KR102819831B1 - A Light-Weight Expanded Foam Composition for Organic-Inorganic Hybrid Fireproof Filler with Increasing Flame Retardant and Preparation Methods of Light-Weight Expanded Foam Using Thereof - Google Patents
A Light-Weight Expanded Foam Composition for Organic-Inorganic Hybrid Fireproof Filler with Increasing Flame Retardant and Preparation Methods of Light-Weight Expanded Foam Using Thereof Download PDFInfo
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Abstract
본 발명은 멜라민 수지 100중량부 기준으로, 섬유 4 내지 30중량부; 탄산나트륨 6 내지 30중량부; 탈크 15 내지 30중량부; 산화마그네슘 15 내지 70중량부; 생석회 4 내지 15중량부; 팽창질석 15 내지 25중량부; 펄라이트 6 내지 25중량부; 물유리 100 내지 120중량부; 난연제 5 내지 8중량부; 및 경화제 1 내지 10중량부를 포함하는 내화충진재용 경량발포폼 조성물을 제공한다.
본 발명에 따른 내화충진재용 경량발포폼 조성물, 특정적으로 난연성이 향상된 유무기 혼합 내화충진재용 경량발포폼 조성물은 포르말린과 멜라민의 축합반응 후 난연 및 무기계 화합물을 첨가하여 건축내장재 기준의 준불연 효과를 갖는 경량성 멜라민 수지를 제조함으로써, 기존 멜라민 수지의 장점을 유지하면서도 건축물 내장재 기준에 부합하는 난연성이 향상된 유무기 혼합 내화충진재용 경량발포폼 조성물을 제공한다.The present invention provides a lightweight foam composition for a refractory filler, comprising, based on 100 parts by weight of a melamine resin, 4 to 30 parts by weight of fiber; 6 to 30 parts by weight of sodium carbonate; 15 to 30 parts by weight of talc; 15 to 70 parts by weight of magnesium oxide; 4 to 15 parts by weight of quicklime; 15 to 25 parts by weight of expanded vermiculite; 6 to 25 parts by weight of perlite; 100 to 120 parts by weight of water glass; 5 to 8 parts by weight of a flame retardant; and 1 to 10 parts by weight of a curing agent.
A lightweight foam composition for a refractory filler according to the present invention, specifically a lightweight foam composition for an organic/inorganic mixed refractory filler with improved flame retardancy, is produced by adding a flame retardant and inorganic compound after a condensation reaction of formalin and melamine to produce a lightweight melamine resin having a quasi-fireproof effect meeting the standards for building interior materials, thereby providing a lightweight foam composition for an organic/inorganic mixed refractory filler with improved flame retardancy that meets the standards for building interior materials while maintaining the advantages of existing melamine resins.
Description
본 발명은 난연성이 향상된 유무기 혼합 내화충진재용 경량발포폼 조성물 및 이를 이용한 경량발포폼 제조방법에 관한 것으로서, 보다 상세하게는 건축 내장재용 기준에 맞는 준불연급의 난연성능을 제공하면서 경량성을 향상시킬 수 있도록 하는 난연성이 향상된 유무기 혼합 내화충진재용 경량발포폼 조성물 및 이를 이용한 내화충진재용 경량발포폼 제조방법에 관한 것이다.The present invention relates to a lightweight foam composition for an organic/inorganic mixed refractory filler with improved flame retardancy, and a method for manufacturing a lightweight foam using the same. More specifically, the present invention relates to a lightweight foam composition for an organic/inorganic mixed refractory filler with improved flame retardancy, which provides flame retardancy performance at a quasi-noncombustible level that meets the standards for building interior materials while improving lightness, and a method for manufacturing a lightweight foam for a refractory filler with the same.
일반적으로 건축자재는 건축물 내/외장재로 많이 사용되고 있는 합성 유기화학물질을 이용한 스치로폼, 우레탄, 합성수지 등과 기타 비닐, 나일론, 멜라민 등 수지류로 만든 샌드위치 판넬 및 천연 건축재료로 목재와 종이 및 부직포(Non woven fabric)등을 활용하여 합판(Veneer board) 및 천장(Board a ceiling)재와 벽지(Wall paper) 등 수 많은 종류의 건축자재가 생산되어 사용되고 있다.In general, building materials are widely used as interior/exterior materials for buildings, including styrofoam, urethane, synthetic resins, and other synthetic organic chemical substances; sandwich panels made of resins such as vinyl, nylon, and melamine; and veneer boards, ceiling materials, and wallpaper made of natural building materials such as wood, paper, and non-woven fabric.
이러한 건축자재들은 화재가 발생하게 되면 인화성이 강하여 대형화재로 발전할 수 있고, 화재발생시 많은 양의 유독성물질과 독가스 및 매연 등을 발생시켜 많은 인명과 재산 피해를 유발하고, 소화(消火)시킬 때도 소화가 잘 되지 않는 문제점을 내포하고 있지만, 저렴한 가격 및 간편한 시공성과 용도의 적합성으로 인하여, 그 사용량이 증가하고 있다.These building materials are highly flammable and can develop into large-scale fires if a fire breaks out, and when a fire breaks out, they produce a large amount of toxic substances, poisonous gases, and smoke, causing many casualties and property damage. In addition, they are difficult to extinguish when put out, but their use is increasing due to their low price, easy construction, and suitability for use.
이에, 정부에서는 화재에 대한 취약성이 높고 안전성이 담보되지 못한 전술한 건축자재를 난연 및 불연성 건축자재로 대체하여 사용하는 것을 권장하고 있다.Accordingly, the government recommends replacing the aforementioned building materials, which are highly vulnerable to fire and have unsafe properties, with flame-retardant and non-combustible building materials.
한편, 건축자재의 내화충진재로 사용되는 우레탄폼은 할로겐계 화합물로써 인(Phosphate)을 첨가시킬 경우, 난연성을 띠기는 하나 불연성은 아니며, 한번 불이 붙으면 폭열을 일으키며 연소하는 특성이 있다.Meanwhile, urethane foam, which is used as a fireproofing material for building materials, is a halogen compound, and although it is flame retardant when phosphorus is added, it is not non-flammable, and once ignited, it has the characteristic of burning and exploding.
특히, 일반적인 발포제로 사용되는 물질로는 발포성이 뛰어난 할로겐족계열 화합물을 사용하는 경향이 있지만. 본 발명에 따른 발명자들은 이에 대한 대체품으로써 비할로겐계 물질로서 친환경이면서도 우레탄폼과 같이 경량성을 확보할 수 있는 준불연계 멜라민폼을 개발하여 본 발명을 완성하기에 이르렀다.In particular, there is a tendency to use halogen compounds with excellent foaming properties as materials used as general foaming agents. However, the inventors of the present invention have developed a semi-fireproof melamine foam that is an environmentally friendly, non-halogen material that can secure lightness like urethane foam as a substitute for this, and have thus completed the present invention.
특히, 상기 멜라민폼은 내열성이 약 305℃까지 유지되므로 내열성과 난연성이 동시에 요구되는 곳에 적용이 가능하여, 현재 난연 규제가 엄격한 건축용 내장재로 제시되고 있다. In particular, since the melamine foam maintains heat resistance up to approximately 305°C, it can be applied in places where both heat resistance and flame retardancy are required, and is currently being suggested as an architectural interior material subject to strict flame retardancy regulations.
하지만, 상기 멜라민폼이 난연 재료라 해도 건축 내장재용으로 사용하기에는 상대적으로 낮은 수준의 난연성 및 경량성을 나타내고 있다는 문제점은 극복하여야 한다.However, even though the above melamine foam is a flame retardant material, it has a problem that it exhibits relatively low levels of flame retardancy and lightness for use as building interior materials, and this problem must be overcome.
한편, 국내공개특허 10-2012-0077898호에는 표면에 멜라민을 코팅시킨 무기 충진제를 포함하는 발포체 조성물을 개시하고 있다.Meanwhile, domestic patent publication No. 10-2012-0077898 discloses a foam composition containing an inorganic filler having melamine coated on the surface.
본 발명은 전술한 문제점을 극복하기 위해 창출된 것으로서, 건축 내장재용 기준에 맞는 준불연급의 난연성능을 제공하면서 경량성을 향상시킬 수 있도록 하는 내화충진재용 경량발포폼 조성물 및 이를 이용한 내화충진재용 경량발포폼 제조방법을 제공하고자 한다.The present invention has been created to overcome the aforementioned problems, and aims to provide a lightweight foam composition for a fire-resistant filler material that can improve lightness while providing flame retardancy performance at a quasi-noncombustible level that meets the standards for building interior materials, and a method for manufacturing a lightweight foam composition for a fire-resistant filler material using the same.
본 발명은 The present invention
멜라민 수지 100중량부 기준으로,Based on 100 parts by weight of melamine resin,
섬유 4 내지 30중량부;4 to 30 parts by weight of fiber;
탄산나트륨 6 내지 30중량부;6 to 30 parts by weight of sodium carbonate;
탈크 15 내지 30중량부;15 to 30 parts by weight of talc;
산화마그네슘 15 내지 70중량부;15 to 70 parts by weight of magnesium oxide;
생석회 4 내지 15중량부;4 to 15 parts by weight of quicklime;
팽창질석 15 내지 25중량부;15 to 25 parts by weight of expanded clay;
펄라이트 6 내지 25중량부;6 to 25 parts by weight of perlite;
물유리 100 내지 120중량부;100 to 120 parts by weight of water glass;
난연제 5 내지 8중량부; 및5 to 8 parts by weight of flame retardant; and
경화제 1 내지 10중량부를 포함하는 내화충진재용 경량발포폼 조성물을 제공한다.A lightweight foam composition for refractory filling material containing 1 to 10 parts by weight of a hardener is provided.
또한, 본 발명은In addition, the present invention
멜라민수지 100중량부 기준으로, 섬유 4 내지 30중량부, 탄산나트륨 6 내지 30중량부, 탈크 15 내지 30중량부, 산화마그네슘 15 내지 70중량부, 생석회 4 내지 15중량부, 팽창질석 15 내지 25중량부, 펄라이트 6 내지 25중량부, 물유리 100 내지 120중량부, 및 난연제 5 내지 8중량부를 혼합하는 경량발포폼 조성물 제조단계;A step for producing a lightweight foam composition, wherein 4 to 30 parts by weight of fiber, 6 to 30 parts by weight of sodium carbonate, 15 to 30 parts by weight of talc, 15 to 70 parts by weight of magnesium oxide, 4 to 15 parts by weight of quicklime, 15 to 25 parts by weight of expanded vermiculite, 6 to 25 parts by weight of perlite, 100 to 120 parts by weight of water glass, and 5 to 8 parts by weight of a flame retardant are mixed based on 100 parts by weight of melamine resin;
상기 경량발포폼 조성물 제조단계를 통해 제조한 경량발포폼 조성물과 멜라민수지 100중량부 기준으로 경화제 1 내지 10중량부를 각각 발포기에 투입하여 발포하는 발포단계;A foaming step of foaming by adding 1 to 10 parts by weight of a hardener based on 100 parts by weight of a melamine resin and the lightweight foam composition manufactured through the above lightweight foam composition manufacturing step into a foaming machine;
상기 발포단계가 종료된 경량발포폼을 원하는 모양으로 성형하는 성형단계; 및A molding step for molding the lightweight foam into a desired shape after completing the foaming step; and
상기 성형단계가 종료된 후 성형된 경량발포폼을 건조하는 건조단계를 포함하는 내화충진재용 경량발포폼 제조방법을 제공한다.A method for manufacturing lightweight foam for refractory filling material is provided, which includes a drying step of drying the molded lightweight foam after the above molding step is completed.
본 발명에 따른 내화충진재용 경량발포폼 조성물, 특정적으로 난연성이 향상된 유무기 혼합 내화충진재용 경량발포폼 조성물은 포르말린과 멜라민의 축합반응 후 난연 및 무기계 화합물을 첨가하여 건축내장재 기준의 준불연 효과를 갖는 경량성 멜라민 수지를 제조함으로써, 기존 멜라민 수지의 장점을 유지하면서도 건축물 내장재 기준에 부합하는 난연성이 향상된 유무기 혼합 내화충진재용 경량발포폼 조성물을 제공한다.A lightweight foam composition for a refractory filler according to the present invention, specifically a lightweight foam composition for an organic/inorganic mixed refractory filler with improved flame retardancy, is produced by adding a flame retardant and inorganic compound after a condensation reaction of formalin and melamine to produce a lightweight melamine resin having a quasi-fireproof effect meeting the standards for building interior materials, thereby providing a lightweight foam composition for an organic/inorganic mixed refractory filler with improved flame retardancy that meets the standards for building interior materials while maintaining the advantages of existing melamine resins.
이하, 본 발명을 구체적으로 설명한다.Hereinafter, the present invention will be described in detail.
한 가지 관점에서, 본 발명은 멜라민 수지 100중량부 기준으로, 섬유 4 내지 30중량부; 탄산나트륨 6 내지 30중량부; 탈크 15 내지 30중량부; 산화마그네슘 15 내지 70중량부; 생석회 4 내지 15중량부; 팽창질석 15 내지 25중량부; 펄라이트 6 내지 25중량부; 물유리 100 내지 120중량부; 난연제 5 내지 8중량부; 및 경화제 1 내지 10중량부를 포함하는 내화충진재용 경량발포폼 조성물을 제공한다.In one aspect, the present invention provides a lightweight foam composition for a refractory filler, comprising, based on 100 parts by weight of a melamine resin, 4 to 30 parts by weight of fiber; 6 to 30 parts by weight of sodium carbonate; 15 to 30 parts by weight of talc; 15 to 70 parts by weight of magnesium oxide; 4 to 15 parts by weight of quicklime; 15 to 25 parts by weight of expanded vermiculite; 6 to 25 parts by weight of perlite; 100 to 120 parts by weight of water glass; 5 to 8 parts by weight of a flame retardant; and 1 to 10 parts by weight of a curing agent.
다른 관점에서, 본 발명은 멜라민수지 100중량부 기준으로, 섬유 4 내지 30중량부, 탄산나트륨 6 내지 30중량부, 탈크 15 내지 30중량부, 산화마그네슘 15 내지 70중량부, 생석회 4 내지 15중량부, 팽창질석 15 내지 25중량부, 펄라이트 6 내지 25중량부, 물유리 100 내지 120중량부, 및 난연제 5 내지 8중량부를 혼합하는 경량발포폼 조성물 제조단계; 상기 경량발포폼 조성물 제조단계를 통해 제조한 경량발포폼 조성물과 멜라민수지 100중량부 기준으로 경화제 1 내지 10중량부를 각각 발포기에 투입하여 발포하는 발포단계; 상기 발포단계가 종료된 경량발포폼을 원하는 모양으로 성형하는 성형단계; 및 상기 성형단계가 종료된 후 성형된 경량발포폼을 건조하는 건조단계를 포함하는 내화충진재용 경량발포폼 제조방법을 제공한다.From another perspective, the present invention provides a lightweight foam composition manufacturing step of mixing, based on 100 parts by weight of a melamine resin, 4 to 30 parts by weight of fiber, 6 to 30 parts by weight of sodium carbonate, 15 to 30 parts by weight of talc, 15 to 70 parts by weight of magnesium oxide, 4 to 15 parts by weight of quicklime, 15 to 25 parts by weight of expanded vermiculite, 6 to 25 parts by weight of perlite, 100 to 120 parts by weight of water glass, and 5 to 8 parts by weight of a flame retardant; a foaming step of foaming by introducing, into a foaming machine, respectively, the lightweight foam composition manufactured through the lightweight foam composition manufacturing step and 1 to 10 parts by weight of a hardener based on 100 parts by weight of the melamine resin; a molding step of molding the lightweight foam, after the foaming step, into a desired shape; The present invention provides a method for manufacturing lightweight foam for refractory filling, including a drying step of drying the formed lightweight foam after the forming step is completed.
본 발명에 따른 멜라민 수지는 내수성, 내약품성, 내열성이 뛰어날 뿐만 아니라, 무색투명하여 다양한 착색이 용이하며, 발포폼 형태로 제조될 경우 내열성이 약 305℃까지 유지되므로 내열성과 난연성이 동시에 요구되는 곳에 적용하는 것이 가능하다.The melamine resin according to the present invention not only has excellent water resistance, chemical resistance, and heat resistance, but is also colorless and transparent, making it easy to color in various ways. When manufactured in the form of a foam, the heat resistance is maintained up to about 305°C, so it can be applied to places where both heat resistance and flame retardancy are required.
본 발명에 따른 멜라민 수지는 당업계의 통상적인 멜라민 수지라면 어떠한 것을 사용하여도 무방하지만, 제조되는 발포폼, 특정적으로 내화충진재용 경량발포폼의 크랙 또는 파열 등에 대한 내구성을 향상시키기 위해 순수 멜라민 수지보다는 변성멜라민 수지를 사용하는 것을 추천한다.The melamine resin according to the present invention may be any conventional melamine resin in the art, but it is recommended to use a modified melamine resin rather than a pure melamine resin in order to improve the durability of the manufactured foam, specifically, lightweight foam for use as a refractory filler, against cracking or bursting.
여기서, 상기 변성멜라민 수지는 20 내지 30중량% 정도의 유리아 수지가 함유된 것을 사용하는 것이 좋은바, 상기 변성멜라민 수지에 함유된 유리아 수지의 함량이 30중량% 보다 많을 때에는 물에 대한 흡수성이 높아지므로 내수성이 떨어지는 데 반해, 20중량% 보다 적을 때에는 경성이 높으므로 충격에 대한 내구성이 감소하게 됨으로 유리아 수지의 함량이 상기한 범위 내에서 유지될 있도록 하는 것이 좋다.Here, it is preferable to use the modified melamine resin containing about 20 to 30 wt% of uranium resin. When the content of uranium resin contained in the modified melamine resin exceeds 30 wt%, the water absorbency increases, so the water resistance decreases. On the other hand, when it is less than 20 wt%, the hardness increases, so the impact durability decreases. Therefore, it is preferable to maintain the content of uranium resin within the above-mentioned range.
본 발명에 따른 경량발포폼 조성물, 특정적으로 내화충진재용 경량발포폼 조성물, 보다 특정적으로 난연성이 향상된 유무기 혼합 내화충진재용 경량발포폼 조성물을 구성하는 멜라민 수지 외 나머지 성분들의 함량은 멜라민 수지 100중량부 기준으로 한다.The content of the remaining components other than the melamine resin constituting the lightweight foam composition according to the present invention, specifically the lightweight foam composition for refractory fillers, and more specifically the lightweight foam composition for inorganic/organic mixed refractory fillers with improved flame retardancy, is based on 100 parts by weight of the melamine resin.
본 발명에 따른 섬유는 경량발포폼 조성물, 특정적으로 내화충진재용 경량발포폼 조성물 또는 이들로부터 제조되는 멜라민폼 구조체의 균열저항성, 내마모성, 구조 안정성 등을 향상시키고, 구조적 충격 및 파괴력을 분산시키기 위한 것으로서, 이러한 목적을 갖는 당업계의 통상적인 섬유라면 어떠한 것을 사용하여도 무방하지만, 바람직하게는 폴리에틸렌(PE)섬유, 폴리프로필렌(PP)섬유, 폴리에틸렌테레프탈레이트(PET)섬유, 탄소섬유 또는 이들로부터 선택된 적어도 하나 이상의 혼합물을 사용하는 것이 좋지만, 보다 바람직하게는 폴리프로필렌 섬유를 사용하는 것을 추천한다.The fiber according to the present invention is intended to improve the crack resistance, wear resistance, structural stability, etc. of a lightweight foam composition, specifically a lightweight foam composition for refractory filling material, or a melamine foam structure manufactured therefrom, and to disperse structural impact and destructive force. Any fiber conventional in the art having such a purpose may be used, but it is preferably polyethylene (PE) fiber, polypropylene (PP) fiber, polyethylene terephthalate (PET) fiber, carbon fiber, or a mixture of at least one selected therefrom, but it is more preferably recommended to use polypropylene fiber.
바람직한 섬유의 사용량은 사용자의 선택에 따라 변경 가능하지만, 추천하기로는 멜라민 수지 100중량부 기준으로 4 내지 30중량부인 것이 좋다.The amount of desired fiber to be used can be varied depending on the user's preference, but it is recommended to use 4 to 30 parts by weight based on 100 parts by weight of melamine resin.
본 발명에 따른 탄산나트륨은 경량발포폼 조성물의 수화반응을 촉진시켜 조기강도 발현을 향상시키도록 하는 것으로서, 이러한 목적을 위해 당업계에서 통상적으로 사용하는 탄산나트륨이라면 어떠한 것을 사용하여도 무방하며, 그 사용량은 멜라민 수지 100중량부 기준으로 6 내지 30중량부인 것이 좋다.The sodium carbonate according to the present invention promotes the hydration reaction of a lightweight foam composition to improve early strength development. For this purpose, any sodium carbonate commonly used in the art may be used, and the amount used is preferably 6 to 30 parts by weight based on 100 parts by weight of melamine resin.
본 발명에 따른 탈크는 내화충진재용 경량 발포폼 조성물의 경량성을 향상시키는 동시에 점도를 증진시키기 위한 것이다.The talc according to the present invention is intended to improve the lightness of a lightweight foam composition for use as a refractory filler while increasing viscosity.
바람직한 탈크의 사용량은 사용자의 선택에 따라 변경 가능하지만, 추천하기로는 멜라민 수지 100중량부 기준으로 15 내지 30중량부인 것이 좋다.The preferred amount of talc to be used can be varied depending on the user's preference, but it is recommended to use 15 to 30 parts by weight based on 100 parts by weight of melamine resin.
본 발명에 따른 산화마그네슘은 수화작용의 진행속도를 조절, 바람직하게는 느리게 진행되도록 조절하여 내화충진재용 경량발포폼 조성물이 멜라민폼으로 제조될 때, 멜라민폼의 건조수축을 감소시키고, 장기 팽창성을 향상시키기 위한 것이다.Magnesium oxide according to the present invention is used to control the rate of hydration, preferably to control it to proceed slowly, so as to reduce the drying shrinkage of melamine foam and improve long-term expansion properties when a lightweight foam composition for refractory filler is manufactured with melamine foam.
바람직한 산화마그네슘의 사용량은 사용자의 선택에 따라 변경 가능하지만, 추천하기로는 멜라민 수지 100중량부 기준으로 15 내지 70중량부인 것이 좋다.The preferred amount of magnesium oxide to be used can be varied depending on the user's preference, but is recommended to be 15 to 70 parts by weight based on 100 parts by weight of melamine resin.
본 발명에 따른 생석회는 내화충진재용 경량발포폼 조성물의 건조 초기와 건조 후기의 수축을 일정하게 저감시켜 조성물 전체적으로 균일한 발포성을 나타내도록 하는 동시에 수축율을 감소시키기 위한 것으로서, 이러한 목적을 갖는 당업계의 통상적인 생석회라면 어떠한 것을 사용하여도 무방하다.The quicklime according to the present invention is intended to reduce shrinkage in the early and late stages of drying of a lightweight foam composition for refractory filler material, thereby ensuring uniform foamability throughout the composition, while reducing shrinkage. Any conventional quicklime used in the art for this purpose may be used.
바람직한 생석회의 사용량은 사용자의 선택에 따라 변경 가능하지만, 추천하기로는 멜라민 수지 100중량부 기준으로 4 내지 15중량부를 사용하는 것이 좋다.The preferred amount of quicklime to be used can be varied depending on the user's preference, but it is recommended to use 4 to 15 parts by weight per 100 parts by weight of melamine resin.
본 발명에 따른 팽창질석은 경량발포폼 조성물, 특정적으로 내화충진재용 경량발포폼 조성물로 제조되는 발포폼의 공극크기의 단일화 구조 안정성을 향상시키기 위한 것이다.The expanded stone according to the present invention is intended to improve the single-structure stability of the pore size of a foam manufactured from a lightweight foam composition, specifically a lightweight foam composition for use as a refractory filler.
바람직한 팽창질석의 사용량은 멜라민 수지 100중량부 기준으로 15 내지 25중량부인 것을 추천한다.The recommended amount of expanded stone to be used is 15 to 25 parts by weight based on 100 parts by weight of melamine resin.
본 발명에 따른 펄라이트는 내화충진재용 경량발포폼 조성물의 경량성과 점도증진을 향상시키기 위한 것으로서, 이러한 목적을 갖는 당업계의 통상적인 펄라이트라면 어떠한 것을 사용하여도 무방하고, 그 사용량은 멜라민 수지 100중량부 기준으로 6 내지 25중량부인 것이 좋다.The perlite according to the present invention is intended to improve the lightness and viscosity of a lightweight foam composition for use as a refractory filler. Any perlite conventional in the art for this purpose may be used, and the amount used is preferably 6 to 25 parts by weight based on 100 parts by weight of melamine resin.
본 발명에 따른 물유리는 내화충진재용 경량발포폼 조성물의 접착성을 제공하기 위한 것으로서, 이러한 목적을 갖는 당업계의 통상적인 물유리라면 어떠한 것을 사용하여도 무방하다.The water glass according to the present invention is intended to provide adhesiveness to a lightweight foam composition for use as a refractory filler, and any water glass conventional in the art for this purpose may be used.
바람직한 물유리는 사용자의 선택에 따라 변경 가능하지만, 추천하기로는 멜라민 수지 100중량부 기준으로 100 내지 120중량부인 것이 좋다.The preferred water glass content can be varied according to the user's preference, but it is recommended to be 100 to 120 parts by weight based on 100 parts by weight of melamine resin.
본 발명에 따른 난연제는 상기 물유리의 접착강도를 보강하는 동시에 내화창진재용 경량발포폼 조성물의 난연성을 제공하기 위한 것으로서, 이러한 목적을 위해 당업계에서 통상적으로 사용하는 난연제라면 어떠한 것을 사용하여도 무방하지만, 바람직하게는 멜라민시아누레이트, 인계 난연제, 예를 들면 "DAIGUARD-880 다이하치사"에서 제조되는 난연제 또는 이들로부터 선택된 적어도 하나 이상의 혼합물을 사용하는 것이 좋다.The flame retardant according to the present invention is intended to provide flame retardancy of a lightweight foam composition for fireproof and earthquake-resistant materials while reinforcing the adhesive strength of the water glass. For this purpose, any flame retardant commonly used in the art may be used, but it is preferably used melamine cyanurate, a phosphorus-based flame retardant, for example, a flame retardant manufactured by "DAIGUARD-880 Daihachi", or a mixture of at least one selected therefrom.
바람직한 난연제의 사용량은 멜라민 수지 100중량부 기준으로 5 내지 8중량부인 것을 추천한다.The recommended amount of flame retardant is 5 to 8 parts by weight based on 100 parts by weight of melamine resin.
본 발명에 따른 경화제는 경량발포폼 조성물, 특정적으로 내화충진재용 경량발포폼 조성물, 보다 특정적으로 난연성이 향상된 유무기 혼합 내화충진재용 경량발포폼 조성물을 경화시키기 위한 것으로서, 이러한 목적을 갖는 당업계의 통상적인 경화제라면 어떠한 것을 사용하여도 무방하며, 그 사용량은 멜라민 수지 100중량부 기준으로 1 내지 10중량부인 것이 바람직하다.The curing agent according to the present invention is for curing a lightweight foam composition, specifically a lightweight foam composition for refractory fillers, and more specifically a lightweight foam composition for organic/inorganic mixed refractory fillers with improved flame retardancy. Any curing agent conventional in the art having this purpose may be used, and the amount used is preferably 1 to 10 parts by weight based on 100 parts by weight of melamine resin.
특정 양태로서, 본 발명에 따른 경화제는 인산 100중량부 기준으로, 포름산 50 내지 120중량부; 옥살산 20 내지 110중량부; 용매 200 내지 400중량부; 및 기포제 20 내지 50중량부를 포함하는 것이 좋다.In a specific embodiment, the curing agent according to the present invention preferably contains 50 to 120 parts by weight of formic acid; 20 to 110 parts by weight of oxalic acid; 200 to 400 parts by weight of solvent; and 20 to 50 parts by weight of foaming agent, based on 100 parts by weight of phosphoric acid.
여기서, 상기 인산은 당업계의 통상적인 인산을 사용하는 것이 좋지만, 바람직하게는 80 내지 90% 인산수용액을 사용하는 것을 추천한다.Here, it is recommended to use the phosphoric acid commonly used in the art, but it is recommended to use an 80 to 90% phosphoric acid aqueous solution.
또한, 상기 용매는 당업계의 통상적인 용매, 예를 들면 물, 정제수 등이라면 어떠한 것을 사용하여도 무방하다.In addition, any solvent that is commonly used in the art, such as water or purified water, may be used.
또한, 상기 기포제는 당업계의 통상적인 기포제라면 어떠한 것을 사용하여도 무방하지만, 추천하기로는 고급알콜 유도체 유산에스텔, 도데실벤젠설폰산 나트륨, 및 알킬올레핀설폰산나트륨이 단독 또는 조합하여 사용될 수 있다.In addition, any foaming agent that is conventional in the art may be used as the foaming agent, but it is recommended that higher alcohol derivatives such as lactic acid ester, sodium dodecylbenzene sulfonate, and sodium alkyl olefin sulfonate be used alone or in combination.
특정 양태로서, 상기 경화제는 전술한 경화제 조성물을 3 내지 5의 pH 및 60 내지 80℃의 온도조건에서 혼합하여 사용할 수 있다.In a specific embodiment, the curing agent can be used by mixing the above-described curing agent composition under conditions of a pH of 3 to 5 and a temperature of 60 to 80°C.
본 발명에 따른 경량발포폼 조성물, 특정적으로 내화충진재용 경량발포폼 조성물, 보다 특정적으로 난연성이 향상된 유무기 혼합 내화충진재용 경량발포폼 조성물은 하기의 특정 양태로 실시되는 부가물을 1종 또는 1종 이상 더 포함할 수 있다.The lightweight foam composition according to the present invention, specifically the lightweight foam composition for refractory fillers, and more specifically the lightweight foam composition for inorganic-organic mixed refractory fillers with improved flame retardancy, may further comprise one or more additives implemented in the following specific embodiments.
특정 양태로서, 본 발명에 따른 경량발포폼 조성물, 특정적으로 내화충진재용 경량발포폼 조성물, 보다 특정적으로 난연성이 향상된 유무기 혼합 내화충진재용 경량발포폼 조성물은 조성물의 발포시 중공을 형성하여 발포성을 향상시키기 위하여 멜라민 수지 100중량부 기준으로 1 내지 10중량부의 이산화탄소를 더 포함할 수 있다.In a specific embodiment, the lightweight foam composition according to the present invention, specifically the lightweight foam composition for refractory fillers, and more specifically the lightweight foam composition for organic/inorganic mixed refractory fillers with improved flame retardancy, may further contain 1 to 10 parts by weight of carbon dioxide based on 100 parts by weight of melamine resin to form a hollow cavity during foaming of the composition and thereby improve foamability.
다른 특정 양태로서, 본 발명에 따른 경량발포폼 조성물은 경량성과 강성을 제공하기 위하여 멜라민 수지 100중량부 기준으로 1 내지 5중량부의 폴리비닐알코올 분말을 더 포함할 수 있다.In another specific embodiment, the lightweight foam composition according to the present invention may further include 1 to 5 parts by weight of polyvinyl alcohol powder based on 100 parts by weight of melamine resin to provide lightness and rigidity.
여기서, 상기 폴리비닐알코올 분말은 0.1 내지 10㎛인 기공을 0.05 내지 0.4cc/g의 범위로 포함한다.Here, the polyvinyl alcohol powder contains pores of 0.1 to 10 μm in a range of 0.05 to 0.4 cc/g.
또 다른 양태로서, 본 발명에 따른 경량발포폼 조성물은 조성물에 포함된 각 구성성분이 서로 잘 분산되도록 하여 경화시 경화된 조성물 전체 물성이 균일할 수 있도록 하기 위하여 멜라민 수지 100중량부 기준으로 1 내지 5중량부의 수분산 폴리우레탄 분산제를 더 포함할 수 있다.In another embodiment, the lightweight foam composition according to the present invention may further include 1 to 5 parts by weight of a water-dispersible polyurethane dispersant based on 100 parts by weight of melamine resin to ensure that each component included in the composition is well dispersed with one another so that the overall physical properties of the cured composition are uniform during curing.
또 다른 특정 양태로서, 본 발명에 따른 경량발포폼 조성물은 조성물이 신속히 경화를 진행하여도 크랙 및 탈락현상을 개선하고, 조성물의 가공성, 밀착력 및 안정성 등을 제공하기 위하여 폴리비닐리덴플로라이드수지를 멜라민 수지 100중량부 기준으로 0.1 내지 3중량부로 더 포함할 수 있다.In another specific embodiment, the lightweight foam composition according to the present invention may further include 0.1 to 3 parts by weight of polyvinylidene fluoride resin based on 100 parts by weight of melamine resin in order to improve cracking and peeling phenomena even when the composition quickly hardens, and to provide processability, adhesion, stability, etc. of the composition.
또 다른 특정 양태로서, 본 발명에 따른 경량발포폼 조성물은 조성물의 경화시 수축을 방지하기 위하여 멜라민 수지 100중량부 기준으로 0.1 내지 3중량부의 네오펜틸글리콜(Neopentylglycol, NPG)을 더 포함할 수 있다.In another specific embodiment, the lightweight foam composition according to the present invention may further include 0.1 to 3 parts by weight of neopentylglycol (NPG) based on 100 parts by weight of melamine resin to prevent shrinkage during curing of the composition.
또 다른 특정 양태로서, 본 발명에 따른 경량발포폼 조성물은 강도, 내마모성 및 내화성을 개선하기 위하여 멜라민 수지 100중량부 기준으로 1 내지 3중량부의 깁사이트를 더 포함할 수 있다. In another specific embodiment, the lightweight foam composition according to the present invention may further contain 1 to 3 parts by weight of gibbsite based on 100 parts by weight of melamine resin to improve strength, wear resistance and fire resistance.
여기서, 상기 깁사이트의 사용량은 1중량부 미만일 경우 성능 개선 효과가 미약할 수 있고, 상기 깁사이트의 사용량이 3중량부를 초과할 경우에는 작업성이 저하되고 제조 원가가 높아져 경제적이지 못하다.Here, if the amount of gibbsite used is less than 1 part by weight, the performance improvement effect may be insignificant, and if the amount of gibbsite used exceeds 3 parts by weight, workability deteriorates and the manufacturing cost increases, making it uneconomical.
또 다른 특정 양태로서, 본 발명에 따른 경량발포폼 조성물은 강도, 내화성 및 내식성을 개선하기 위하여 멜라민 수지 100중량부 기준으로 0.1 내지 5중량부의 세륨을 더 포함할 수 있다. In another specific embodiment, the lightweight foam composition according to the present invention may further contain 0.1 to 5 parts by weight of cerium based on 100 parts by weight of melamine resin to improve strength, fire resistance, and corrosion resistance.
또 다른 특정 양태로서, 본 발명에 따른 경량발포폼 조성물은 조성물의 강도, 내화성, 내마모성, 및 내부식성 등을 개선하기 위하여 멜라민 수지 100중량부 기준으로 0.1 내지 2중량부의 할로이사이트(halloysite)를 더 포함할 수 있는데, 상기 할로이사이트는 알루미늄과 실리콘이 약 1:1의 비율로 포함되어 있는 점토질 광물질로서 이를 조성물에 포함시키면 상기와 같은 효과를 발현하게 된다.In another specific embodiment, the lightweight foam composition according to the present invention may further contain 0.1 to 2 parts by weight of halloysite based on 100 parts by weight of melamine resin in order to improve the strength, fire resistance, wear resistance, corrosion resistance, etc. of the composition. The halloysite is a clay mineral containing aluminum and silicon in a ratio of about 1:1, and when it is included in the composition, the above-described effects are exhibited.
또 다른 특정 양태로서, 본 발명에 따른 경량발포폼 조성물은 조성물의 장기강도 발현 및 내구성 증진을 위하여 겔라이트 미분말을 멜라민 수지 100중량부 기준으로 1 내지 3중량부로 더 포함할 수 있는데, 상기 겔라이트는 황토의 187배 이상의 효과를 가진 광물질로서 상기 효과 이외에 양질의 원적외선 방출 효과도 있는 것으로서, 바람직한 평균입도는 1 내지 5㎛ 이다.In another specific embodiment, the lightweight foam composition according to the present invention may further contain 1 to 3 parts by weight of gellite fine powder based on 100 parts by weight of melamine resin in order to improve the long-term strength expression and durability of the composition. The gellite is a mineral having an effect at least 187 times that of yellow clay, and in addition to the above effect, also has a high-quality far-infrared ray emission effect. The preferable average particle size is 1 to 5 ㎛.
또 다른 특정 양태로서, 본 발명에 따른 경량발포폼 조성물은 조성물의 건조 수축을 방지하기 위하여 멜라민 수지 100중량부 기준으로 0.1 내지 3중량부의 알루민산 칼슘을 더 포함할 수 있는데, 알루민산 칼슘이 경량발포폼 조성물에 포함되면 팽창성을 띄게 되어 조성물의 건조수축을 방지하게 되는 것으로, 그 사용량이 멜라민 수지 100중량부 기준으로 0.1중량부 미만이면 그 효과가 미미하며, 3중량부를 초과할 경우 과다하여 작업성을 저하시킬 수 있어 좋지 않다.In another specific embodiment, the lightweight foam composition according to the present invention may further contain 0.1 to 3 parts by weight of calcium aluminate based on 100 parts by weight of melamine resin in order to prevent drying shrinkage of the composition. When calcium aluminate is included in the lightweight foam composition, it exhibits expandability, thereby preventing drying shrinkage of the composition. However, if the amount used is less than 0.1 parts by weight based on 100 parts by weight of melamine resin, the effect is minimal, and if it exceeds 3 parts by weight, it is excessive and may lower workability, which is not good.
또 다른 특정 양태로서, 본 발명에 따른 경량발포폼 조성물은 조성물의 압축강도 및 휨강도를 향상시키기 위하여 멜라민 수지 100중량부 기준으로 1 내지 5중량부의 메타규산나트륨을 더 포함할 수 있는데, 그 함량이 1중량부 미만이면 유동성이 낮아지고 불규칙한 기포가 형성되며, 5중량부를 초과하면 경화시간을 확보하기 어려워 좋지 않다.In another specific embodiment, the lightweight foam composition according to the present invention may further contain 1 to 5 parts by weight of sodium metasilicate based on 100 parts by weight of melamine resin in order to improve the compressive strength and flexural strength of the composition. If the content is less than 1 part by weight, fluidity decreases and irregular bubbles are formed, and if it exceeds 5 parts by weight, it is difficult to secure a curing time, which is not good.
또 다른 특정 양태로서, 본 발명에 따른 경량발포폼 조성물은 조성물의 강도, 내마모성, 및 내구성을 향상시키기 위하여 질화마그네슘을 멜라민 수지 100중량부 기준으로 0.1 내지 3중량부로 더 포함할 수 있다.In another specific embodiment, the lightweight foam composition according to the present invention may further contain 0.1 to 3 parts by weight of magnesium nitride based on 100 parts by weight of melamine resin to improve the strength, wear resistance, and durability of the composition.
또 다른 특정 양태로서, 본 발명에 따른 경량발포폼 조성물은 조성물의 경화속도를 조절하고, 방수성 및 내식성을 개선하기 위하여 규불화마그네슘을 멜라민 수지 100중량부 기준으로 0.5 내지 3중량부로 더 포함할 수 있다. In another specific embodiment, the lightweight foam composition according to the present invention may further include 0.5 to 3 parts by weight of magnesium silicofluoride based on 100 parts by weight of melamine resin to control the curing speed of the composition and improve waterproofing and corrosion resistance.
또 다른 특정 양태로서, 본 발명에 따른 경량발포폼 조성물은 조성물을 구성하는 성분들간의 배합을 용이하게 하고 조성물의 안정성을 향상하기 위하여 술폭시폴리에틸렌글리콜알릴에테르를 멜라민 수지 100중량부 기준으로 0.1 내지 3중량부로 더 포함할 수 있는데, 그 함량이 멜라민 수지 100중량부 기준으로 0.1중량부 미만이면 조성물의 배합이 용이하지 못하며, 3중량부를 초과하면 과량으로 안정성이 저하되어 좋지 않다.In another specific embodiment, the lightweight foam composition according to the present invention may further contain 0.1 to 3 parts by weight of sulfoxy polyethylene glycol allyl ether based on 100 parts by weight of melamine resin in order to facilitate mixing of components constituting the composition and improve the stability of the composition. If the content is less than 0.1 parts by weight based on 100 parts by weight of melamine resin, mixing of the composition is not easy, and if it exceeds 3 parts by weight, stability is deteriorated due to excessive amount, which is not good.
또 다른 특정 양태로서, 본 발명에 따른 경량발포폼 조성물은 조성물의 발포속도를 조절하고, 제품의 외관을 양호하게 하며, 내구성을 향상시키기 위하여 파라-톨루엔설폰산(p-toluene sulfonic acid)을 멜라민 수지 100중량부 기준으로 1 내지 5중량부로 더 포함할 수 있다.In another specific embodiment, the lightweight foam composition according to the present invention may further contain 1 to 5 parts by weight of p-toluene sulfonic acid based on 100 parts by weight of melamine resin in order to control the foaming speed of the composition, improve the appearance of the product, and improve durability.
또 다른 특정 양태로서, 본 발명에 따른 경량발포폼 조성물은 화재시 경량발포폼 조성물의 열적 저항성을 향상시키고 유독가스를 흡착시키기 위하여 리튬실리케이트를 멜라민 수지 100중량부 기준으로 1 내지 5중량부로 더 포함할 수 있다.In another specific embodiment, the lightweight foam composition according to the present invention may further include 1 to 5 parts by weight of lithium silicate based on 100 parts by weight of melamine resin to improve the thermal resistance of the lightweight foam composition in case of fire and to adsorb toxic gases.
또 다른 특정 양태로서, 본 발명에 따른 경량발포폼 조성물은 조성물의 난연성 및 흡음성을 향상시키기 위하여 제올라이트를 멜라민 수지 100중량부 기준으로 1 내지 3중량부로 더 포함할 수 있는데, 상기 제올라이트는 경량발포폼 조성물에 원적외선 및 음이온 방출효과도 부여할 수 있다.In another specific embodiment, the lightweight foam composition according to the present invention may further include zeolite in an amount of 1 to 3 parts by weight based on 100 parts by weight of melamine resin to improve flame retardancy and sound absorption of the composition, and the zeolite may also impart far-infrared and negative ion emission effects to the lightweight foam composition.
또 다른 특정 양태로서, 본 발명에 따른 경량발포폼 조성물은 조성물의 내화성, 단열성 및 흡습성을 향상시키기 위하여 산화나트륨을 멜라민 수지 100중량부 기준으로 1 내지 3중량부로 더 포함할 수 있다.In another specific embodiment, the lightweight foam composition according to the present invention may further contain 1 to 3 parts by weight of sodium oxide based on 100 parts by weight of melamine resin to improve the fire resistance, thermal insulation, and moisture absorption of the composition.
또 다른 특정 양태로서, 본 발명에 따른 경량발포폼 조성물은 재료의 분리, 탈락 등을 방지하여 조성물의 결합강도 향상시키기 위하여 메타카올린을 멜라민 수지 100중량부 기준으로 1 내지 5중량부로 더 포함할 수 있다.In another specific embodiment, the lightweight foam composition according to the present invention may further include 1 to 5 parts by weight of metakaolin based on 100 parts by weight of melamine resin to prevent separation, detachment, etc. of materials and improve the bonding strength of the composition.
이와 같은 구성을 갖는 본 발명에 따른 경량발포폼 조성물, 특정적으로 내화충진재용 경량발포폼 조성물, 보다 특정적으로 난연성이 향상된 유무기 혼합 내화충진재용 경량발포폼 조성물을 이용한 내화충진재용 경량발포폼 제조방법을 설명하면 다음과 같다.The lightweight foam composition according to the present invention having such a configuration, specifically the lightweight foam composition for refractory fillers, and more specifically the lightweight foam composition for organic-inorganic mixed refractory fillers with improved flame retardancy, is described as follows for manufacturing a lightweight foam for refractory fillers.
여기서, 상기 경량발포폼 제조방법은 당업계의 통상적인 발포폼 제조방법이라면 어떠한 것을 사용하여도 무방하지만, 바람직하게는 멜라민수지 100중량부 기준으로, 섬유 4 내지 30중량부, 탄산나트륨 6 내지 30중량부, 탈크 15 내지 30중량부, 산화마그네슘 15 내지 70중량부, 생석회 4 내지 15중량부, 팽창질석 15 내지 25중량부, 펄라이트 6 내지 25중량부, 물유리 100 내지 120중량부, 및 난연제 5 내지 8중량부를 혼합하는 경량발포폼 조성물 제조단계;Here, the lightweight foam manufacturing method may use any conventional foam manufacturing method in the art, but preferably, the lightweight foam composition manufacturing step comprises mixing, based on 100 parts by weight of melamine resin, 4 to 30 parts by weight of fiber, 6 to 30 parts by weight of sodium carbonate, 15 to 30 parts by weight of talc, 15 to 70 parts by weight of magnesium oxide, 4 to 15 parts by weight of quicklime, 15 to 25 parts by weight of expanded vermiculite, 6 to 25 parts by weight of perlite, 100 to 120 parts by weight of water glass, and 5 to 8 parts by weight of a flame retardant;
상기 경량발포폼 조성물 제조단계를 통해 제조한 경량발포폼 조성물과 멜라민수지 100중량부 기준으로 경화제 1 내지 10중량부를 각각 발포기에 투입하여 발포하는 발포단계;A foaming step of foaming by adding 1 to 10 parts by weight of a hardener based on 100 parts by weight of a melamine resin and the lightweight foam composition manufactured through the above lightweight foam composition manufacturing step into a foaming machine;
상기 발포단계가 종료된 경량발포폼을 원하는 모양으로 성형하는 성형단계; 및 상기 성형단계가 종료된 후 성형된 경량발포폼을 건조, 바람직하게는 20 내지 30℃의 온도범위에서 24 내지 30시간 동안 건조하는 건조단계를 포함한다.A molding step of molding the lightweight foam into a desired shape after the foaming step is completed; and a drying step of drying the molded lightweight foam after the molding step is completed, preferably at a temperature range of 20 to 30°C for 24 to 30 hours.
여기서, 본 발명에 따른 내화충진재용 경량발포폼 제조방법은 전체 경량발포폼 조성물을 구성하는 구성성분 중 경화제를 그 외의 구성성분과 발포하기 직전에 혼합하여 발포하는 것이며, 상기 경화제는 당업계의 통상적인 경화제를 사용할 수도 있지만, 바람직한 발포폼을 제조하기 위하여, 인산, 예를 들면 80 내지 90% 인산수용액 100중량부 기준으로, 포름산 50 내지 120중량부; 옥살산 20 내지 110중량부; 용매, 예를 들면 물 200 내지 400중량부; 및 기포제, 예를 들면 고급알콜 유도체 유산에스텔, 도데실벤젠설폰산 나트륨, 알킬올레핀설폰산나트륨 또는 이들로부터 선택된 적어도 하나 이상의 혼합물로 이루어진 기포제 20 내지 50중량부를 혼합하여 제조하는 것이 바람직하다.Here, the method for manufacturing a lightweight foam for refractory filling according to the present invention is to mix a curing agent among the components constituting the entire lightweight foam composition with the other components immediately before foaming and to foam the foam. The curing agent may be a conventional curing agent in the art, but in order to manufacture a desirable foam, it is preferable to manufacture the foam by mixing 20 to 50 parts by weight of a foaming agent composed of phosphoric acid, for example, 50 to 120 parts by weight of formic acid based on 100 parts by weight of an 80 to 90% phosphoric acid aqueous solution; 20 to 110 parts by weight of oxalic acid; 200 to 400 parts by weight of a solvent, for example, water; and a foaming agent, for example, a higher alcohol derivative lactic acid ester, sodium dodecylbenzenesulfonate, sodium alkylolefinsulfonate, or at least one mixture selected from these.
이때, 상기 경화제는 이를 구성하는 조성물이 3 내지 5의 pH 및 60 내지 80℃의 온도조건에서 혼합되는 방법으로 제조되는 것을 포함한다.At this time, the curing agent includes a composition comprising the curing agent that is manufactured by a method in which the composition is mixed under conditions of a pH of 3 to 5 and a temperature of 60 to 80°C.
또한, 상기 발포단계의 발포기는 경량발포폼을 제조하기 위한 당업계의 통상적인 발포기, 예를 들면 라인믹서 발포기라면 어떠한 것을 사용해도 무방하며, 경량팔포폼 조성물과 경화제는 각각 발포기의 다른 투입구에 투입하여 혼합 발포하는 것이 바람직하며, 성형단계는 발포된 경량발포폼을 원하는 모양으로 성형하는 것으로, 예를 들면 샌드위치 패널 등을 들수 있다.In addition, the foaming machine of the foaming step may be any conventional foaming machine in the art for producing lightweight foam, such as a line mixer foaming machine. It is preferable to input the lightweight foam composition and the curing agent into different inlets of the foaming machine and mix and foam them. The molding step is to mold the foamed lightweight foam into a desired shape, such as a sandwich panel.
이하에서 실시예를 통하여 본 발명을 구체적으로 설명하기로 한다. 그러나 하기의 실시예는 오로지 본 발명을 구체적으로 설명하기 위한 것으로 이들 실시예에 의해 본 발명의 범위를 한정하는 것은 아니다.Hereinafter, the present invention will be specifically described through examples. However, the following examples are only intended to specifically describe the present invention and the scope of the present invention is not limited by these examples.
[실시예 1][Example 1]
멜라민 수지 100g, 폴리프로필렌 섬유 17g, 탄산나트륨 18g, 탈크 22g, 산화마그네슘 45g, 생석회 5g, 팽창질석 20g, 펄라이트 15g, 물유리 110g, 멜라민시아누레이트 7g, 및 경화제 5g을 혼합하여 경량발포폼 조성물을 제조하였다.A lightweight foam composition was prepared by mixing 100 g of melamine resin, 17 g of polypropylene fiber, 18 g of sodium carbonate, 22 g of talc, 45 g of magnesium oxide, 5 g of quicklime, 20 g of expanded vermiculite, 15 g of perlite, 110 g of water glass, 7 g of melamine cyanurate, and 5 g of a hardener.
여기서, 상기 경화제는 약 pH 4 및 약 70℃의 온도에서 85% 인산 수용액 100g, 포름산 85g, 옥살산 65g, 물 300g 및 도데실벤젠설폰산 나트륨 35g을 혼합하여 제조한 혼합물이다.Here, the curing agent is a mixture prepared by mixing 100 g of an 85% phosphoric acid aqueous solution, 85 g of formic acid, 65 g of oxalic acid, 300 g of water, and 35 g of sodium dodecylbenzenesulfonate at a temperature of about 70°C and a pH of about 4.
[실시예 2][Example 2]
실시예 1과 동일한 방법으로 실시하되, 이산화탄소 5g을 더 부가하여 실시하였다.The same method as Example 1 was used, but 5 g of carbon dioxide was added.
[실시예 3][Example 3]
실시예 1과 동일한 방법으로 실시하되, 약 5㎛ 크기의 기공이 약 0.05 내지 0.2cc/g의 범위로 포함된 폴리비닐알코올 분말 3g을 더 부가하여 실시하였다.The same method as Example 1 was performed, but 3 g of polyvinyl alcohol powder containing pores of about 5 ㎛ in a range of about 0.05 to 0.2 cc/g was additionally added.
[실시예 4][Example 4]
실시예 1과 동일한 방법으로 실시하되, 수분산 폴리우레탄 분산제 2g을 더 부가하여 실시하였다.The same method as Example 1 was used, but 2 g of a water-dispersible polyurethane dispersant was added.
[실시예 5][Example 5]
실시예 1과 동일한 방법으로 실시하되, 폴리비닐리덴플로라이드수지 1g을 더 부가하여 실시하였다.The same method as Example 1 was performed, but 1 g of polyvinylidene fluoride resin was additionally added.
[실시예 6][Example 6]
실시예 1과 동일한 방법으로 실시하되, 네오펜틸글리콜 1g을 더 부가하여 실시하였다.The same method as Example 1 was performed, but 1 g of neopentyl glycol was added.
[실시예 7][Example 7]
실시예 1과 동일한 방법으로 실시하되, 깁사이트 1g을 더 부가하여 실시하였다.The same method as Example 1 was performed, but 1 g of gibbsite was added.
[실시예 8][Example 8]
실시예 1과 동일한 방법으로 실시하되, 할로이사이트 1g을 더 부가하여 실시하였다.The same method as Example 1 was performed, but 1 g of halloysite was added.
[실시예 9][Example 9]
실시예 1과 동일한 방법으로 실시하되, 평균입도가 3㎛인 겔라이트 미분말 2g을 더 부가하여 실시하였다.The same method as Example 1 was used, but 2 g of gel-lite fine powder having an average particle size of 3 μm was additionally added.
[실시예 10][Example 10]
실시예 1과 동일한 방법으로 실시하되, 알루민산 칼슘 2g을 더 부가하여 실시하였다.The same method as Example 1 was performed, but 2 g of calcium aluminate was added.
[실시예 11][Example 11]
실시예 1과 동일한 방법으로 실시하되, 메타규산나트륨 3g을 더 부가하여 실시하였다.The same method as Example 1 was performed, but 3 g of sodium metasilicate was added.
[실시예 12][Example 12]
실시예 1과 동일한 방법으로 실시하되, 질화마그네슘 1g을 더 부가하여 실시하였다.The same method as Example 1 was performed, but 1 g of magnesium nitride was added.
[실시예 13][Example 13]
실시예 1과 동일한 방법으로 실시하되, 규불화마그네슘 1g을 더 부가하여 실시하였다.The same method as Example 1 was performed, but 1 g of magnesium silicofluoride was added.
[실시예 14][Example 14]
실시예 1과 동일한 방법으로 실시하되, 술폭시폴리에틸렌글리콜알릴에테르 1g을 더 부가하여 실시하였다.The same method as Example 1 was performed, but 1 g of sulfoxy polyethylene glycol allyl ether was additionally added.
[실시예 15][Example 15]
실시예 1과 동일한 방법으로 실시하되, 파라-톨루엔설폰산 2g을 더 부가하여 실시하였다.The same method as Example 1 was performed, but 2 g of para-toluenesulfonic acid was additionally added.
[실시예 16][Example 16]
실시예 1과 동일한 방법으로 실시하되, 리튬실리케이트 3g을 더 부가하여 실시하였다.The same method as Example 1 was used, but 3 g of lithium silicate was added.
[실시예 17][Example 17]
실시예 1과 동일한 방법으로 실시하되, 제올라이트 2g을 더 부가하여 실시하였다.The same method as Example 1 was performed, but 2 g of zeolite was added.
[실시예 18][Example 18]
실시예 1과 동일한 방법으로 실시하되, 산화나트륨 2g을 더 부가하여 실시하였다.The same method as Example 1 was performed, but 2 g of sodium oxide was added.
[실시예 19][Example 19]
실시예 1과 동일한 방법으로 실시하되, 메타카올린 3g을 더 부가하여 실시하였다.The same method as Example 1 was performed, but 3 g of metakaolin was added.
[실시예 20][Example 20]
실시예 1과 동일한 방법으로 실시하되, 실시예 2 내지 실시예 19에 따라 부가된 부가물을 모두 부가하여 실시하였다.The same method as Example 1 was used, but all additives added according to Examples 2 to 19 were added.
[실 험][Experiment]
실시예에 따라 제조된 경량발포폼 조성물에 있어서, 경화제와 그 외의 조성물을 각각 라인믹서 발포기에 투입하여 발포하여 가로, 세로, 및 높이가 200mm, 200mm, 30mm 크기인 경량발포폼을 제조한 뒤 약 25℃의 온도에서 약 27시간 동안 건조시킨 후 난연성, 경량성, 및 인장신율을 측정하여 표 1로 나타내었다.In the lightweight foam composition manufactured according to the embodiment, the curing agent and other compositions were each put into a line mixer foaming machine and foamed to manufacture lightweight foam having a width, length, and height of 200 mm, 200 mm, and 30 mm, and then dried at a temperature of about 25°C for about 27 hours. The flame retardancy, lightweight, and tensile elongation were measured, which are shown in Table 1.
여기서, 난연성은 최대 출력 가스로 약 10분간 가열하여 연소여부를 확인하였으며, 경량성은 KSM3809 기준에 맞는 평가방법으로 시험환경은 온도(22±1)℃ 습도(60±2)% R.H. 조건 하에 최소경량성을 측정하였다.Here, flame retardancy was checked for combustion by heating with maximum output gas for about 10 minutes, and lightness was measured for minimum lightness under the test environment conditions of temperature (22±1)℃ and humidity (60±2)% R.H. using an evaluation method that meets the KSM3809 standard.
표 1에 나타낸 바와 같이, 본 발명에 따른 경량발포폼 조성물을 사용한 실시예들은 난연성이 높고, 경량성 및 인장신율이 좋은 것을 확인할 수 있었다.As shown in Table 1, it was confirmed that examples using the lightweight foam composition according to the present invention had high flame retardancy, light weight, and good tensile elongation.
이상에서 설명한 바와 같이, 본 발명이 속하는 기술 분야의 당업자는 본 발명이 그 기술적 사상이나 필수적 특징을 변경하지 않고서 다른 구체적인 형태로 실시될 수 있다는 것을 이해할 수 있을 것이다. 그러므로 이상에서 기술한 실시예는 모두 예시적인 것이며 한정적인 것이 아닌 것으로서 이해해야만 한다. 본 발명의 범위는 상기 상세한 설명보다는 후술하는 특허청구범위의 의미 및 범위 그리고 그 등가개념으로부터 도출되는 모두 변경 또는 변형된 형태가 본 발명의 범위에 포함되는 것으로 해석되어야 한다.As described above, those skilled in the art will understand that the present invention can be implemented in other specific forms without changing the technical idea or essential characteristics thereof. Therefore, it should be understood that the embodiments described above are all exemplary and not restrictive. The scope of the present invention should be interpreted that all changes or modifications derived from the meaning and scope of the claims described below and their equivalent concepts, rather than the detailed description above, are included in the scope of the present invention.
Claims (5)
섬유 4 내지 30중량부;
탄산나트륨 6 내지 30중량부;
탈크 15 내지 30중량부;
산화마그네슘 15 내지 70중량부;
생석회 4 내지 15중량부;
팽창질석 15 내지 25중량부;
펄라이트 6 내지 25중량부;
물유리 100 내지 120중량부;
난연제 5 내지 8중량부; 및
경화제 1 내지 10중량부를 포함하고,
상기 경화제는 인산 100중량부 기준으로, 포름산 50 내지 120중량부; 옥살산 20 내지 110중량부; 용매 200 내지 400중량부; 및 기포제 20 내지 50중량부를 포함하는 내화충진재용 경량발포폼 조성물.
Based on 100 parts by weight of melamine resin,
4 to 30 parts by weight of fiber;
6 to 30 parts by weight of sodium carbonate;
15 to 30 parts by weight of talc;
15 to 70 parts by weight of magnesium oxide;
4 to 15 parts by weight of quicklime;
15 to 25 parts by weight of expanded clay;
6 to 25 parts by weight of perlite;
100 to 120 parts by weight of water glass;
5 to 8 parts by weight of flame retardant; and
Containing 1 to 10 parts by weight of a hardener,
A lightweight foam composition for refractory filler, wherein the curing agent comprises 50 to 120 parts by weight of formic acid; 20 to 110 parts by weight of oxalic acid; 200 to 400 parts by weight of a solvent; and 20 to 50 parts by weight of a foaming agent, based on 100 parts by weight of phosphoric acid.
상기 섬유는 폴리에틸렌(PE)섬유, 폴리프로필렌(PP)섬유, 폴리에틸렌테레프탈레이트(PET)섬유, 탄소섬유 또는 이들로부터 선택된 적어도 하나 이상의 혼합물을 포함하는 내화충진재용 경량발포폼 조성물.
In the first paragraph,
The above fiber is a lightweight foam composition for use as a fire-resistant filler, comprising at least one or more mixtures selected from polyethylene (PE) fiber, polypropylene (PP) fiber, polyethylene terephthalate (PET) fiber, carbon fiber, or these.
상기 경량발포폼 조성물 제조단계를 통해 제조한 경량발포폼 조성물과 멜라민수지 100중량부 기준으로 경화제 1 내지 10중량부를 각각 발포기에 투입하여 발포하는 발포단계;
상기 발포단계가 종료된 경량발포폼을 원하는 모양으로 성형하는 성형단계; 및
상기 성형단계가 종료된 후 성형된 경량발포폼을 건조하는 건조단계를 포함하고,
상기 경화제는 인산 100중량부 기준으로, 포름산 50 내지 120중량부; 옥살산 20 내지 110중량부; 용매 200 내지 400중량부; 및 기포제 20 내지 50중량부를 포함하는 내화충진재용 경량발포폼 제조방법.
A step for producing a lightweight foam composition, wherein 4 to 30 parts by weight of fiber, 6 to 30 parts by weight of sodium carbonate, 15 to 30 parts by weight of talc, 15 to 70 parts by weight of magnesium oxide, 4 to 15 parts by weight of quicklime, 15 to 25 parts by weight of expanded vermiculite, 6 to 25 parts by weight of perlite, 100 to 120 parts by weight of water glass, and 5 to 8 parts by weight of a flame retardant are mixed based on 100 parts by weight of melamine resin;
A foaming step of foaming by adding 1 to 10 parts by weight of a hardener based on 100 parts by weight of a melamine resin and the lightweight foam composition manufactured through the above lightweight foam composition manufacturing step into a foaming machine;
A molding step for molding the lightweight foam into a desired shape after completing the foaming step; and
After the above molding step is completed, a drying step is included for drying the molded lightweight foam,
A method for manufacturing a lightweight foam for a refractory filler, wherein the hardener comprises 50 to 120 parts by weight of formic acid; 20 to 110 parts by weight of oxalic acid; 200 to 400 parts by weight of a solvent; and 20 to 50 parts by weight of a foaming agent, based on 100 parts by weight of phosphoric acid.
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