WO2006043435A1 - Procede de production de mousse - Google Patents

Procede de production de mousse Download PDF

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Publication number
WO2006043435A1
WO2006043435A1 PCT/JP2005/018642 JP2005018642W WO2006043435A1 WO 2006043435 A1 WO2006043435 A1 WO 2006043435A1 JP 2005018642 W JP2005018642 W JP 2005018642W WO 2006043435 A1 WO2006043435 A1 WO 2006043435A1
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WO
WIPO (PCT)
Prior art keywords
beads
resin
flame retardant
particles
foam
Prior art date
Application number
PCT/JP2005/018642
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English (en)
Japanese (ja)
Inventor
Takashi Fujimori
Original Assignee
Takashi Fujimori
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by Takashi Fujimori filed Critical Takashi Fujimori
Priority to JP2006542328A priority Critical patent/JP3950980B2/ja
Publication of WO2006043435A1 publication Critical patent/WO2006043435A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/22—After-treatment of expandable particles; Forming foamed products
    • C08J9/224—Surface treatment
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/22—After-treatment of expandable particles; Forming foamed products
    • C08J9/228—Forming foamed products
    • C08J9/232—Forming foamed products by sintering expandable particles
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/20—Oxides; Hydroxides
    • C08K3/22—Oxides; Hydroxides of metals
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/38—Boron-containing compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L25/00—Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers
    • C08L25/02—Homopolymers or copolymers of hydrocarbons
    • C08L25/04—Homopolymers or copolymers of styrene
    • C08L25/06—Polystyrene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L61/00—Compositions of condensation polymers of aldehydes or ketones; Compositions of derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2325/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Derivatives of such polymers
    • C08J2325/02—Homopolymers or copolymers of hydrocarbons
    • C08J2325/04—Homopolymers or copolymers of styrene
    • C08J2325/06—Polystyrene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2461/00—Characterised by the use of condensation polymers of aldehydes or ketones; Derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/20—Oxides; Hydroxides
    • C08K3/22—Oxides; Hydroxides of metals
    • C08K2003/2227—Oxides; Hydroxides of metals of aluminium

Definitions

  • the present invention relates to a method for producing a foam resistant to fire and heat.
  • heat insulation boards used for building materials and the like are foamed with a resin such as polystyrene in order to have heat insulation properties, and then formed into a predetermined shape such as a board shape as a V or a loose foam molded body. These closed cells provide heat insulation.
  • These heat insulation boards are lightweight, inexpensive, and have excellent properties of heat insulation. When exposed to high temperatures due to fire, etc., the resin material in these heat insulation boards dissolves quickly due to the low melting point. Then the bubbles collapse. For this reason, the entire structure of these heat insulation boards quickly shrinks, and at the same time, the resin material in these heat insulation boards starts to vaporize and burn with heat, generating black smoke and harmful with combustion. There is a risk of generating gas.
  • this type of heat-resistant board has a bubble wall made of an inorganic substance containing silicon or boron, and a synthetic resin containing hydroxyaluminum hydroxide is integrated with the wall.
  • a structure of a synthetic resin foam in which non-combustible inorganic particles are disposed between them is known (for example, see Patent Document 1).
  • this type of heat-resistant board a large number of inorganic foam particles and a foam in which gaps between these numerous inorganic foam particles are filled and these numerous inorganic foam particles are bonded to each other. It is a synthetic resin foam in which greasy inorganic powder is mixed. In the synthetic resin foam, when the inorganic powder particles in the synthetic resin foam are foamed, an amount of a volume larger than the gaps between many inorganic foam particles is mixed in the synthetic resin foam. Fireproof Insulating agent.
  • the structure of the inorganic foam and an inorganic granular and synthetic resin foam is composed of a foamed molded by foaming of inorganic granular material is known (e.g., see Patent Document 2.) 0
  • the expanded polystyrene product as the expanded molded body constituting this type of heat-resistant board contains the surface of the expanded styrene beads containing boric acid, which is a boric acid-based inorganic substance, and phenol resin, which is a thermosetting resin. It is covered with a coating film.
  • Styrofoam products coated with a coating are prepared by subjecting styrene beads to pretreatment foaming by various treatment methods and then aging, and then, for example, boric acid inorganic materials such as boric acid powder and boric acid aqueous solution, and boric acid based inorganic materials.
  • boric acid inorganic materials such as boric acid powder and boric acid aqueous solution
  • boric acid based inorganic materials such as boric acid powder and boric acid aqueous solution
  • thermosetting resin such as phenolic resin, and if necessary, amino-based resin, polyamide resin, fiber material, etc.
  • Patent Document 2 Japanese Patent Application Laid-Open No. 51-67625 (Page 2-3, Figure 1- Figure 2)
  • Patent Document 3 Japanese Patent No. 3163282 (Page 3-4, Figure 1- Figure 2)
  • boric acid-based inorganic material, thermosetting resin, etc. are again added to the pre-foamed beads obtained by mixing boric acid-based inorganic material with pre-expanded beads. Is added to produce added beads, and then the added beads are foamed. Therefore, when this added bead is subjected to water vapor and subjected to main foaming, boric acid-based inorganic material or thermosetting resin flows from the surface of the added bead, and the surface of the added bead There is a risk that it will not be coated with a coating film containing boric acid-based inorganic substances and thermosetting resin. For this reason, the primary beads must be dried twice and coated with a boric acid-based inorganic substance before the main foaming. However, this foaming operation takes time, and it is difficult to improve productivity.
  • the present invention has been made in view of the above points, and it is possible to improve the productivity of a foam in which generation of black smoke during combustion is prevented, fire resistance and heat resistance are improved, and shrinkage deformation due to heat is suppressed. It aims at providing the manufacturing method of the molded object which can be manufactured.
  • a large number of particles capable of forming a fine hollow body by foaming are pre-foamed into a large number of pre-foamed particles,
  • the flame retardant inorganic material and the thermosetting resin are mixed, dried and crushed from the glass, and each of the numerous pre-foamed particles contains the flame retardant inorganic material and the thermosetting resin.
  • a mixed layer is formed, a large number of pre-foamed particles formed on the surface of the mixed layer are filled in a mold, and a large number of pre-foamed particles filled in the mold and the mixed layer is formed on the surface
  • a foam having a predetermined shape is formed by subjecting water vapor to water and subjecting it to main foaming.
  • a large number of particles capable of forming a fine hollow body by foaming are pre-foamed to obtain a large number of pre-foamed particles.
  • the large number of pre-foamed particles are mixed with a flame-retardant inorganic material and a thermosetting resin, and then dried and crushed, so that the surface of each of these many pre-foamed particles is flame retardant.
  • a mixed layer containing an inorganic material and a thermosetting resin is formed.
  • a large number of pre-foamed particles having a mixed layer containing a flame-retardant inorganic material and a thermosetting resin on the surface are made into single particles simultaneously with drying.
  • a large number of pre-expanded particles formed on the surface of the mixed layer are filled in a mold and subjected to main steam by applying force steam to form a single particle on the surface.
  • Water vapor can be fed into the gap between the mixed layers of the pre-foamed particles on which the mixed layer is formed.
  • sufficient flame retardancy can be secured with one mixed layer, and a large number of preliminary layers can be obtained by feeding water vapor.
  • the foamed particles can be fully foamed in a shorter time. Therefore, it is possible to efficiently produce a foam having a predetermined shape having flame retardancy in a short time. Therefore, generation of black smoke during combustion such as fire is prevented, fire resistance and heat resistance are improved, and shrinkage due to fire and heat A foam with suppressed deformation can be produced with high productivity.
  • the method for producing a foam according to claim 2 is the method for producing a foam according to claim 1, wherein the large number of particles capable of forming a fine hollow body by foaming are polystyrene resin particles, and are flame retardant.
  • the functional inorganic material is aluminum hydroxide and boric acid, and the thermosetting resin is at least one of phenol resin and carboxylic acid resin.
  • a large number of particles capable of forming a fine hollow body by foaming are polystyrene resin particles, the flame-retardant inorganic material is hydroxyaluminum and boric acid, and the thermosetting resin is phenolic resin. It was set as at least any one of fat and carboxylic acid rosin. As a result, a foam composed of a large number of polystyrene resin particles on the surface of which a mixed layer containing at least one of phenol resin and carboxylic acid resin, hydroxyaluminum, and boric acid was formed. Can be manufactured with high productivity.
  • the method for producing a foam according to claim 3 is the method for producing a foam according to claim 1 or 2, wherein a number of pre-foamed particles are difficult to be added together with a flame-retardant inorganic material and a thermosetting resin.
  • a flame retardant is mixed, dried and crushed, and a mixture containing the flame retardant inorganic material, the thermosetting resin and the flame retardant on the surface of each of these pre-foamed particles. It forms a composite layer.
  • a large number of pre-expanded particles are mixed with a flame-retardant agent together with a flame-retardant inorganic material and a thermosetting resin, and then dried and crushed.
  • a mixed layer containing each of a flame retardant inorganic material, a thermosetting resin and a flame retardant is formed on each surface.
  • the method for producing a foam according to claim 4 is the method for producing a foam according to claim 3, wherein the flame retardant is at least one of red phosphorus and ammonium polyphosphate. It is.
  • the method for producing a foam according to claim 5 is the method for producing a foam according to claim 1, wherein the flame retardant inorganic material is a flame retardant inorganic viscosity modifier. Therefore, mica is used as the flame retardant inorganic viscosity modifier.
  • the flame retardant inorganic material is a flame retardant inorganic viscosity modifier, and the viscosity can be adjusted by using mica as the flame retardant inorganic viscosity modifier. It becomes difficult for fine powder to scatter and fall off. Therefore, the flame retardancy can be further improved, and at the same time, the thermosetting resin can be made sticky, so that the strength can be further improved and cracking during combustion can be prevented.
  • a single mixed layer has sufficient flame retardancy.
  • a large number of pre-expanded particles can be foamed in a shorter time by feeding water vapor. Therefore, a foam with a predetermined shape having flame retardancy can be produced efficiently and in a short time, so that the generation of black smoke during combustion such as a fire is prevented and the fire resistance and heat resistance are improved.
  • a large number of particles capable of forming a fine hollow body by foaming are polystyrene resin particles, and the flame-retardant inorganic material is hydroxyaluminum hydroxide and Boric acid, thermosetting resin, thermosetting resin at least one of phenolic resin and carboxylic acid resin, and at least one of phenolic resin and carboxylic acid resin;
  • a foam composed of a large number of polystyrene resin particles having a mixed layer containing aluminum hydroxide and boric acid formed on the surface can be produced with high productivity.
  • each of the pre-foamed particles is mixed with a mixed layer containing each of the flame-retardant inorganic material, the thermosetting resin and the flame retardant.
  • red phosphorus and polyphosphorus are used as the flame retardant.
  • the flame retardant can be properly used according to the operating temperature, so it is easier to ensure the flame retardancy of the foam.
  • the viscosity is adjusted by using the flame retardant inorganic material as a flame retardant inorganic viscosity modifier, and using mica as the flame retardant inorganic viscosity modifier.
  • FIG. 1 is a perspective view showing an embodiment of a polystyrene foam product according to the present invention.
  • FIG. 2 is a partially enlarged cross-sectional view showing the same expanded polystyrene product.
  • FIG. 3 is a photograph showing the combustion state of the polystyrene foam product.
  • FIG. 4 is a photograph showing Example 5 of the expanded polystyrene product of the present invention.
  • FIG. 5 A photograph showing a combustion test of the above polystyrene foam product.
  • FIG. 6 This is a photograph showing the state immediately after the completion of the 9-minute combustion test of the polystyrene foam product.
  • A Photograph showing the entire expanded polystyrene product after the combustion test
  • b Photograph showing the burning part of the foamed polystyrene product from the above
  • c Photograph showing the central part of the burning part of the foamed polystyrene product
  • d Photograph showing the cross section of the center of the burning part
  • FIG. 7 is a graph showing the results of a corn calorimeter test in Example 6 of the expanded polystyrene product of the present invention.
  • FIG. 8 is a photograph showing the same polystyrene foam product.
  • FIG. 9 is a photograph showing the same polystyrene foam product. Explanation of symbols
  • reference numeral 1 denotes a polystyrene foam product as a foam.
  • This polystyrene product 1 is made of polystyrene ( ⁇ CH—CH (C H) ⁇ ) resin as a molded body made of a porous foamed resin to which a foaming material is added.
  • porous foamed resin particles 2 that are foamed to a predetermined size by foaming treatment of styrene beads, which are beads.
  • these porous foamed resin particles 2 are particles obtained by impregnating butane gas or the like into styrene beads and foaming. Further, on the surface which is the outer peripheral surface of the porous foamed resin particles 2, a skin 2a of styrene beads is formed.
  • Each of the porous foamed resin particles 2 is formed into a substantially spherical shape.
  • each of these porous foamed resin particles 2 is consolidated into a predetermined shape, for example, a rectangular plate shape as a whole.
  • the expanded polystyrene product 1 has a foamed molded article structure in which the porous foamed resin particles 2 are in close contact with each other and are integrally molded.
  • the polystyrene foam product 1 is used as, for example, a building material board used for a building material or material that requires flame retardancy, a panel as a structural member, a molded product, and a lightweight molded member.
  • the coating layer 3 includes, for example, a flame retardant inorganic compound that is a flame retardant inorganic material, a flame retardant, a thermosetting resin, an amino resin, a polyamide resin, a fiber material, and the like.
  • a flame retardant inorganic compound for example, hydroxyaluminum (Al (OH)) or hydroxide magnesium hydroxide is used.
  • Flame retardant inorganic powders such as Nesmu (Mg (OH)), and boron-based inorganic compounds such as Boric acid BO). Further, as a flame retardant, for example, red phosphorus (P)
  • the coating layer 3 is made to be extremely flame retardant with polyphosphorus ammonium such as polyphosphorus ammonium.
  • the thermosetting resin include resol resin as phenol resin, and carboxylic acid resin.
  • this carboxylic acid resin has substantially the same properties as phenolic resin and is not relatively expensive, it can be used in place of this phenolic resin or as a thermosetting resin with this phenolic resin. .
  • red phosphorus is included in the coating layer 3 as a flame retardant, the red phosphorus is immediately carbonized during heating to block oxygen, so that the coating layer 3 can be made difficult to burn. Further, red phosphorus is added to the coating layer 3 when the temperature during the main foaming cannot be increased. Further, ammonium polyphosphate is added to the coating layer 3 when the temperature during the main foaming is raised. At this time, when the porous foamed resin particle 2 under the coating layer 3 is styrene, the heat-resistant temperature is low, so the temperature cannot be raised so much. In this case, red phosphorus is added. .
  • the coating layer 3 has a molecular weight of about 2500, preferably about 3000. Further, the coating layer 3 is composed of at least one of a boron-based inorganic compound and a flame retardant inorganic compound, and a thermosetting resin containing a flame retardant mixed as necessary. Yes. At this time, the coating layer 3 is integrated by bringing a large number of porous foamed resin particles 2 into close contact via the coating layer 3. Further, the resin constituting the cell-like structure of each of these many porous foamed resin particles only needs to be capable of forming a minute hollow body by a technique such as foaming.
  • the resin constituting the porous foamed resin particles 2 is not particularly limited, for example, general-purpose plastics such as polystyrene, polyethylene, polypropylene, polysulphated bulls, polyamides, polycarbonates, modified polyphenylene ethers.
  • Engineering plastics such as polyethersulfone and polyester ABS can be applied.
  • the softening point of polystyrene is 80 ° C or higher and 100 ° C or lower, and the long-term continuous use temperature is 50 ° C. Therefore, when used in an environment above this temperature, it is necessary to use engineering plastics such as polycarbonate resin and polyamide resin, which have a softer point and higher strength.
  • red phosphorus is suitable when the long-term continuous use temperature is 50 ° C. Therefore, it is preferable to add red phosphorus to the coating layer 3. If the softening point is higher than this, polyphosphoric acid ammonium is suitable. Therefore, it is preferable to add polyphosphoric acid ammonium to the coating layer.
  • thermosetting resin containing at least one of a boron-based inorganic compound, a flame retardant inorganic compound, and a flame retardant constituting the coating layer 3
  • a phenol resin or a coal acid resin is used as the thermosetting resin containing at least one of a boron-based inorganic compound, a flame retardant inorganic compound, and a flame retardant constituting the coating layer 3.
  • urea resin, melanin resin, guanamine resin, silicone resin, and polyimide resin can be used as thermosetting resin such as polyamideimide resin.
  • this coating layer 3 contains
  • flame retardant inorganic compounds include shirasu balloons, which are fine hollow glass spheres, aluminum hydroxide (Al ( ⁇ ), silicon (Si), or diatomaceous earth): L m or more 200
  • Inorganic powders which are inorganic fibers as an inorganic material exhibiting a neutral or acidic size of about m or less, are suitable.
  • various ceramics, carbon black, and the like can be used as the inorganic powder particles in order to ensure more flame retardancy.
  • the flame retardant added in a small amount to the coating layer 3 is one that causes an instantaneous dissolution carbonization phenomenon at the time of combustion, blocks oxygen from the outside, and exerts a great effect in preventing combustion. That's fine.
  • the flame retardant inorganic material contained in the coating layer 3 includes mica, which is a silicate mineral having a foil-like structure, alumina (Al 2 O 3), white clay (kaolin or China
  • Clay calcium carbonate (CaCO), chromium oxide (Cr O or CrO, etc.),
  • a cellular structure is formed in order to obtain a molded body in which a large number of porous foamed resin particles 2 are in close contact with each other.
  • a certain degree of adhesion is required between polystyrene, which is a resin, and a thermosetting resin containing a boron-based inorganic compound or a flame-retardant inorganic compound and a flame retardant. Even if the properties are not sufficient, the cohesive properties of both types of coffins are intercalated between the porous foamed resin particles 2 and the coating layer 3 as an intermediate layer (not shown). It is also possible to improve this.
  • thermosetting resin in addition to the thermosetting resin contained in the coating layer 3, another thermosetting resin different from the thermosetting resin may be added and mixed.
  • other thermosetting resins different from this thermosetting resin include, for example, polyimide resin, polyvinyl formal resin, polyethersulfone resin, and acrylonitrile whose terminal group is carboxylic acid. Polybutadiene copolymer or the like can be used.
  • the coating layer 3 which is a layer of a thermosetting resin containing a boron-based inorganic compound or a flame-retardant inorganic compound and a flame retardant constitutes an outer layer of the porous foamed resin particles 2.
  • the porous foamed resin particles 2 are given fire resistance, heat resistance and flame retardancy.
  • Sarakuko this coating layer 3 is usually in a solidified or semi-cured state at the temperature in the foaming process in order to obtain the foaming process of the primary beads to obtain a cellular structure.
  • the coating layer 3 is added with a reinforcing resin such as carbon short fiber as carbon fiber, glass short fiber as glass fiber, synthetic resin fiber, natural fiber, etc.
  • a reinforcing resin such as carbon short fiber as carbon fiber, glass short fiber as glass fiber, synthetic resin fiber, natural fiber, etc.
  • the properties such as strength, fire resistance, heat resistance and flame retardancy can be improved.
  • the coating layer 3 is mixed with a curing accelerator that promotes mixing of the thermosetting resin contained in the coating layer 3. And this hardening accelerator adjusts the hardening acceleration of a thermosetting resin by adjusting the mixing amount of this hardening accelerator, and blocks hardening acceleration of the coating layer 3.
  • the curing accelerator include phenol sulfonic acid and toluene sulfonic acid.
  • polystyrene beads that have been pretreated by impregnation with a foaming agent, etc., and containing the foaming agent are used as the primary beads.
  • the primary bead is a commercially available polystyrene bead having an original diameter of about 0.2 mm or more and 1. Om m or less.
  • the above-mentioned raw beads are pre-expanded to a predetermined ratio, for example, 5 to 90 times or 20 to 100 times (preferably 90 times) to obtain pre-expanded beads. That is, the primary beads are pre-foamed prior to the coating step described later. And The pre-expanded beads are used after being aged for 12 to 24 hours (preferably about 20 hours) and completed to maintain the stability of commercialization. In addition, the pre-expanded beads may be consumed within the molding process, which will be described later, within one week as much as possible, and used up without significant influence due to diffusion of residual gas in the pre-expanded beads. ,.
  • pre-foaming method used when producing the pre-foamed beads there are various treatment methods such as steam, radiant heat, infrared hot air, hot water and the like.
  • thermosetting resin a thermosetting resin, a boron-based inorganic compound, and a flame-retardant inorganic compound are mixed 1: 1 or each alone.
  • the pre-expanded beads are contained in these many pre-expanded beads.
  • a flame-retardant material is used in combination with the flame-retardant inorganic compound mixed in the mixture so that the ratio is about 5 to 20% by mass, and the mixture is mixed and stirred to form a coating layer 3 having a predetermined thickness.
  • the pre-expanded beads are mixed so that the total of the thermosetting resin, boron-based inorganic compound, and flame-retardant inorganic compound is in the ratio of 5: 1 to 1: 5.
  • thermosetting resin increases due to the flame-retardant inorganic compound added to the thermosetting resin used as the coating layer 3, and the coating layer 3 is thick and thick. If it does not become a so-called chocolate-like state, add 3 to 10% by weight of water or 5 to 10% by weight of methanol to the thermosetting resin. Then, adjust the viscosity of this thermosetting resin.
  • thermosetting resin phenol resin (resol), boron-based inorganic compound, Boric acid (H BO), and hydrated aluminum hydroxide as a flame retardant inorganic compound,
  • thermosetting resin a required amount of a curing accelerator such as phenolsulfonic acid or toluenesulfonic acid having a solid content of about 75% is added to the thermosetting resin, and then stirred and dispersed well. At this time, mix with a specified machine such as an automatic stirrer or a ribbon mixer for about 2 minutes for 4 minutes (preferably about 2 minutes for 2 minutes). After this mixing, stir for 4 to 5 minutes.
  • a curing accelerator such as phenolsulfonic acid or toluenesulfonic acid having a solid content of about 75%
  • these large numbers of coated pre-expanded beads are dried by blowing air, that is, air-dried. A portion of a number of coated pre-expanded beads is crushed.
  • the coated pre-expanded beads partially crushed are dried while being crushed at a temperature of about 55 ° C to 3 ° C until they are completely made into single particles.
  • the drying time at this time should be as short as possible with hot air, preferably within 5 minutes, more preferably about 3 minutes, if the coated pre-expanded beads have become single grains. Further, if the drying temperature at this time is too high, gas escapes from the covered pre-expanded beads, which is not preferable. Therefore, drying is performed at a temperature of about 55 ° C ⁇ 3 ° C. At this time, special care must be taken when setting a high magnification of 60 times or more and 90 times or less.
  • these numerous coated pre-expanded beads are vibrated into a single particle by shaking them with a sieve. It is set as the single particle bead.
  • Single particle beads produced by the above drying process are automatically molded or blocked.
  • the mold is automatically filled with air.
  • vacuum cooling which is vacuum cooling, is performed after heating in the same manner as in a general expanded polystyrene resin (Expandable PolyStyrene: EPS) molding method. Demold after molding. At this time, generally, the larger the foaming rate, the shorter the heating amount and the cooling time.
  • EPS Expandable PolyStyrene
  • the heating time is about 30 seconds or more and 60 seconds or less. Therefore, it is suitable for Styrofoam product 1 foamed at high magnification. However, a heating time of about 60 seconds is sufficient, depending on the size of the molded product.
  • a high-quality foamed polystyrene product 1 can be manufactured by a high-frequency heating method, a hot plate heating method, or a hot plate press method, but generally one cycle time is required as compared with the steam forming method. It takes.
  • the high-frequency heating method, etc. it is possible to use the panel depending on the situation because it can be made very efficient by forming it while adhering the single particle beads to the metal plate.
  • It can also be formed by chopping and filling by a normal steam forming method or high-frequency heating method, or by chopping by a chopping method in which the rice is horizontally filled so as to measure rice.
  • these single particle beads are formed on the outer surface of these single particle beads into a thermosetting resin containing a boron-based inorganic compound, a flame retardant inorganic compound, and a flame retardant. It expands together with the coating layer 3 configured as described above and comes into contact with each other. At this time, the inner layer and the outer layer of these single particle beads are bonded and cured by heating, and are cured and bonded together with the coating layer 3 on the outer surface of the adjacent single particle beads. As a result, the porous foamed resin particles are bonded to each other in the form of cells to form a group of cells (cells), so that the molded body has a predetermined shape along the inner surface of the mold.
  • Styrofoam product 1 Styrofoam product 1
  • the primary bead is pre-expanded into a pre-foamed bead. Thereafter, the pre-foamed beads are mixed with a thermosetting resin containing a flame retardant inorganic compound, and the surface is coated with a coating layer 3 containing the flame retardant inorganic compound and the thermosetting resin. The pre-expanded beads were then dried and crushed into single particles. [0059] As a result, a large number of pre-expanded particles whose surfaces are covered with the coating layer 3 containing a flame-retardant inorganic compound and a thermosetting resin are converted into single particles to form a large number of single-particle beads.
  • the molecular weight of phenol resin in the coating layer 3 on the surface of the large number of single-particle beads is increased to about 3000, and the amount of the curing accelerator used in the coating layer is adjusted.
  • the coating layer 3 also flows over the surface force of these many single particle beads. It becomes ⁇ . Therefore, compared to the double coat method, which coats the surface of a large number of single particle beads in two stages, a single coat that forms a single coating layer on the surface of these large number of single particle beads is sufficient.
  • the foamed polystyrene product 1 to be finally produced has a thickness of about 100 mm to 60 Omm, the heating time of about 30 to 60 seconds, and the effect of subsequent vacuum cooling As a result, one cycle of the foaming of the expanded polystyrene product 1 can be performed in about 3 to 4 minutes, which enables mass production of the expanded polystyrene product 1.
  • the expanded polystyrene product 1 formed by the main foaming of these many single-particle beads can be efficiently produced. For this reason, as shown in Fig. 3 (a) to Fig. 3 (c), it is possible to prevent the generation of black smoke during combustion, improve the fire resistance, and suppress the shrinkage deformation due to heat. 1 can be manufactured with good productivity. At this time, as shown in FIG. 3 (c), the surface of the ignited and carbonized portion of the expanded polystyrene product remains smooth even immediately after the flame is removed. There is. As shown in Fig. 3 (d), in the conventional polystyrene, a large amount of black smoke is generated even after 10 seconds of ignition, so it is not easy to copy the combustion state in the photograph.
  • the coating layer 3 is of extremely low molecular weight or the resin is slowly cured, a large number of single particle bead forces may flow through the coating layer 3 in this case.
  • the coating layer 3 is not preferable because it adheres to the inner surface of the mold.
  • the porous foamed resin particles 2 are made of polystyrene resin, and the flame retardant inorganic compound contained in the coating layer 3 on the surface of the porous foamed resin particles 2 is made of hydroxyaluminum hydroxide and boron. System Boric acid, an inorganic compound.
  • the thermosetting resin contained in the coating layer 3 was phenol resin.
  • the coating layer 3 contains a boron-based inorganic compound, when the coating layer 3 is ignited, the coating layer 3 is cracked and the generation of smoke is reduced.
  • the expanded polystyrene product 1 can be easily and inexpensively manufactured by the same manufacturing method as conventional expanded polystyrene, the expanded polystyrene product 1 can be manufactured with higher productivity.
  • the foamed polystyrene product 1 to be produced is strong against fire, and it is possible to surely suppress shrinkage deformation due to heat, and the fibers in the coating layer 3 of the foamed polystyrene product 1
  • the strength can be further improved by adding the fiber of the material. Therefore, it is possible to further improve the fire resistance and flame retardancy of the produced expanded polystyrene product 1 and to further suppress shrinkage deformation.
  • a flame retardant such as ammonium polyphosphate or red phosphorus is added at a ratio of 5% to 10% in the inorganic powder. Add more.
  • the flame retardant due to the carbonization effect of the expanded polystyrene product 1, that is, the oxygen barrier effect.
  • red phosphorus or ammonium polyphosphate as a flame retardant to be mixed with the coating layer 3, the flame retardant can be properly used according to the operating temperature at the time of foaming. It is easier to ensure the flame retardancy of 1.
  • a boron accelerator, a flame retardant inorganic compound, and a thermosetting resin together with a curing accelerator mixed with a number of pre-foamed beads, and dried and crushed into a large number of single particles. Formed single particle beads.
  • the curing of the coating layer 3 when the large number of single particle beads are foamed can be adjusted by adjusting the amount of the curing accelerator contained in the coating layer 3. Therefore, a large number of single-particle beads whose surfaces are coated with the coating layer 3 to form single particles can be more effectively foamed in a short time.
  • the primary beads that will become the porous foamed resin particles 2 are pre-foamed at a predetermined ratio and preliminarily expanded. Use foamed beads.
  • the main foaming step of the pre-foamed beads after the coating layer 3 is formed can be made smooth.
  • the expanded polystyrene product 1 in which the surface of the porous foamed resin particle 2 is coated with a coating layer 3 made of a boron-based inorganic compound, a flame-retardant inorganic compound, and a thermosetting resin is V
  • the fire-resistant and heat-resistant properties can be effectively exhibited by the cellular structure of the porous foamed resin particles 2 constituting the expanded polystyrene product 1.
  • the cellular structure of the porous foamed resin particles 2 enhances the heat insulating effect
  • the coating layer 3 is resistant to heat such as fire due to heat resistance and oxygen blocking effect due to rapid carbonization. Contributes to the further effect of flame retardancy.
  • the coating layer 3 made of a mixture of a boron-based inorganic compound, a flame retardant inorganic compound and a thermosetting resin does when heated.
  • the thermosetting resin is considered to be thermoset with heating to maintain the cellular structure of the porous foamed resin particles 2.
  • the vitrified boron-based inorganic compound covers the thermosetting resin that maintains the shape of the cured bubbles and shields it from the outside air.
  • ⁇ ⁇ aluminum hydroxide, a flame-retardant inorganic compound used in combination also contributed to moisture (HO).
  • combustion and burning are prevented by releasing 2 to the outside air, preventing flammability, and combining with a small amount of carbonization such as red phosphorus to quickly shut off oxygen in the outside air.
  • thermosetting resin that is cured by fire and heat such as a fire to maintain a foam-like structure, and porous foamed resin particles that are melted and cured in the process of curing the thermosetting resin 2
  • the combination of inorganic compounds to be mixed with the thermosetting resin is limited to the above-described embodiment as long as the reaction can be prevented by blocking the oxygen from the outside air and preventing the reaction at a higher temperature. Absent.
  • the reaction region of the expanded polystyrene product 1 also progresses to some extent with the progress of the heating, but the porous foamed structure by the porous expanded resin particles 2 described above. Since the range to which the heating is applied is limited by maintaining the temperature, the heating of the expanded polystyrene product 1 does not proceed beyond a certain level.
  • the porous foamed resin supporting the shape of the porous foamed resin particles 2 constituting the foamed polystyrene product 1 is converted into the porous foamed resin by a heating process when the foamed polystyrene product 1 is produced. It fuses with the thermosetting resin in the coating layer 3 that coats the particles 2 to be integrated.
  • the porous foamed resin particles 2 have a synergistic effect with the vitrification of boron-based inorganic compounds and the rapid action carbonization of red phosphorus and the like, and the synergistic effect of water release by the flame-retardant inorganic compounds. And the shape of the coating layer 3 is maintained.
  • the foamed polystyrene product 1 has characteristics such as lightness, strength, water resistance, and stability as a raw material, and boron based inorganic compounds and flame retardant inorganic compounds covering the surface of the porous foamed resin particles 2 are also used.
  • the coating layer 3 made of red phosphorus or polyphosphoric acid ammonium and a thermosetting resin in an amount of 5% by mass to 20% by mass of the inorganic additive is relatively light, thin and chemically stable. It has a certain strength. At this time, the strength required in the expanded polystyrene product 1 is for a relatively uniform surface load, and therefore, the inherent properties such as strength can be maintained.
  • this expanded polystyrene product 1 it can be efficiently and effectively produced by utilizing a conventional foam molding process such as polystyrene foam. Therefore, in order to form the porous foamed resin particles 2, a foaming agent is included! / Soot is pre-foamed beads impregnated with foaming gas and pretreated to complete foaming at the desired magnification.
  • a coating layer 3 is formed by coating with a thermosetting resin mixed with a boron-based inorganic compound, a flame-retardant inorganic compound, and a small amount of a flame retardant such as red phosphorus or ammonium polyphosphate. Into single particles. Thereafter, the single-particle beads formed with the coating layer 3 and formed into single particles are heated and foamed to obtain a foamed polystyrene product 1 having a predetermined shape.
  • a boron-based inorganic compound or a flame-retardant inorganic compound is formed on the outer surface of the porous foamed resin particles 2 forming the original cellular structure by the coating layer 3 constituting the expanded polystyrene product 1. It has the same effect as a structure in which a number of thermosetting resin layers having a flame-retardant carbonization blocking action composed of a flame retardant are stacked. Therefore, the coating layer 3 having a very rapid effect can be formed on the surface of the porous foamed resin particles 2.
  • the structure in which the coating layer 3 is formed on the surface of the porous foamed resin particles 2 makes it possible to achieve a fire resistance that cannot be achieved by using only the porous foamed resin particles 2 that essentially form a cellular structure.
  • Properties such as heat resistance, flame retardancy, and shape maintenance characteristics can be imparted to the expanded polystyrene product 1.
  • boron-based inorganic compounds constituting the coating layer 3 flame retardant aluminum hydroxide, aluminum
  • a liquid thermosetting resin is used.
  • the precursor or the uncured thermosetting resin may be applied by various methods, or the solvent may be evaporated after being dissolved in a solvent such as alcohol.
  • these methods have appropriate characteristics and fluidity under conditions such as heating in the above-described foaming step, which may be appropriately selected according to the type and properties of the thermosetting resin. It is sufficient that the coating layer 3 having a uniform film thickness can be generated on the surface of the porous foamed resin particles 2 formed by the foaming.
  • semi-hardened pre-foamed beads which are in a state where the coating layer 3 having a uniform film thickness is formed on the surface and hardened to some extent, are filled in the mold as they are and heated to about 110 ° C by indirect heat.
  • this method takes too much time to form. Therefore, the pre-expanded beads whose surface is uniformly coated with the coating layer 3 are dried while tacking with hot air having a temperature of about 55 ° C ⁇ 3 ° C, and with a small amount of pressure.
  • the block-shaped material is pulverized to form single grains, and further shaken while shaking to completely form single particles to obtain a large number of single particle beads.
  • the drying at this time may be a little longer, but in the case of forced drying, it should be completed in about 3 to 5 minutes at a temperature of about 55 ° C ⁇ 3 ° C. That is, the purpose is to make the pre-foamed beads into single particles.
  • thermosetting resin in these pre-expanded beads obtains the B stage that is the standard flow from the cottage before the standard flow, and the C stage exceeds the standard flow. Complete curing. For this reason, in the case of heating drying at a temperature of about 55 ° C and 3 ° C, centering on air drying, the curing of the thermosetting resin was stopped in the middle of the B stage. If it can be crushed and semi-cured particles are produced, the force of 2 minutes should be as short as 3 minutes.
  • Phenolic sulfonic acid (curing accelerator) 7.5PHR (for thermosetting resin) d Boric acid (boron-based inorganic compound) 30PHR (for pre-foamed beads)
  • the foam coated beads formed by mixing from a to f were air-dried and then roughly crushed. After that, it was dried for about 5 to 10 minutes at a temperature of 55 ° C ⁇ 3 ° C, pulverized, vibrated with a force sieve and made into single particles, and the surface was coated with a coating layer 3. Single particle beads.
  • a hot plate press method using a mold having a length of 230 mm x width 230 mm x thickness 30 mm and a hot plate is 110 ° Heat at C temperature for about 5 minutes, then cool for about 20 minutes to form Styrofoam product 1.
  • this expanded polystyrene product 1 was a density of 76 kgZm 3 , a compressive strength of 42 NZcm 2 , a water absorption of 0.31 gZlOOcm 2 and an oxygen index of 38.7.
  • Example 2
  • Phenolic sulfonic acid (curing accelerator) 10PHR (for thermosetting resin)
  • a large number of these single particle beads are formed by a vapor method which is an automatic forming method. Specifically, after filling a large number of these single-particle beads into a heating mold having an internal dimension of 300 mm in height, 300 mm in width, and 30 mm in thickness, after heating with 0.6 kgZcm 3 of water vapor for about 40 seconds, 2 Cool for about a minute to form Styrofoam product 1.
  • the main physical property of this expanded polystyrene product 1 is that the density is 0. O47g / cm 3 0lS A
  • red phosphorus (flame retardant) 10 PHR (7 mass 0/0 of boron-based inorganic compound and flame-retardant inorganic compound)
  • this chocolate-like product was mixed in a prepared in a stirrer and mixed with power. After stirring for about 2 to 3 minutes, finally put h and power for 1 minute. Gently stir for about 2 minutes to discharge the stirrer power as coated beads.
  • the coated beads are spread thinly to increase the surface area and air-dried, and then roughly crushed while maintaining a certain tackiness. Furthermore, hot air of about 55 ° C ⁇ 3 ° C is applied to the roughly crushed coated beads and dried for about 8 minutes for 5 minutes, and then further crushed and made into single particles. Store and use a large number of single-particle beads that have been completely made into single particles.
  • the stored single particle beads are subjected to vapor molding by an automatic molding method. Concrete Specifically, after filling a large number of single-particle beads into a mold having internal dimensions of 300 mm in height, 300 mm in width, and 30 mm in thickness, after heating for about 35 seconds at a steam pressure of 0.6 kgZcm 3 Cool for about 2 minutes to form Styrofoam product 1.
  • this expanded polystyrene product 1 is as follows: density is 0.04 gZcm 3 , compression strength is 20 NZcm 2 , water absorption is 0.3 gZlOOcm 2 , and thermal conductivity is 0.032 W / m- At K, the oxygen index was 30.5.
  • the flame retardant contained in the coating layer 3 of the expanded polystyrene product 1 has a fireproof temperature and a heat resistant temperature when the porous foamed resin particles 2 such as polystyrene are used. Since this is low, red phosphorus is generally more suitable.
  • the porous foamed resin particles 2 having a fire resistance and heat resistance of 100 ° C or higher the polyphosphate ammonia is red depending on the decomposition temperature of the porous foamed resin particles 2.
  • red phosphorus is generally suitable because it is more effective at low temperatures than ammonium polyphosphate.
  • the expanded polystyrene product 1 molded in each of the above-described embodiments can exhibit fire resistance, heat resistance and flame retardancy in applications of conventional expanded molded articles such as polystyrene and polyurethane. It can also be used appropriately for powerful applications that cannot be applied.
  • it can be a three-dimensional box-shaped product with various shapes or a foamed molded product with a pattern.
  • a resin-enhanced material added to the thermosetting resin constituting the coating layer 3, a powdered inorganic material, and a combination of resin can give new characteristics and can be applied for various uses. .
  • roof materials such as heat insulating tiles, outer heat insulating materials, heat insulation materials such as a ceiling or a floor, and the like are conceivable.
  • Panels, furniture, partitions, wall materials, etc. can be considered as lightweight flame retardant boards for various applications.
  • heat insulation structural materials for various applications heat insulation materials for air conditioning ducts, cold insulation and heat insulation equipment, mannequins, and the like are conceivable.
  • the above-mentioned expanded polystyrene product 1 has the same lightness and heat insulation properties as those of conventional foamed molded products such as foamed polystyrene and polyurethane foam as foamed molded products for various applications. Can be used similarly, heat resistance, flame retardant It is excellent in safety and shape maintenance, and can cope with the safety aspect of disaster countermeasures such as fire.
  • the coating layer 3 that covers the surface of the porous foamed resin particles 2 can be selected by appropriately selecting the type of resin that constitutes the coating layer 3, or other types of resin can be inorganic or organic substances. For example, properties such as flexibility, strength, and hardness can be imparted more favorably by mixing and mixing.
  • the flame retardant inorganic compound an inorganic material having a density as low as possible is used, and the weight is reduced so as to be close to the density of ordinary styrene, urethane, phenol foam, and the like.
  • the heating time and the cooling time are shortened and the product density is reduced, so that the material cost ratio can be reduced and the thermal conductivity can be improved.
  • the so-called flame retardant grade 3 can be ensured, but the flame retardant property of the expanded polystyrene product 1 is further improved to ensure the so-called flame retardant grade 2. Therefore, various ceramics, diatomaceous earth, carbon black, etc. may be mixed as a mixture of the coating layer 3 of the expanded polystyrene product 1.
  • Example 4
  • the expansion ratio of the expanded polystyrene resin is a force that varies depending on the strength to be obtained. Generally, the expanded ratio of the expanded polystyrene resin is preferably from 60 to 100. In addition, since resole resin generally has a smaller mass of the expanded polystyrene resin as the base material when the expansion ratio is increased, this resin resin is generally 120 PHR or more and 150 PHR or less with respect to the expanded polystyrene resin. It is good to use.
  • toluenesulfonic acid it is preferable to use it in the range of 6 PHR or more and 10 PHR or less with respect to resol resin.
  • boric acid has a low density, it is desirable to use it in large quantities. However, it may be partially dissolved by steam during molding. For this reason, when manufacturing Styrofoam products 1, it is better to reduce the use ratio of boric acid to about 1% as much as possible under the conditions of factory facilities where the cooling water is drained directly to river 11.
  • mica is used as a flame retardant inorganic viscosity modifier, and generally used in a range of 5 PHR to 50 PHR with respect to expanded polystyrene resin.
  • inorganic flame retardant powder iller
  • the viscosity of this expanded polystyrene resin can be adjusted by adding mica to the expanded polystyrene resin, so that fine powder will not scatter during drying and other inorganic additives will not fall off.
  • the other flame retardant added to the expanded polystyrene resin does not fall off, the flame retardancy of the expanded polystyrene product 1 can be further improved.
  • the resole resin added as a binder to the expanded polystyrene resin becomes somewhat sticky.
  • the strength of the polystyrene product 1 can be further improved, and the problem of cracks occurring when the foamed polystyrene product 1 is burned can be prevented to some extent.
  • red phosphorus is generally a very expensive material, it should be used as much as possible with respect to the expanded polystyrene resin at a level of 5 PHR to 10 PHR, preferably 7.5 PHR or less.
  • a polystyrene foam product 1 having a density of 0.075 and a fusion rate of 100% can be produced.
  • the portable cylinder (not shown) fully opened to a flame length of about 25 cm to 30 cm, bring this portable cylinder close to a position 10 mm away from the polystyrene foam product 1 to create a flame.
  • the after-flame disappeared in 4 seconds in the part where the foamed polystyrene product 1 was exposed to flame, and the depth of the carbonized part was about 49 mm.
  • Aluminum hydroxide (a flame retardant inorganic compound) 150PHR (for pre-expanded beads) e Boric acid (boron-based inorganic compound) 5PHR (for pre-expanded beads)
  • a polystyrene foam product 1 having a density of 0.0812 and a fusion rate of 100% can be manufactured.
  • the portable cylinder in the state where the portable cylinder was fully opened as a combustion test and the flame length was about 25 cm to 30 cm, the portable cylinder was When approaching a position 25 mm away from 1 and igniting the flame for 10 minutes and burning it, as shown in Fig. 6 (a) to 6 (c), this foamed polystyrene product 1 was exposed to flame.
  • Total heat generation 10. 24 MJ / m 2
  • the amount of aluminum hydroxide in the expanded polystyrene product 1 is 170 PHR for pre-expanded beads
  • the amount of boric acid added is 15 PHR for pre-expanded beads
  • the amount of red phosphorus added As shown in Table 3, a corn calorimeter test was conducted on the expanded polystyrene product 1 made by changing the pre-expanded beads to 7.5PHR as shown in Table 3. calorific value became 8.84MjZm 2.
  • Average heat generation rate T 300 1 5. 53 kW / m 2
  • SEA Average specific attenuation area
  • the above-mentioned expanded polystyrene product 1 has a total calorific value further equal to 8 MjZm 2 after 10 minutes of heating time, and is less than lOOgZm 2 and the maximum heat generation rate continues for more than 10 seconds and exceeds 200 kWZm 2 .
  • the cone is heated for 20 minutes at 200 gZm 2 or less. since the total heating value of the calorimeter test 8 MJ Zm 2 it can be sufficiently below is used as a quasi-noncombustible, and aluminum foil Ya, calcium silicate plate having a thickness of about 5,6Mm, a thickness of about 4, 5 mm It can be used as a non-combustible material by making a composite with other materials such as laminated mortar.
  • Total heat generation (THR) 1. 7 1 MJ / m 2
  • Average heat generation rate T 300 1. 33 kW / m 2
  • Average heat generation rate T 60 2. 42 kW / m 2
  • Average heat generation rate T 180 5. 73 kW / m 2
  • Average heat generation rate T 300 7. 78 kW / m 2
  • SEA Average specific attenuation area
  • the above-mentioned expanded polystyrene product 1 has a total calorific value of 8 MjZm 2 or less in a heating time of 10 minutes, and as shown in Fig. 7, the maximum heat generation rate continues for 10 seconds or more at lOOgZm 2 or less. did not exceed 200kW / m 2 Te. Therefore, this Styrofoam product 1 can be used as an organic foam insulation material, and it can maintain a shape that is resistant to flames, generates almost no smoke or gas, and does not absorb moisture, and is a condition of 8MjZm 2 in a 10-minute cone calorimeter test for semi-incombustibility. It can be used as a semi-incombustible material that completely satisfies
  • the size is 910mm (3 scales) X 1820mm (6 scales) X 600mm (thickness) or 910mm (3 scales) X 3640mm (12 scales) X 600mm (thickness)
  • Molded sheets of Styrofoam products 1 can be molded in a cycle of every 4 minutes. Furthermore, as shown in FIG. 9, by cutting this molded plate at a constant interval along the thickness direction at a time and dividing the thickness, a plurality of polystyrene foam products 1 having a constant thickness are simultaneously obtained. Since it can be produced, the production of this expanded polystyrene product 1 can be increased, and productivity can be greatly improved.
  • the method for producing a foam of the present invention is widely used as a method for producing a foam used for, for example, a building material.

Abstract

Cette invention prévoit un procédé permettant de produire, avec une bonne productivité, des produits en mousse de styrène pouvant empêcher la production de fumée noire, améliorer la résistance au feu et à la chaleur et supprimer la déformation par rétrécissement causée par le feu et par la chaleur. Des perles pré-expansées sont mélangées à une résine phénolique contenant de l’acide borique et de l’hydroxyde d’aluminium, afin de former des perles enduites, une surface de chaque perle étant recouverte d’une couche d'enduction (3) contenant de l’acide borique, de l’hydroxyde d’aluminium et une résine phénolique. Les perles enduites sont séchées et désintégrées afin de produire un grand nombre de perles monoparticulaires, une surface de chacune étant recouverte de la couche d'enduction (3). Les perles monoparticulaires sont placées dans un moule puis subissent un moussage principal. Il est possible de fournir efficacement de la chaleur de vapeur entre les couches d’enduction (3) des perles monoparticulaires. Dans ce cas, étant donné que le temps de chauffe et le temps de refroidissement nécessaires pour le moussage principal des perles monoparticulaires peuvent être extrêmement réduits, une production de masse à faible coût est possible.
PCT/JP2005/018642 2004-10-22 2005-10-07 Procede de production de mousse WO2006043435A1 (fr)

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