WO2008105595A1 - Procédé de fabrication de blocs de polystyrène expansé ignifuges et de produits moulés associés - Google Patents

Procédé de fabrication de blocs de polystyrène expansé ignifuges et de produits moulés associés Download PDF

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Publication number
WO2008105595A1
WO2008105595A1 PCT/KR2008/000990 KR2008000990W WO2008105595A1 WO 2008105595 A1 WO2008105595 A1 WO 2008105595A1 KR 2008000990 W KR2008000990 W KR 2008000990W WO 2008105595 A1 WO2008105595 A1 WO 2008105595A1
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WO
WIPO (PCT)
Prior art keywords
expanded polystyrene
flame
coated beads
beads
water
Prior art date
Application number
PCT/KR2008/000990
Other languages
English (en)
Inventor
Young-Joon Moon
Original Assignee
Young-Joon Moon
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
Application filed by Young-Joon Moon filed Critical Young-Joon Moon
Publication of WO2008105595A1 publication Critical patent/WO2008105595A1/fr

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Classifications

    • 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
    • C08J9/36—After-treatment
    • C08J9/365—Coating
    • 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
    • C08J9/36—After-treatment
    • C08J9/40—Impregnation
    • C08J9/405—Impregnation with polymerisable 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
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2201/00—Foams characterised by the foaming process
    • C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
    • C08J2201/038—Use of an inorganic compound to impregnate, bind or coat a foam, e.g. waterglass
    • 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
    • C08J2429/00—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 alcohol, ether, aldehydo, ketonic, acetal, or ketal radical; Hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Derivatives of such polymer
    • 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
    • C08J2433/00—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 only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; 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
    • 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
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2201/00—Properties
    • C08L2201/02—Flame or fire retardant/resistant

Definitions

  • the aged expanded polystyrene beads are filled in an aluminum mold having a large number of small holes perforated therethrough, and steam having a temperature of 105-118 0 C, and cooling water having a temperature of about 60 0 C, are sequentially injected through the holes for about 1-5 minutes, thus manufacturing expanded polystyrene blocks and molded products (hereinafter, referred to as "post-expansion"). Then, the post-expanded polystyrene blocks and molded products are dried in a drying chamber for about 1 hour or longer, thus completing the manufacture of expanded polystyrene blocks and molded products.
  • the water-resistant coating material should cover the expanded polystyrene beads, such that it swells together with the expanded polystyrene beads, even when the expanded polystyrene beads swell by 40% due to a large amount high-temperature steam and cooling water during post-expansion in a mold, while the silicate flame retardant coated inside thereof is not dissolved or washed out. Also, the water-resistant coating material should have ensured water resistance to prevent the dissolution and removal of the silicate flame retardant, even when it comes into contact with steam, having a temperature of 104-118 0 C, for 5 minutes.
  • the present invention allows the manufacture of flame-retardant polystyrene blocks and molded products, which serve as an insulation barrier against the heat and flame of flame and, at the same time, block the supply of oxygen, which assists in burning, so as to minimize the generation of hazardous gases, such as carbon monoxide and carbon dioxide, caused by burning.
  • flame-retardant expanded polystyrene blocks and molded products according to the present invention there is an advantage in that the cost for producing the polystyrene blocks and molded products is low, because silicate flame retardants, including liquid sodium silicate and potassiun silicate, which are expensive and have excellent flame retardancy, are used.
  • expanded polystyrene beads are coated with the water-resistant coating material for imparting both water resistance and flame retardancy.
  • the sodiun or potassium component of the flame retardant being readily dissolved and removed by the water or moisture of rain or snow during the use of the polystyrene blocks and molded products as structural materials or insulation materials for buildings. Accordingly, the flame retardancy of the polystyrene blocks and molded products is ensured.
  • the flame-retardant expanded polyester blocks and molded products manufactured according to the present invention have heat resistance, antibacterial properties, insecticidal properties, and far infrared ray-emitting functions, because one or more selected from among charcoal, zeoilte and yellow earth are added to the water- resistant coating material.
  • FIG. 1 is a flow chart showing a method for manufacturing flame-retardant expanded polypropylene blocks and molded products according to the present invention.
  • FIG. 2 is a flow chart showing a method for manufacturing flame-retardant expanded polypropylene blocks and molded products, which comprises, in addition to the steps shown in FIG. 1, a step of coating expanded polypropylene beads with an organic coating material.
  • FIG. 3 is a cross-sectional view showing a mold in a state in which injection pipes are positioned at an insertion position.
  • FIG. 4 is a cross-sectional view showing a mold in a state in which injection pipes are positioned at a withdrawing position.
  • HG. 6 is a photograph showing a flame retardancy test for an expanded polystyrene molded product manufactured according to the prior art.
  • HGS. 7 and 8 are photographs showing flame retardancy tests for flame-retardant expanded polystyrene molded products manufactured according to the present invention.
  • HG. 9 is a photograph showing the results of flame retardancy tests for the flame- retardant polystyrene molded products manufactured according to the present invention and the expanded polystyrene molded product manufactured according to the prior art. Mode for the Invention
  • the method for manufacturing flame-retardant expanded polystyrene blocks and molded products according to the present invention comprises a step (Sl) of making first coated beads.
  • the first coated beads 20 are produced by primarily coating expanded polystyrene beads 10 with a silicate flame retardant.
  • the silicate flame retardant can be provided with potassiun silicate.
  • Potassiun silicate is represented by a molecular formula of K 2 OnSi0 2 x H 2 0 and can be provided in various forms having a silicon dioxide content of 10-45%.
  • potassium silicate having a silicon dioxide content of 30-40% is preferably used, because it is inexpensive and, at the same time, exhibits the functionality and action of the present invention.
  • sodiun silicate When sodiun silicate is used as the silicate flame retardant, the sodiun component can be dissolved in water or moisture.
  • modified sodiun silicate from which sodiun has been removed through ion exchange, can be used as the silicate flame retardant in the present invention.
  • colloidal silica which contains silicon dioxide (SiO 2 ) and a hydroxyl (OH-) compound in an amount of 10-50% and has a cluster structure, can be used.
  • liquid lithium silicate in which lithiun having the lightest specific gravity (about 0.543) among solid elements is dispersed in colloidal silica, may also be used.
  • the lithiun silicate is characterized in that it has high water resistance compared to those of other inorganic silicate flame retardants, has high heat resistance and is stable even at low temperatures, such as room temperature (about 25 0 C).
  • the process of coating the expanded polystyrene beads 10 with the silicate flame retardant are repeated two times or more, such that the silicate flame retardant can be uniformly coated on the surface of the expanded polystyrene beads 10. Also, the number of coating with the silicate flame retardant can be controlled to adjust the thickness of the coating layer.
  • coating the expanded polystyrene beads 10 with the silicate flame retardant can be performed by mixing the expanded polystyrene beads 10 with the silicate flame retardant in a ribbon mixer and drying the mixture with hot air.
  • the construction and function of the ribbon mixer are obvious to those skilled in the art, and thus the detailed description thereof will be emitted herein.
  • a mixture of 50-99.99 wt% of the silicate flame retardant with 0.01-50 wt% of any one selected from among flame-retardant ammoniun phosphate, aluninun hydroxide, magnesium hydroxide, antimony pentoxide, calciun carbonate, sodium carbonate and az ⁇ dicarbonamide may be used as the silicate flame retardant.
  • the step of making the first coated beads 20 may further comprise a step (SIa) of coating the silicate flame retardant-coated expanded polystyrene beads 10 with an organic coating material, such as acrylate, polyvinyl alcohol, melamine, phenol or urea, thus making first coated beads.
  • an organic coating material such as acrylate, polyvinyl alcohol, melamine, phenol or urea
  • the organic coating material is provided in order to enhance water resistance to steam and cooling water, which are supplied in a post-expansion process to be described later.
  • the organic coating material can be coated on the first coated beads 20 by itself, it is to be understood that a mixture of 50-99.9 wt% of the silicate flame retardant with 0.01-50 wt% of the organic coating material may be coated on the expanded polystyrene beads 10.
  • the first coated beads can be post-expanded in a mold 40, but the silicate flame retardant can be dissolved and removed by steam and cooling water, which are supplied into the mold 40 during the post-expansion.
  • the inventive method comprises, after making the first coated beads 20 and 21 as described above, a step (S2) of coating the first coated beads 20 and 21 with the water-resistant coating material in order to impart water resistance properties to the first coated beads 20 and 21, thus making second coated beads 30.
  • coating the first coated beads with the water-resistant coating material can be performed in the above -described ribbon mixer.
  • the water-resistant coating material can be provided as a liquid coating material having heat resistance and water resistance.
  • the water resistant coating material can be provided as ethylene acrylic acid in the form of a solution of an acrylic resin, having an acrylate solid content of 10-75%, in ethyl alcohol, methyl alcohol or water.
  • the water-resistant coating material can be provided as an aqueous solution of polyester or acrylate such as acryl.
  • a melamine-, phenol- or urea-containing organic resin in acetic formaldehyde, a mixed solution of said acrylate and inorganic silicon (6:4 w/w), polyvinyl alcohol (PVA), acetic acid vinyl resin solution, industrial casein, or casein sodiun.
  • silicate flame retardant can be added to the water-resistant coating material to increase the water resistance of the second coated beads 30 and at the same time, increase the flame retardant properties of the beads.
  • the injection unit 50 comprises a plurality of injection pipes 51. Although two injection pipes 51 are illustrated by way of example in HGS. 3 and 4, it is to be understood that one or two or more injection pipes 51 can be provided.
  • the injection pipes 51 are positioned at the insertion position A close to the bottom of the inside of the inner mold 42. Then, the second coated beads 30 are filled in the inner mold 42, and immediately after high- temperature steam is injected into the inner mold 42, the injection pipes 51 move to the withdrawing position B, while the water-resistant coating material, heated to 80 0 C or higher, is injected between the second coated beads uniformly through the injection pipes. After the movement of the injection pipes 51 to the withdrawing position B is completed, cooling water is introduced into the inner mold 42 to cool the expanded second coated beads 30, thus manufacturing flame-retardant expanded polystyrene blocks and molded products.
  • the water-resistant coating material injected through the injection pipes 51 are positioned between the expanded second coated beads 30, such that it also functions to bond the expanded second coated beads 30 with each other.
  • a water-resistant coating material consisting of 60 wt% of ethylene acrylic acid, having an acryl solid content of 75%, 10 wt% of ammoniun phosphate, and 30 wt% of lithiun silicate, was mixed with 600 g of the first coated beads 20 and 21 in the ribbon mixer.
  • the mixture was dried with hot air, having a temperature of 70 0C, for 5 minutes, and then aged and dried in a drying chamber at a hot air temperature of 80 0 C for more than 2 hours, thus obtaining 780 g of white second coated beads 30.
  • the gray and white second coated beads 30 were placed in a mold and a steam molding machine and applied with steam at a pressure of about 0.75 kg/m 2 for 20 seconds and with cooling water for 1 minute. Then, the second coated beads 30 are dried, thus obtaining white and gray flame -retardant expanded polystyrene molded products.
  • the present invention allows the manufacture of flame-retardant polystyrene blocks and molded products, which serve as an insulation barrier against the heat and flame of flame and, at the same time, block the supply of oxygen, which assists in burning, so as to minimize the generation of hazardous gases, such as carbon monoxide and carbon dioxide, caused by burning.
  • the silicate flame retardant is provided on the surface of the polyester blocks and molded products.
  • the flame- retardant expanded polystyrene blocks and molded products according to the present invention can be attached to cement or concrete without using a separate adhesive material such as mortar, and thus they can be used as building materials.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)

Abstract

La présente invention concerne un procédé permettant de fabriquer des blocs de polystyrène expansé ignifuges et des produits moulés associés. Plus précisément, le procédé selon l'invention comprend les étapes consistant : à déposer un produit ignifuge à base de silicate contenant du dioxyde de silicium sur des billes de polystyrène expansé dans un préexpanseur, et à sécher les billes revêtues afin d'obtenir des premières billes revêtues; à revêtir les premières billes revêtues d'une matière de revêtement résistante à l'eau contenant un ou plusieurs éléments sélectionnés parmi l'acide éthylène acrylique sous forme de solution de résine acrylique dans de l'éthanol, du méthanol ou de l'eau, une solution aqueuse à base d'acrylate, une solution aqueuse à base d'une résine organique contenant de la mélamine, du phénol ou de l'urée dans un formaldéhyde acétique, une solution aqueuse mixte d'acrylate et de silicium, un alcool polyvinylique, une solution de résine vinylique d'acide acétique, la caséine industrielle et le caséinate de sodium, et à sécher la matière de revêtement résistante à l'eau revêtue, ce qui permet d'obtenir des secondes billes revêtues; et à fabriquer des blocs de polystyrène expansé et des produits moulés à partir des secondes billes revêtues. Conformément au procédé selon l'invention, l'on empêche la dissolution et l'élimination, par la vapeur et l'eau de refroidissement, d'une première matière de revêtement déposée sur ledit polystyrène expansé aux fins d'ignifugation, pendant la fabrication du bloc de polystyrène expansé ignifuge et du produit moulé, ce qui garantit l'ininflammabilité.
PCT/KR2008/000990 2007-02-28 2008-02-20 Procédé de fabrication de blocs de polystyrène expansé ignifuges et de produits moulés associés WO2008105595A1 (fr)

Applications Claiming Priority (2)

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KR1020070020621A KR100799282B1 (ko) 2007-02-28 2007-02-28 난연 발포폴리스티렌 블록 및 형물의 제조방법
KR10-2007-0020621 2007-02-28

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010146146A1 (fr) * 2009-06-19 2010-12-23 Basf Se Particules de mousse synthétique enrobées
WO2011064230A1 (fr) * 2009-11-27 2011-06-03 Basf Se Composition de revêtement pour particules de mousse
WO2011107365A1 (fr) * 2010-03-04 2011-09-09 Basf Se Matériaux lignocellulosiques ayant de bonnes propriétés mécaniques
WO2011113795A2 (fr) 2010-03-17 2011-09-22 Basf Se Mousse composite ignifugée
FR3011242A1 (fr) * 2013-09-30 2015-04-03 Saint Gobain C R E E Polystyrene expanse ignifuge par hydroxyde d’aluminium
CN109593363A (zh) * 2018-11-23 2019-04-09 唐山师范学院 阻燃室温硫化硅橡胶配方及阻燃室温硫化硅橡胶
US10612736B2 (en) 2014-08-25 2020-04-07 Molex, Llc Luminaire

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KR101480191B1 (ko) 2008-08-21 2015-01-08 오광환 난연성 스티로폼 보드의 제조방법
KR101083334B1 (ko) 2009-12-08 2011-11-14 한강석 준불연 방음벽체
KR101493434B1 (ko) 2014-10-07 2015-02-16 엄봉섭 발포 폴리스티렌용 난연성 코팅제 조성물
KR101802383B1 (ko) * 2015-12-08 2017-11-29 주식회사 휴비스 코어-쉘 구조의 발포체
KR101966645B1 (ko) * 2018-07-03 2019-04-09 (주)에스씨글로벌 발포폴리스티렌(eps) 코팅 조성물 및 이를 이용한 경량골재의 제조방법
KR101967334B1 (ko) * 2018-11-05 2019-08-14 (주)에이티산업 경량내화블록 제조 거푸집 및 이를 이용한 블록 제조방법
CZ2019445A3 (cs) * 2019-07-05 2020-09-23 First Point a.s. Izolační materiál a způsob jeho výroby

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US7128973B2 (en) * 2004-01-30 2006-10-31 Bong-Kuk Park Expanded polystyrene bead having functional skin layer, manufacturing process thereof, and functional EPS product and manufacturing process thereof using the same

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US5985943A (en) * 1996-05-14 1999-11-16 Basf Aktiengesellschaft Expandable polystyrene particles
KR20020060053A (ko) * 2001-01-09 2002-07-16 박종원 내열성이 우수한 초경량의 난연성 단열재 조성물과 그제조장치 및 그를 이용한 제조방법
US20060175586A1 (en) * 2002-12-18 2006-08-10 Prometheus Developments Limited Fire resistant materials
KR20040084006A (ko) * 2003-03-26 2004-10-06 주식회사 현암 난연 폴리스티렌 패널 및 그 제조방법
US7128973B2 (en) * 2004-01-30 2006-10-31 Bong-Kuk Park Expanded polystyrene bead having functional skin layer, manufacturing process thereof, and functional EPS product and manufacturing process thereof using the same

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010146146A1 (fr) * 2009-06-19 2010-12-23 Basf Se Particules de mousse synthétique enrobées
WO2011064230A1 (fr) * 2009-11-27 2011-06-03 Basf Se Composition de revêtement pour particules de mousse
WO2011107365A1 (fr) * 2010-03-04 2011-09-09 Basf Se Matériaux lignocellulosiques ayant de bonnes propriétés mécaniques
WO2011113795A2 (fr) 2010-03-17 2011-09-22 Basf Se Mousse composite ignifugée
FR3011242A1 (fr) * 2013-09-30 2015-04-03 Saint Gobain C R E E Polystyrene expanse ignifuge par hydroxyde d’aluminium
US10612736B2 (en) 2014-08-25 2020-04-07 Molex, Llc Luminaire
CN109593363A (zh) * 2018-11-23 2019-04-09 唐山师范学院 阻燃室温硫化硅橡胶配方及阻燃室温硫化硅橡胶
CN109593363B (zh) * 2018-11-23 2021-05-25 唐山师范学院 阻燃室温硫化硅橡胶配方及阻燃室温硫化硅橡胶

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