WO2006054819A1 - Styrofoam heat-insulator and board for architecture having fire retardant and manufacturing method thereof and system for injecting noninflammables - Google Patents

Styrofoam heat-insulator and board for architecture having fire retardant and manufacturing method thereof and system for injecting noninflammables

Info

Publication number
WO2006054819A1
WO2006054819A1 PCT/KR2005/001273 KR2005001273W WO2006054819A1 WO 2006054819 A1 WO2006054819 A1 WO 2006054819A1 KR 2005001273 W KR2005001273 W KR 2005001273W WO 2006054819 A1 WO2006054819 A1 WO 2006054819A1
Authority
WO
Grant status
Application
Patent type
Prior art keywords
flame retardant
styrofoam
filler
retardant material
insulators
Prior art date
Application number
PCT/KR2005/001273
Other languages
French (fr)
Inventor
Ok-Pyo Hong
Original Assignee
Ik Steel Co., Ltd
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.)
Filing date
Publication date

Links

Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74Heat, sound or noise insulation, absorption, or reflection . Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76Heat, sound or noise insulation, absorption, or reflection . Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/78Heat insulating elements
    • E04B1/80Heat insulating elements slab-shaped
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/92Protection against other undesired influences or dangers
    • E04B1/94Protection against other undesired influences or dangers against fire
    • E04B1/941Building elements specially adapted therefor
    • E04B1/942Building elements specially adapted therefor slab-shaped

Abstract

A flame retardant Styrofoam insulator and a manufacturing method thereof is provided, which not only improves heat insulation but also prevents the building from being completely incinerated in the event of a fire. Also, the invention relates to a new type of flame retardant construction board wherein the flame retardant capability is improved allowing for better suppression of early fires, the demolition of the building may be avoided allowing for reduced losses in property and lives, and the manufacture of the construction board is made easier. According to the invention, a flame retardant Styrofoam insulator is provided, wherein typical flame retardant paint is spray-injected inside each foamy grain by means of a spray nozzle which penetrates and extends through each of the foamy grains, and the flame retardant paint is coated on the outer surface of the Styrofoam insulator. Also, a flame retardant construction board is provided, wherein numerous indentations of predetermined depth are formed on at least one surface between the front and back surfaces, and flame retardant paint is filled in the indentations, for a board made of Styrofoam or glass wool. Further, the invention relates to a flame retardant material injection system for a sandwich panel filler, wherein the flame retardant property is improved by injecting flame retardant material into the filler so that the spreading of flames may be delayed in the event of a fire to reduce damage to the sandwich panel structure and emission of toxic gases.

Description

Title of the Invention

STYROFOAM HEAT-INSULATOR AND BOARD FOR ARCHITECTURE

HAVING FIRE RETARDANT AND MANUFACTURING METHOD THEREOF AND

SYSTEM FOR INJECTING NONINFLAMMABLES

Field of the invention

The invention relates to a flame retardant Styrofoam insulator and a

manufacturing method thereof, particularly to a flame retardant Styrofoam insulator and

a manufacturing method thereof wherein liquid flame retardant paint is sprayed into

each foamy grain and onto the outer surface of the Styrofoam, allowing not only for

improved heat insulation but also for minimizing damage in the event of a fire by

preventing the building from being completely incinerated.

Also, the invention relates to a new type of flame retardant construction board,

particularly to a flame retardant construction board wherein the flame retardant

capability is improved allowing for better suppression of early fires, the demolition of

the building may be avoided allowing for reduced losses in property and lives, and the

manufacture of the construction board is made easier.

Further, the invention relates to a flame retardant material injection system for

a sandwich panel filler, particularly to a flame retardant material injection system

wherein the flame retardant property is improved by injecting flame retardant material into the filler so that the fire resistant property of the sandwich panel structure is

increased and less toxic gases are emitted in the event of a fire.

Background of the invention

For insulators and sandwich panel fillers used in the walls of buildings, etc.,

Styrofoam is generally widely used. However, Styrofoam is not fire resistant, so that a

building may easily be incinerated in the event of a fire.

To overcome this problem, Styrofoam boards are used as insulators with

common liquid flame retardant paint applied on their outer surfaces, or with flame

retardant paint applied on the surface of each foamy grain before foaming.

However, cutting and using the insulator mentioned above wherein flame

retardant paint was applied on the outer surface of the Styrofoam board had the problem

that the flame retardant paint was not applied to certain parts so that they were directly

exposed to fire, as the flame retardant paint did not penetrate to the inside of the

insulator. Also, the insulator wherein flame retardant paint was applied on the surface of

each foamy grain had the problem that the flame retardant paint was destroyed because

of the foaming process and that the foamy grains inside the flame retardant paint was

melted in the event of a fire.

Also, Styrofoam boards are widely used as insulators in a building or as

sandwich panel fillers, because of their high insulation property and low costs. However, Styrofoam boards are vulnerable to heat and melt within a short period of time in the

event of a fire, so that buildings constructed with sandwich panels that use Styrofoam

boards as fillers are demolished within a short period of time in the event of a fire, and

have the disadvantage of high toxic gas emission.

With regard to the above problems of the Styrofoam board, products with fire

retardant material coated on the surface of the board are often proposed to improve the

flame retardant property of the Styrofoam board. However, products with fire retardant

coating do not provide the required degree of flame retardation due to the relatively low

thickness of the flame retardant coating. Also, the flame retardant property is improved

only on the surface portions of the board, as the flame retardant material and the board

form layers.

On the other hand, those products have been proposed wherein the procedure

of coating the flame retardant material is repeated several times so that the flame

retardant coating layer is made to be thick, but the repeated coating procedures render

the disadvantage of high costs.

The sandwich panel, which is a pair of outer panels made of metal between

which is positioned a filler made of a foam body of synthetic resin such as Styrofoam or

polyurethane foam, is created by manufacturing the filler and outer panels separately

and attaching the outer panels on both sides of the filler, or by foaming the filler to fill

the gap between two outer panels. Since the fillers used in these sandwich panels are made of foam-molded

synthetic resins as mentioned above, both the material and composition were inevitably

highly vulnerable to fire. Therefore, in structures made of conventional sandwich panels,

flames rapidly spread in the event of a fire to cause immense damage in a short period

of time, and more notably, a great amount of toxic gases were emitted, creating the risk

of a high mortality rate.

Detailed description of the invention

The invention is presented to overcome the above problems, and it is an

object of the invention to provide a flame retardant Styrofoam insulator and a

manufacturing method thereof, wherein liquid flame retardant paint is sprayed into each

foamy grain and each pore produced between the foamy grains and onto the outer

surface of the Styrofoam, allowing not only for improved heat insulation but also for

minimizing damage in the event of a fire by preventing the building from being

completely incinerated.

Also, it is another object of the invention to provide a new type of flame

retardant construction board, wherein the flame retardant capability is improved

allowing for better control of early fires, the demolition of the building may be avoided

or delayed allowing for reduced losses in property and lives, and the manufacture of the

construction board is made easier so that the costs are lowered. Further, it is another object of the invention to provide a flame retardant

material injection system for a sandwich panel filler, wherein the flame retardant

property is improved by injecting flame retardant material into the filler so that the

spreading of flames may be delayed in the event of a fire to reduce damage to the

sandwich panel structure and emission of toxic gases.

To attain the above objectives, a flame retardant Styrofoam insulator formed

by numerous foamy grains is provided, wherein typical flame retardant paint is spray-

injected by means of a spray nozzle which penetrates and extends through each of the

foamy grains, and the flame retardant paint is coated on the outer surface of the

Styrofoam insulator.

Also, a method of manufacturing flame retardant Styrofoam insulators is

provided, comprising: cutting a common Styrofoam insulators, formed by numerous

foamy grains, to fit common standards (Sl); spraying common liquid flame retardant

paint at a pressure of 0.5-5kg/cnf for 2-5 minutes, after inserting numerous spray

nozzles into the insides of the Styrofoam insulators (S2); removing the spray nozzles

from the Styrofoam insulators, after the completion of the spraying inside the Styrofoam

insulators (S3); and coating the outer surfaces of the Styrofoam insulators using the

same flame retardant paint as the flame retardant paint (S4), after the completion of

removing the spray nozzles (S3). As described above, according to the invention, liquid flame retardant paint is

sprayed into each foamy grain and each pore created between the foamy grains and onto

the outer surface of the Styrofoam, allowing not only for improved heat insulation but

also for minimizing damage in the event of a fire by preventing the building from being

completely incinerated.

According to the invention, a flame retardant construction board 210 is

provided, wherein numerous indentations 212 are formed on at least one surface

between the front and back surfaces, and flame retardant material 220 is filled in the

indentations 212, for a board made of Styrofoam or glass wool.

According to the invention, a flame retardant construction board 210 is

provided, wherein numerous penetrations 214 are formed through the front and back

surfaces, and flame retardant material 220 is filled in the penetrations 214, for a board

made of Styrofoam or glass wool.

According to another feature of the invention, a flame retardant construction

board 210 is provided, wherein the front and back surfaces of the board is coated with

flame retardant material 220.

According to the invention to attain the above objectives, a flame retardant

material injection system is provided for a sandwich panel filler, on which outer panels

of metal are attached to form a sandwich panel, comprising : a means of transportation

for the filler; an injection hole forming device, which creates numerous injection holes on the surface of the transported filler for the injection of flame retardant material; and a

flame retardant material injection device, which pressurizes and supplies liquid flame

retardant material into each injection hole through the surface of the filler.

In the flame retardant material injection system for a filler according to the

invention, the injection hole forming device may rotatably be installed along the

direction of transportation of the filler and has a slotting roller with numerous slotting,

pins on the perimeter thereof to form the injection holes in predetermined intervals.

Also, the flame retardant material injection device may comprise: an injector

installed to be in contact with at least one side of the transported filler, which has in its

interior a holding space for flame retardant material and has flame retardant material

outlets on the side facing the filler surface; and a supply means, which is connected to

the injector via supply pipes and supplies flame retardant material.

The flame retardant material injection system according to the invention may

further comprise a cleaning device installed behind the flame retardant material

injection device, which removes flame retardant material residue from the surface of the

filler.

Further, the system according to the invention may further comprise a

neutralizer device installed between the flame retardant material injection device and

the cleaning device, which supplies neutralization liquid on the surface of the filler in

order to solidify the flame retardant material through a neutralization process when alkali flame retardant material is used, and may comprise a dryer device installed behind

the cleaning device composed of a heater-dryer positioned inside a dryer booth in which

the filler is held, which removes the residue on the outside of the filler and at the same

time dries the flame retardant material injected into the filler.

Brief description of the drawings

Fig. 1 is a schematic drawing illustrating the order in which a flame retardant

Styrofoam according to Embodiment 1 of the invention is manufactured.

Fig. 2 is a cross section view illustrating the spray nozzles of Fig. 1

penetrating each foamy grain.

Fig. 3 is a schematic drawing illustrating the order in which a flame retardant

Styrofoam according to Embodiment 2 of the invention is manufactured.

Fig. 4 is a schematic drawing illustrating the order in which a flame retardant

Styrofoam insulator according to Embodiment 1 of the invention is manufactured.

Fig. 5 is a schematic drawing illustrating the order in which a flame retardant

Styrofoam insulator according to Embodiment 2 of the invention is manufactured.

Fig. 6 is a cross section view of a flame retardant construction board

according to Embodiment 3 of the invention.

Fig. 7 is a cross section view of a flame retardant construction board

according to Embodiment 4 of the invention. Fig. 8 is a cross section view of a flame retardant construction board

according to Embodiment 5 of the invention.

Fig. 9 is a cross section view of a flame retardant construction board

according to Embodiment 6 of the invention.

Fig. 10 is a front elevation view of a flame retardant material injection system

for sandwich panel fillers according to Embodiment 7 of the invention.

Fig. 11 is a plan view of the flame retardant material injection system

illustrated in Fig. 10.

Fig. 12 is a plan view illustrating an injection hole forming device in a flame

retardant material injection system according to Embodiment 7 of the invention.

Fig. 13 is a pian view illustrating an flame retardant material injection device

in a flame retardant material injection system according to Embodiment 7 of the

invention.

Fig. 14 is a plan view illustrating a neutralizer device and cleaning device in a

flame retardant material injection system according to Embodiment 7 of the invention.

Embodiments

Hereinafter, embodiments of the flame retardant Styrofoam insulator and a

manufacturing method thereof according to the invention will be described in more

detail with reference to the accompanying drawings. Although the invention relates to a flame retardant Styrofoam insulator and a construction board, aspects of the invention

will be described individually for convenience, with embodiments concerning the flame

retardant Styrofoam insulator and the manufacturing method thereof described in

Embodiments 1 and 2, embodiments concerning the flame retardant construction board

described in Embodiments 3 to 6, and embodiments concerning the flame retardant

material injection system described in Embodiment 7.

[Embodiments 1 , 2]

Fig. 1 illustrates the order in which a flame retardant Styrofoam according to

Embodiment 1 of the invention is manufactured, Fig. 2 illustrates schematically the

spray nozzles of Fig. 1 penetrating each foamy grain, and Fig. 4 illustrates the order in

which a flame retardant Styrofoam insulator according to Embodiment 1 of the

invention is manufactured.

Referring to Figs. 1 and 4, to manufacture a flame retardant Styrofoam 50

according to Embodiment 1 of the invention, a Styrofoam insulator 10 formed by

numerous foamy grains 12 is first cut to fit common standards (step Sl). With the

Styrofoam insulator 10 cut in such a manner, common liquid flame retardant paint 30 is

sprayed at a pressure of 0.5-5kg/cuf for 2-5 minutes, after inserting numerous spray

nozzles 20 into the insides of the cut Styrofoam insulators 10 (step S2). Here, if the

spraying pressure is below 0.5kg/cnf, the flame retardant paint 30 cannot penetrate to the pores within the grains 12, and if the spraying pressure is above 5kg/ciif, the structure of

the grains 12 is destroyed.

The spray nozzles 20 have a length equal to the thickness of the Styrofoam

insulator 10, so as to penetrate each of the grains 12 of the Styrofoam 10, and numerous

spray holes 22 are formed along the perimeters of the spray nozzles 20, through which

flame retardant paint 30 may be sprayed (see Fig. 2). Preferably, the spray nozzles 20

are positioned in a grid of 3-10mm intervals.

With the spraying of flame retardant paint 30 inside the Styrofoam insulator

10 completed, the spray nozzles 20 are removed from the Styrofoam insulators 10 (step

S3), and the outer surfaces of the Styrofoam insulators 10 are coated using the same

flame retardant paint 30 as the flame retardant paint 30 described above (step S4).

With flame retardant paint 30 applied on the inside and outside of the

Styrofoam insulator 10, it is moved through a common dryer 40 to complete the flame

retardant Styrofoam insulator 50 (step S5). Here, the dryer has a temperature less than

100 "C and a drying time between 1-10 minutes.

Fig. 3 illustrates the order in which a flame retardant Styrofoam according to

Embodiment 2 of the invention is manufactured, and Fig. 5 illustrates the order in which

a flame retardant Styrofoam insulator according to Embodiment 2 of the invention is

manufactured.

Referring to Figs. 3 and 5, to manufacture a flame retardant Styrofoam 50 according to Embodiment 2 of the invention, a Styrofoam insulator 110 formed by

numerous foamy grains 112 and cut to fit common standards is first cut to have a

thickness of 3-5 mm by means of a common hot wire (step SlO). With the Styrofoam

insulator 10 cut in such a manner, the outer surfaces of each Styrofoam insulator 110 are

coated with common flame retardant paint 120 (step S20).

With the outer surfaces of each Styrofoam insulator 110 coated with flame

retardant paint 120, the cut Styrofoam insulators 110 are aligned and are compressed

and glued by means of a common compressor 130 (step S30), and then they are moved

through a common dryer 140 to complete the flame retardant Styrofoam insulators 50

(step S5). Here, the dryer has a temperature less than 100°C and a drying time between

1-10 minutes.

[Embodiments 3, 4, 5, 6]

Fig. 6 is a cross section view of an embodiment of the invention, where the

invention is applied on a Styrofoam board. The invention, as seen in the figure, involves

numerous indentations 212 formed on the front and back surfaces, and flame retardant

material t 220 filled in the indentations 212. This aspect of the invention is

manufactured as follows.

First, indentations 212 are processed on the surface of a typically

manufactured Styrofoam board 210. This is performed by means of a roller with protrusions on the perimeter thereof or a cutter, and indentations 212 are formed on the

board 210 as the protrusions of a roller pierce it or a cutter removes a portion of the

surface. The indentations 212 are distributed continuously or intermittently across the

entire surface of the board 210, and their depth is adjusted according to the front and

back thickness of the board 210.

The board 210 indented in this manner is dipped in a tank wherein liquid

flame retardant material is stored, taken out, and then dried. This allows the flame

retardant liquid to fill the indentations 212, and the entire surface of the board 210 is

coated with flame retardant material 220. During this process, the flame retardant liquid

may drip from the surface of the board 210 without filling the indentations 212,

depending on the viscosity of the flame retardant liquid, in which case the board 210

coated with flame retardant material 220 is dipped in a tank wherein flame retardant

material 220 is stored for repeatedly coating with flame retardant material 220.

Water glass, sodium hydrogen carbonate, magnesium hydroxide, aluminum

hydroxide, etc., may be used as the flame retardant material 220.

According to circumstances, the flame retardant material 220 may be scraped

off the surface of the board 210, after dipping into and removing from the tank wherein

flame retardant material 220 is stored, so that the flame retardant material 220 is filled

only in the indentations 212 of the board 210, but since the flame retardant property of

the board 210 is relatively increased when the entire board 210 is coated with flame retardant material 220 and not just the indentations 212, there is no present need to

scrape off the flame retardant material 220 from the surface of the board 210 and

include an additional procedure.

The operation of forming indentations 212 as described above may be carried

out inside the tank wherein flame retardant material 220 is stored. This shortens the

work process, as while the indentations 212 are formed the flame retardant material 220

is applied in the indentations 2.12 and on the surface of the board 210 simultaneously.

Also, the roller or cutter which processes the indentations 212 may be configured to

spray the flame retardant material 220, so that the flame retardant material 220 may be

sprayed and filled automatically in the indentations 212 while processing the

indentations 212.

Fig. 7 illustrates indentations 212 formed along the length or width of a board

and shows that indentations 212 may be formed in a variety of patterns.

With the invention of the foregoing composition, indentations 212 are formed

on the surface of a board 210, and flame retardant material 220 is filled in these

indentations 212, so that compared to a board 210 simply coated with flame retardant

material 220 on the surface, better flame retardation is achieved, along with easier

production due to the omission of repetitive coating operations.

The foregoing description used a board 210 with indentations 212 as an

example, but as seen in Fig. 8, the board 210 may be manufactured by forming penetrations 214 in the front-to-back direction and injecting flame retardant material

220 into these penetrations 214. In this case, a pin, drill, or hole-punch, etc., may be

used to process the penetrations 214, and flame retardant material 220 is injected into

the penetrations 124 in the manner described above. According to circumstances,

indentations 212 and penetrations 214 may be formed together for the injection of flame

retardant material 220, as seen in Fig. 9.

The foregoing description used a Styrofoam board as an example^ but the

same may be applied to a glass board, as seen in Fig. 8. A glass wool board is in itself

better than a Styrofoam board in terms of flame retardation, but the flame retardant

property is further improved by forming indentations 2.12 or penetrations 214 and

injecting flame retardant material 220.

[Embodiment 7]

Fig. 10 is a front elevation view illustrating to an embodiment of a flame

retardant material injection system for sandwich panel fillers according the invention,

and Fig. 11 is a plan view thereof.

The flame retardant material injection system of the invention transports the

sandwich panel filler 1010 while injecting liquid flame retardant material into it, and

supplies chemical and thermal treatment according to the type of flame retardant

material to increase the flame retardant property while maintaining the adhesion property of the filler to the outer panels. As seen in Figs. 10 and 11, the system

comprises an injection hole forming device 1000 installed along the transportation path

of the filler 1010, a flame retardant material injection device 1200, a neutralizer device

300, a cleaning device 400, and a dryer device 500, with numerous rollers installed on

the respective devices to support in a typical manner both sides, top, and bottom of the

filler 1010 as a means to transport the filler 1010 through each device. Although the

embodiment is illustrated as being configured to transport and process the filler 1010

with its sides positioned to face the top and bottom, it will be understood that the

transportation method of the filler 1010 is not limited to this example.

As seen in Figs. 10 and 12, the injection hole forming device 1000 forms

numerous injection holes 1011 on the surface of the filler 1010 in predetermined

intervals, with feeding rollers 1120 and exit rollers 1130 installed respectively in pairs at

the entrance and exit sides as the means of transportation for the filler, a plurality of

support rollers 1140 installed at the bottom to support the bottom of the filler 1010, and

a pair of slotting rollers 1110 installed between the feeding rollers 1120 and exit rollers

1130. Each of the slotting rollers is rotatably installed, with numerous slotting pins

mounted along the perimeter thereof, to form injection holes 1011 of predetermined

depth on the surface of the filler 1010 passing between the rollers. These slotting rollers

1110 may be configured to rotate by a separate driving means such as motors, but it is

preferable that they be made to rotate naturally by the transportation force of the filler 1010 applied to the slotting pins 1111.

As seen in Figs. 10 and 13, the flame retardant material injection device 1200

injects flame retardant material into each injection hole 1011 of the filler 1010 formed

by the injection hole forming device 1000, with support rollers 211 installed at the

bottom to support the bottom of the filler 1010, and a pair of injectors 1220 installed at

the top of the support rollers parallel to the direction of transportation of the filler 1010.

The injectors 1220 assume the shape of a container with a holding space for flame

retardant material in its interior, with at least the sides facing each other formed as

planes so that they may be closely held against the surfaces of the filler 1010, a plurality

of flame retardant material outlets 1221 lined along the width direction of the filler 1010

formed in predetermined intervals on the sides facing the filler 1010, and inlets 1222-

connected to flame retardant material supply pipes 1201 formed on the opposite sides.

The flame retardant material supply pipes 1201 are connected to a supply tank 1260

which contains flame retardant material, and onto the supply pipes 1201 are connected

pumps 1250, which apply pressure to the flame retardant material in the supply tank

1260 and supply it to the injectors 1220, and valves 1241, 1242, which control the

pressure and flow rate of the flame retardant material supplied to the injectors 1220.

Also, as seen in Fig. 10, at the bottom of the flame retardant material injection

device 1200 is installed a collection tank 1201 for collecting the remainder of the flame

retardant material discharged from the injector 1220 that was not injected into the injection holes 1011 of the filler 1010.

The neutralizer device 300 may optionally be installed when alkali metal salts

or alkali earth metal salts such as sodium silicate, magnesium hydroxide, magnesium

sulfate, etc., are used as the flame retardant material, and is intended to solidify and

remove the flame retardant material residue on the surface of the filler 1010 through a

neutralization process. As seen in Figs. 10 and 14, the neutralizer device 300 is formed

with support rollers 301, 302 installed at the bottom of the entrance and exit sides that

support the filler 1010, and a pair of neutralizer fluid suppliers 310 formed to be near to

or in contact with both sides of the transported filler 1010. On the sides of the

neutralizer fluid suppliers 310 facing each other are formed neutralizer fluid outlets 311

lined along the width direction of the filler 1010 in predetermined intervals, configured

to coat the neutralizer fluid on the surface of the filler 1010 transported between them.

Also, the suppliers 310 are connected via supply pipes 320 to the neutralizer fluid tank

330 and pump 340, and collection tanks 320 and drain pipes (not shown) are installed at

the bottom of the neutralizer device 300 for the recovery of used neutralizer fluid. An

aqueous solution with a suitable acidity may be selected for the neutralizer fluid

according to the basicity of the flame retardant material.

The cleaning device 400 removes the flame retardant material residue from

the surface of the filler 1010, and has common cleaning fluid sprayers (not shown),

configured to spray cleaning fluid supplied from an outside source to the filler 1010, and a plurality of cleaning rollers 410, installed along the direction of transportation of

the filler 1010, so that cleaning fluid may be sprayed onto the surface of the filler 1010

while the cleaning rollers 410 may rotate and wipe the surface of the filler 1010 to

remove the flame retardant material.

The dryer device uses heat to remove water residue on the inside/outside of

the filler 1010 while at the same time drying the flame retardant material injected inside

the filler 1010, and is formed with a hot-air type heater-dryer 510 installed inside a

dryer booth configured to hold numerous fillers 1010 placed in predetermined intervals.

The process by which the filler 1010 is treated by the flame retardant material

injection system of the invention with the foregoing composition is as follows.

First, numerous injection holes 1011 are formed in predetermined intervals by

the slotting rollers 1110 on both sides of the filler 1010 fed into the injection hole

forming device 1000. When the filler 1010 is transported to the flame retardant material

injection device 1200, pressurized flame retardant material is discharged through the

outlets 1221 of the injectors 1221 and injected into each injection hole 1011, and the

flame retardant material injected inside each injection hole 1011 penetrates into the

interior spaces within the filler 1010. Next, while the filler 1010 passes through the

neutralizer device 300, flame retardant material residue on the surface of the filler 1010

is neutralized and educed, where a portion of the educed residue is naturally separated

from the surface of the filler 1010 and the remainder is completely removed when passing through the cleaning device 400. Also, the flame retardant material penetrated

inside the filler 1010 is dehydrated during the heat-drying within the dryer device 500,

and is thus unified with the inner structure of the filler 1010 and solidified.

Therefore, a sandwich panel filler 1010 manufactured through the flame

retardant material injection system of the invention as described above is provided a

significantly increased flame retardant property compared to a conventional filler, so

that the spread of flames in the event of a fire may be delayed, damage from the flames

may be reduced, and toxic gas emissions from the fire may significantly be reduced.

Further, the flame retardant material injection system of the invention not only coats the

outside surface of a filler 1010 but also injects flame retardant material inside the filler

1010 and allows it to be unified with the filler 1010, so that the overall flame retardation

of the filler 1010 is improved and also the degradation in the adhesion property may be

avoided when attaching the outer panels.

In addition, when optionally using alkali flame retardant material, the

neutralizer device 300 is used to solidify the flame retardant material residue on the

surface of the filler 1010 for easy removal, and the cleaning device 400 is used for the

additional removal of the flame retardant material residue, allowing an easy and clean

method of flame retardant material removal.

While the invention has been described with reference to the particular

illustrative embodiments, it is to be appreciated that those skilled in the art can change or modify the embodiments without departing from the scope and spirit of the invention

set forth in the appended claims.

Industrial availability

As described above, the flame retardant Styrofoam insulator 50, 150

according to Embodiments 1 and 2 of the invention, for which flame retardant paint 30,

120 is applied to both the inside and outside of the Styrofoam insulator 50, 150,

provides the advantage that the complete incineration of a building is avoided in the

event of a fire to minimize losses.

Also, with the flame retardant construction board according to Embodiments

3 to 6 of the invention, indentations 212 or penetrations 214 are formed, and flame

retardant material 220 is filled in these indentations 212 or penetrations 214, so that

unlike the case where the flame retardant material 220 is coated simply on the surface of

the board, the flame retardant material 220 coexists with the board material to create a

unified effect, thus improving the flame retardant property even inside the board. Since

the board may easily be manufactured through various simple methods such as the

sequential process of filling with flame retardant material after forming indentations 212

or penetrations 214 on the surface or simultaneously filling with flame retardant

material while forming the indentations 212 or penetrations 214, a new flame retardant

construction board may be provided which is easier to manufacture than conventional products. When a building is constructed with sandwich panels using these boards as

fillers, the burning of the boards is prevented or delayed to allow early fire suppression,

so that losses in property and lives may be reduced.

Further, with the flame retardant material injection system according to

Embodiment 7 of the invention, flame retardant material is penetrated deep into the

inner structure of the sandwich panel filler to generally increase the flame retardant

property of the filler, and thus the spread of fire and flames is inhibited in the event of a

fire effecting a reduction of losses in property and a reduction of losses in lives caused

by toxic gas emissions during a fire. In addition, the flame retardant material injection

system of the invention has the advantage of effectively removing flame retardant

material residue on the surface that is not penetrated into the filler to maintain an

adequate adhesion property of the filler to the outer panels.

Claims

Claims
1. A flame retardant Styrofoam insulator formed by numerous foamy grains,
wherein typical flame retardant paint is spray-injected by means of a spray nozzle which
penetrates and extends through each of the foamy grains, and the flame retardant paint
is coated on the outer surface of the Styrofoam insulator.
2. The flame retardant Styrofoam insulator as set forth in claim 1, wherein the
spray nozzle has a length equal to the thickness of the Styrofoam, so as to penetrate
each of the foamy grains, and numerous spray holes are formed along the perimeter of
the spray nozzle, through which the flame retardant paint may be sprayed.
3. A method of manufacturing flame retardant Styrofoam insulators,
comprising:
cutting common Styrofoam insulators, formed by numerous foamy grains, to
fit common standards (Sl);
spraying common liquid flame retardant paint at a pressure of 0.5-5kg/αif for
2-5 minutes, after inserting numerous spray nozzles into the insides of the Styrofoam
insulators (S2);
removing the spray nozzles from the Styrofoam insulators, after the
completion of the spraying inside the Styrofoam insulators (S3); and coating the outer surfaces of the Styrofoam insulators using the same flame
retardant paint as the flame retardant paint (S4), after the completion of removing the
spray nozzles (S3).
4. The method of manufacturing flame retardant Styrofoam insulators as set
forth in claim 3, further comprising moving the insulator through a dryer with a
temperature less than 1001C for 1-10 minutes (S5) after the completion of the coating
(S4).
5. The method of manufacturing flame retardant Styrofoam insulators as set
forth in claim 3, wherein the spray nozzle has a length equal to the thickness of the
Styrofoam, so as to penetrate each of the foamy grains, and numerous spray holes are
formed along the perimeter of the spray nozzle, through which the flame retardant paint
may be sprayed.
6. A flame retardant Styrofoam insulator, from Styrofoam insulators formed
by numerous foamy grains, manufactured by:
cutting the Styrofoam insulators to fit common standards;
coating the outer surfaces of each Styrofoam insulator with flame retardant
paint; and compressing and glueing the coated Styrofoam insulators by means of a
common compressor.
7. A method of manufacturing a flame retardant Styrofoam insulator,
comprising:
cutting common Styrofoam insulators, formed by numerous foamy grains, to
fit common standards, by means of a common hot wire (SlO);
coating each of the cut Styrofoam insulators with common flame retardant
paint (S20); and
compressing and glueing the cut Styrofoam insulators after aligning them, by
means of a common compressor (S30), after the completion of the coating (S20).
8. The method of manufacturing a flame retardant Styrofoam insulator as set
forth in claim 7, further comprising moving the insulator through a dryer with a
temperature less than 100"C for 1-10 minutes (S40) after the completion of the
compressing and glueing (S30).
9. A flame retardant construction board, wherein numerous indentations are
formed on at least one surface between the front and back surfaces, and flame retardant
paint is filled in the indentations, for a board made of Styrofoam or glass wool.
10. A flame retardant construction board, wherein numerous penetrations are
formed through the front and back surfaces, and flame retardant paint is filled in the
penetrations, for a board made of Styrofoam or glass wool.
11. The flame retardant construction board as set forth in claim 9 or claim 10,
wherein the front and back surfaces of the board is coated with flame retardant material.
12. A flame retardant material injection system, for a sandwich panel filler, on
which outer panels of metal are attached to form a sandwich panel, comprising :
a means of transportation for the filler;
an injection hole forming device, which creates numerous injection holes on
the surface of the transported filler for the injection of flame retardant material; and
a flame retardant material injection device, which pressurizes and supplies
liquid flame retardant material into each injection hole through the surface of the filler.
13. The flame retardant material injection system for a sandwich panel filler
as set forth in claim 12, wherein the injection hole forming device is rotatably installed
along the direction of transportation of the filler and has a slotting roller with numerous
slotting pins on the perimeter thereof to form the injection holes in predetermined intervals.
14. The flame retardant material injection system for a sandwich panel filler
as set forth in claim 12, wherein the flame retardant material injection device comprises:
an injector installed to be in contact with at least one side of the transported
filler, which has in its interior a holding space for flame retardant material and has flame
retardant material outlets on the side facing the filler surface; and
a supply means, which is connected to the injector via supply pipes and
supplies flame retardant material.
15. The flame retardant material injection system for a sandwich panel filler
as set forth in any of claims 12 to 14, further comprising a cleaning device installed
behind the flame retardant material injection device, which removes flame retardant
material residue from the surface of the filler.
16. The flame retardant material injection system for a sandwich panel filler
as set forth in claim 15, further comprising a neutralizer device installed between the
flame retardant material injection device and the cleaning device, which supplies
neutralization liquid on the surface of the filler in order to solidify the flame retardant
material through a neutralization process when alkali flame retardant material is used.
17. The flame retardant material injection system for a sandwich panel filler
as set forth in claim 15, further comprising a dryer device installed behind the cleaning
device composed of a heater-dryer positioned inside a dryer booth in which the filler is
held, which removes the residue on the outside of the filler and at the same time dries
the flame retardant material injected into the filler.
PCT/KR2005/001273 2004-11-08 2005-05-02 Styrofoam heat-insulator and board for architecture having fire retardant and manufacturing method thereof and system for injecting noninflammables WO2006054819A1 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
KR10-2004-0090342 2004-11-08
KR20040090342A KR20060041345A (en) 2004-11-08 2004-11-08 Styrofoam heat-insulator having fire retardant and manufacturing method thereof
KR20-2005-0005935 2005-03-05
KR20050005935U KR200384755Y1 (en) 2005-03-05 2005-03-05 Board for architecture
KR20050036236 2005-04-29
KR10-2005-0036236 2005-04-29

Publications (1)

Publication Number Publication Date
WO2006054819A1 true true WO2006054819A1 (en) 2006-05-26

Family

ID=36407342

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/KR2005/001273 WO2006054819A1 (en) 2004-11-08 2005-05-02 Styrofoam heat-insulator and board for architecture having fire retardant and manufacturing method thereof and system for injecting noninflammables

Country Status (1)

Country Link
WO (1) WO2006054819A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2696006B1 (en) * 2012-08-10 2016-03-09 STO SE & Co. KGaA Heat insulation plate for a compound heat insulation system, compound heat insulation system

Citations (5)

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Publication number Priority date Publication date Assignee Title
US4223066A (en) * 1979-05-23 1980-09-16 Arco Polymers, Inc. Fire retardant treatment of fire unstable materials and products obtained
US4486468A (en) * 1982-08-27 1984-12-04 Anti-Fire-Foam, Inc. Fire retardant foam
EP0152491A1 (en) * 1983-12-07 1985-08-28 John Albert Avery Bradbury Composite foamed articles and process for their production
US5230844A (en) * 1987-09-04 1993-07-27 Skis Rossignol, S.A. Process for producing a complex elastic molded structure of the sandwich type
US5516552A (en) * 1993-12-23 1996-05-14 Styro-Stop, Inc. Insulation barrier and a method of making and insulation barrier for a roof insulation system

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4223066A (en) * 1979-05-23 1980-09-16 Arco Polymers, Inc. Fire retardant treatment of fire unstable materials and products obtained
US4486468A (en) * 1982-08-27 1984-12-04 Anti-Fire-Foam, Inc. Fire retardant foam
EP0152491A1 (en) * 1983-12-07 1985-08-28 John Albert Avery Bradbury Composite foamed articles and process for their production
US5230844A (en) * 1987-09-04 1993-07-27 Skis Rossignol, S.A. Process for producing a complex elastic molded structure of the sandwich type
US5516552A (en) * 1993-12-23 1996-05-14 Styro-Stop, Inc. Insulation barrier and a method of making and insulation barrier for a roof insulation system

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2696006B1 (en) * 2012-08-10 2016-03-09 STO SE & Co. KGaA Heat insulation plate for a compound heat insulation system, compound heat insulation system

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