt% of the bcombustible composition may be made of a waste material. Accordbgly, the bcombustible composition of the present bvention is advantageous b that the production costs are reduced, and that it is useful as a constraction finishbg and bterior material because no fire and toxic gases occur when the board or square timber is on fire. Other advantages are that the bcombustible composition has excellent processability (saw processbg, screwbg, planbg, attachment of patterned wood and film, coating, and the like), and that an bcombustible constmction product, produced usbg the bcombustible composition, has excellent strength and water resistance, b addition, the bcombustible construction product is not easily deformed, and can so be applied to fields, to which woods or boards are applied, while havbg bcombustibility, thereby bebg applied to constmction bterior/exterior materials, m case that the bcombustible construction product is applied to a constraction board, the bcombustible construction board serves to prevent a fire from spreadbg and to shield persons from toxic gases generated by fire when the bcombustible constraction board is on fife, thereby providbg a safer environment. The present bvention has been described b an illustrative manner, and it is to be understood that the teimbology used is btended to be b the nature of description rather than of limitation. Many modifications and variations of the present bvention are possible b light of the above teachbgs. Therefore, it is to be understood that withb the scope of the appended claims, the bvention may be practiced otherwise than as specifically described.

Claims

Claims
1. An bcombustible composition, comprisbg 1 to 80 wt% of organic or borganic fiber, 1 to 80 wt% of fly ash or bottom ash, 1 to 80 wt% of fire-proofing agent, and 1 to 30 wt% of curing fire-retardant resb.
2. An bcombustible composition, comprisbg 1 to 80 wt% of organic or borganic fiber, 1 to 80 wt% of fly ash or bottom ash, 1 to 80 wt% of fire-proofing agent, 1 to 30 wt% of curing fire-retardant resin, and 1 to 60 wt% of fire-retardant curing agent.
3. An bcombustible composition, comprisbg 1 to 80 wt% of organic or borganic fiber, 1 to 80 wt% of fly ash or bottom ash, 1 to 80 wt% of fire-proofing agent, and 1 to 60 wt% of fire-retardant curing agent.
4. An bcombustible composition for a fire door/wall, comprisbg 1 to 80 wt% of organic or borganic fiber, 1 to 80 wt% of fly ash or bottom ash, 1 to 80 wt% of fire-proofing agent, 1 to 30 wt% of curing fire-retardant resb, and 1 to 40 wt% of bcombustible hollow filler.
5. The bcombustible composition as set forth b any one of claims 1 to 4, whereb the organic fiber is paper fragments shattered bto fibroid materials, shattered wood fragments, waste fibers, rice bran, vegetable fibers, or a rnixture thereof, and the borganic fiber is rock wool, glass wool, basaltic wool, ceramic wool, or a mixture thereof.
6. The bcombustible composition as set forth b claim 2 or 3, whereb the fire- retardant curing agent is sodium silicate, potassium silicate, or a rnixture thereof.
7. The bcombustible composition as set forth b any one of claims 1 to 4, whereb the fire-proofing agent is calcium carbonate, sodium bicarbonate, sodium carbonate, other carbonates, or a rnixture thereof.
8. The bcombustible composition as set forth b claim 1 or 2 or 4 , whereb the curing fire-retardant resb is a phenol resb, a fire-retardant polyester resin, or a melambe resb.
9. The bcombustible composition as set forth b any one of claims 1 to 4, further comprisbg 1 to 50 wt% of bcombustible tightenbg agent selected from the group consisting of fine perlite particles, fine vermiculite particles, rockwool wastes, diatomites, zeolites, and a mixture thereof.
10. The bcombustible composition as set forth b any one of claims 1 to 4, further comprisbg 1 to 10 wt% of additive selected from the group consisting of a curing acceleration bbder, a surfactant, an borganic coloring agent, and a rnixture thereof, and/or 1 to 60 wt% of water.
11. The bcombustible composition as set forth b claim 10, whereb the curing acceleration bbder is magnesia, plaster, borganic or organic acid mixtures, calcium silicate, or a mixture thereof.
12. The bcombustible composition as set forth b claim 10, whereb the borganic coloring agent is titanium dioxide (TiO2).
13. A method of producbg an bcombustible construction product, comprisbg: mixbg 1 to 80 wt% of organic or borganic fiber, 1 to 80 wt% of fly ash or bottom ash, 1 to 80 wr% of fire-proofing agent, and 1 to 30 wt% of curing fire-retardant resb to produce the bcombustible composition accordbg to claim 1; and pressbg the bcombustible composition usbg a high pressure hot press to give a predetermbed shape to the bcombustible composition.
14. A method of producbg an bcombustible construction product, comprisbg: rnixbg a fly ash or a bottom ash and a fire-proofing agent b a mixbg ratio, correspondbg to contents of the fly ash or bottom ash, and fire-proofbg agent b the bcombustible composition according to claim 2; spraybg a fire-retardant curing agent onto a mixture, and addbg an organic or borganic fiber bto the mixture, containbg the fire-retardant curing agent; extrudbg the resulting rnixture usbg an extrusion system, drybg the extruded mixture b a drybg system, and shattering the dried rnixture bto particles of a predetermbed size usbg a shattering device; and addbg a curing fire-retardant resb and the fire-proofbg agent to the particles to form a paste, and pressbg the paste usbg a high pressure hot press to give a predetermbed shape to the paste.
15. The method as set forth b claim 13 or 14, whereb the bcombustible constmction product is a construction board or a construction square timber.
16. The method as set forth b claim 15, further comprisbg addbg meshes, made of a glass fiber, to the bcombustible construction product to reinforce the bcombustible constraction product b case that the bcombustible constraction product is the constraction board.
17. The method as set forth b claim 15, further comprisbg embeddbg a square timber or plate shape of alumbum, steel, acryl, or wood, acting as a reinforcbg material, bto the bcombustible constmction product to reinforce the bcombustible constraction product b case that the bcombustible constraction product is the constraction square timber.
18. The method as set forth b claim 14, further comprisbg addbg the fire- retardant curing agent and water bto the rnixture, containng the organic or borganic fiber, after the addbg of organic or borganic fiber.
19. The method as set forth b claim 13 or 14, whereb an bcombustible tightenbg agent is further added, accordbg to a specific gravity of the bcombustible constraction product, bto the paste b the pressbg of the paste.
20. An bcombustible constraction product produced accordbg to the method of claim 13 or 14.
21. The bcombustible construction product as set forth b claim 20, comprisbg a board and/or a square timber for a fire door, an bcombustible board, or a fire-resisting board.
22. A method of producbg an bcombustible constraction product, comprisbg: providbg the bcombustible composition accordbg to claim 3; mixbg an organic or borganic fiber, a fly ash or bottom ash, and a fire-proofing agent with each other usbg a mixer after bebg weighed, and spraybg a fire-retardant curing agent and water onto a mixture to form a paste; pressbg the paste usbg a roller press; and drybg and curing the pressed paste usbg a drier b which a temperature is controlled from 10 to 200 °C .
23. The method as set forth b claim 22, whereb the roller press has a high frequency heating function.
24. The method as set forth b claim 22, further comprisbg usbg an autoclave curing device to quickly evaporate the fire-retardant curing agent and water.
25. The method as set forth b claim 22, whereb the bcombustible construction product is a construction finishbg or bterior core material.
26. The method as set forth b claim 22 or 24, further comprisbg feedbg a mixture of water and a surfactant, and air bto a bubble generator to form bubbles, and add g the bubbles bto the paste, before the paste is transmitted to the roller press or autoclave curing device.
27. An bcombustible construction product produced accordbg to the method of any one of claims 22 to 25.
28. The bcornbustible construction product as set forth b claim 20 or 27, comprisbg a core material of a board constituting a fire door, a fire wall, an alum um or steel plate complex board, a mab body and doors of a kitchen table, mab bodies and doors of built-b furniture, furniture, a lavatory partition, a partition wall an access floor, an OA floor, a stair board, a reinforced floor, or a ceilbg finishbg material.
29. A method of producbg an bcombustible constraction product, comprisbg: providbg the bcombustible composition accordbg to claim 4; ixbg a fly ash or bottom ash, a fire-proofbg agent, and a curing fire-retardant resb with each other; addbg an organic or borganic fiber bto a mixture, shattering the mixture contabbg the organic or borganic fiber, and mixbg an bcombustible hollow body with the shattered mixture by use of arnixer usbg air, pressbg the resulting mixture usbg a high pressure hot press to form a board or a square timber; and constructing a frame of the constraction product usbg the board and/or square timber and embeddbg an bcombustible core material bto the constraction product.
30. The method as set forth b claim 29, further comprisbg reinforcbg an inside and/or an outside of the board usbg meshes, made of a glass fiber, to improve compression and tensile strengths of the board b the pressbg of the resulting mixture.
31. The method as set forth b claim 29, further comprisbg embeddbg a square timber or plate shape of alumbum, steel, acryl, or wood bto the square timber to reinforce the square timber to improve compression and tensile strengths of the square timber b the pressbg of the resulting rnixture.
32. The method as set forth b claim 29, further comprisbg mixbg an bcombustible lightenbg agent, a curing acceleration bbder, and or an borganic coloring agent with the mixture of the fly ash or bottom ash, fire-proof g agent, and curing fire- retardant resb b the mixbg of the fly ash or bottom ash, fire-proofbg agent, and curing fire- retardant resb.
33. The method as set forth b claim 29, whereb the bcombustible core material is lightweight foam concrete, autoclaved lightweight concrete (ALC), lightweight foam mberal board, lightweight foam glass board, bulk, blanket, or mat-shaped rock wool, basaltic wool glass wool, or ceramic wool.
34. The method as set forth b claim 29, whereb the bcombustible core material is produced by rnixbg 1 to 80 wt% of organic or borganic fiber, 1 to 80 wt% of fly ash or bottom ash, 1 to 80 wt% of fire-proofbg agent, and 1 to 60 wt% of fire-retardant curing agent with each other to produce the bcombustible composition, and shapbg the bcombustible composition usbg a roller press or an autoclave.
35. An bcombustible construction product produced accordbg to the method of any one of claims 29 to 34.
36. The bcombustible constraction product as set forth b claim 35, whereb an bcombustible steel plate, a mberal board, a rock wool board, a silica board, a plaster board, a magnesium board, or an alurnba board is attached to one or more sides of the bcombustible constraction product
37. The bcombustible construction product as set forth b claim 35, wherein, MDF, plywood, natural patterned-wood, bterior film, an alumbum plate, or decorative paper is attached to one or more sides of the bcombustible constraction product.
PCT/KR2004/002447 2003-09-29 2004-09-23 Incombustible composition, incombustible construction product using incombustible composition, and method of producing incombustible construction product WO2005030671A1 (en)

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KR1020030067418A KR100635810B1 (en) 2003-09-29 2003-09-29 Incombustibility composition for a fire door or fire wall, incombustibility fire door/wall using the same and method for preparing fire door/wall
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