KR101293524B1 - An interior building material using fire protecting yarn of polyester series and method for manufacturing it - Google Patents

Abstract

PURPOSE: A construction interior material made by using polyester flame retarder is characterized in fire retardant and high intensity to present sufficient supporting power, acting as an interior material with thin thickness, while emitting less toxic gas. And the material used in this invention is easy to obtain. CONSTITUTION: A construction interior material is made by heating and pressurizing and molding a mixture of a mineral filler consisting of at least one of water, a retarder, magnesium hydroxide and wollastonite, melamine; a binding material, a release agent, a thickening agent, PVA for elasticity and pieces of polyester flame retarder fibers. The construction interior material comprises as 50-100% by weight of a retarder consisting of ethylene vinyl acetate, aluminum, water, ammonium phosphate and bentonite, as 250-350% by weight of wollastonite (CaOSiO 2) for maintaining a board form after the molding, as 100-150% by weight of magnesium hydroxide, as 200-250% by weight of melamine powder, acting as a binder material, as 6-10% by weight of polyvinyl alchole (PVA), acting as a elastic material and as 70-100% by weight of a polyester based retarder with the length 1.5-2.5 cm.

Description

FIELD OF THE INVENTION [0001] The present invention relates to an interior building material using a polyester-based fire retardant,

The present invention relates to a building interior material used to finish the interior wall or ceiling of a building, in particular, using a flame-retardant polyester-based flame retardant and light weight, can reduce the thickness and low-cost eco-friendly building interior materials and It relates to a manufacturing method.

Generally, various kinds of interior materials used to finish walls and ceilings are made of various materials as building materials.

For example, SMC or aluminum, which is a kind of thermosetting resin, is widely used as a general building interior material.

However, since the SMC is a type of thermosetting resin such as FRP, it contains harmful carcinogens that are harmful to human body and glass fiber penetrating through the respiratory system. Therefore, it is not only harmful but also toxic gas There is a problem that it is not only impossible to recycle but also requires decades of time to return to the natural state.

In addition, although aluminum is a light metal, it is light, clean and easy to handle, so it is often used as a building interior material. However, as the price of light metal increases internationally, it is not only expensive but also expensive to use as a building material. There is a problem that a toxic gas harmful to human body is generated when a fire is generated at a high temperature when the fire is used as a building material.

Various techniques have been proposed to solve the problems with conventional building interior materials. For example, in the patent registration No. 10-0427479 filed by the applicant of the present invention, A " production method "

As can be seen from the title of the invention, the above-mentioned patent uses waste paper and waste fibers which are combustible but do not cause harmful gases to the human body when they are burned, and these waste paper and waste fibers are mixed with synthetic resin and heated and compressed , Which is made by forming a plate, laminating the plates in multiple layers, and applying a flame retardant and a waterproofing agent.

However, even if the interior material according to the present invention is treated by using a flame retardant and a waterproofing agent, since a fire is generated in the building and it can not be burnt when high temperature heat is applied, waste materials, waste fiber and synthetic resin are used as basic raw materials In addition, it has not completely solved the basic problem of not being able to recycle the interior material made of such a synthetic resin as well as generating harmful gas to the human body when the synthetic resin is burned.

On the other hand, as another inventions, there has been proposed a method of producing an injection material based on thermoplastic resin and pulp fiber, an injection material thereof, and a method of producing an injection based on pulp fiber and a thermoplastic resin as disclosed in Japanese Patent Publication No. 1996-16853 A manufacturing method of ash "has been proposed.

The above-mentioned two inventions are basically the same in their contents, and these techniques are also light and easy to burn because they use waste paper and waste fibers which do not generate harmful gas. However, since thermoplastic resin And a resin in the form of a fibrillated fiber is used as a kind of the thermoplastic resin. The product according to the above-described invention made using such a material also produces a harmful gas to the human body when it is burned with good combustion However, there is a problem that the recycling is impossible and the production cost is high and the price of the consumer is expensive.

In addition, when paper is used as a raw material as in the above-mentioned inventions, it is difficult to mix the thermoplastic resin with the thermoplastic resin due to its volume, resulting in poor workability, and a large amount of thermoplastic resin is required There is also a disadvantage that it is not economical due to high production cost.

On the other hand, the ceiling material for finishing the interior ceiling of the building is to install various pipes and wiring on the ceiling when building the building, and then to hang the ceiling material on the hanger beneath these pipes and wiring, conventional conventional interior materials are basically weight Because of its heavy weight, anchor bolts are attached to the ceiling wall of the building, and a sturdy hanger is installed on the anchor bolts to suspend the interior materials.

Therefore, since the conventional general building ceiling material is heavy, it requires a strong anchor and a supporting member in order to support its weight.

In order to solve various problems of the conventional ceiling material as described above, the applicant of the present invention has filed a patent application 10-2012-0129982 entitled "Architectural Interior Material Using Cotton and Its Manufacturing Method" have.

By the way, this invention is based on the polyester type flame retardant cotton, and is made to heat-mold by mixing melamine resin and mineral flame retardant as a binder.

If the material is mixed and heat-molded, there is an advantage that it can have sufficient strength as a building ceiling material even if the thickness is about 1.5 mm, and it is not easily burned, and it can be naturally decomposed, so that it can be eco-friendly.

By the way, the building interior material according to the invention as described above is to use a flame retardant cotton made in advance in the form of a plate, and then to impregnate the melamine and flame retardant in the cotton of the plate form and then dried again to be molded.

In this process, there is a problem that the process for uniformly impregnating the melamine and the flame retardant into the sheet-shaped flame retardant cotton is difficult and difficult.

In addition, in the impregnation process described above, water is used as a medium to impregnate melamine and mineral flame retardant, which are binders, in the flame retardant cotton in the form of plate, that is, melamine and flame retardant are dissolved in water, So that a large amount of water is absorbed into the sheet-form cotton.

In addition, since the sheet-shaped cotton in which the water is so much absorbed can not be formed as it is, it must be dried at a predetermined water content through the drying process, and then molded.

In addition, even if dried to contain a certain amount of water, since the amount of moisture permeated into the cotton sheet-shaped cotton can not be matched with the amount of water on the surface, the surface of the panel of the building material is not smooth due to a large amount of moisture in the pressure- There is a problem that the shape may not be properly formed.

Therefore, the present invention solves the various problems according to the existing building interior materials as described above, the material can be easily obtained, flame retardant, less harmful gases, and above all the strength is high enough to obtain sufficient support even as a thin thickness interior materials On the other hand, it is an object of the present invention to provide a building interior material using a polyester-based flame retardant yarn and a method of manufacturing the same, which makes the molding process simple and can significantly reduce working time.

Building interior material according to the present invention for achieving the object of the above is to transfer the flame retardant yarn of 20-30 denier polyester-based flame retardant 1.5 to 2.5cm in size minerals made of one or more of water and flame retardant, magnesium hydroxide or wollastonite Filler, binder melamine, mold release agent, thickener, PVA for giving elasticity is mixed and kneaded in the state of the lowest moisture content, then spread the dough in the forming mold by heat pressing molding.

If the material is mixed and heat-molded, even if the thickness is about 1 to 1.5mm, it can have sufficient strength as a building interior material, and the flame retardant yarn, melamine resin, and flame retardant material are mixed with a small amount of water to make a dough state so that the work is evenly mixed. This easy and low moisture content mixed in the mixed dough can greatly reduce the drying time, and improve the molding state of the panel during the molding operation.

Building interior materials of the present invention made by mixing the composition as described above is 1.5 ~ 2.5cm in length of the relatively short flame retardant yarns and melamine and fillers and flame retardant materials are mixed together with a small amount of water and mixed in a dough state mixing operation This easy and low moisture content mixed in the mixed dough can greatly reduce the drying time, and improve the molding state of the panel during the molding operation.

Accordingly, the construction interior material of the present invention made of such a material can exhibit sufficient strength as an interior material while making it thin. And by adding and mixing the flame retardant material not only has sufficient flame retardancy as a building interior material, but also serves to maintain the shape and smoothly maintain the surface of the final interior material.

Since the construction interior material according to the present invention is based on fire retardant material, the weight of the interior material can be reduced by 25 to 30% or more compared to the conventional interior material. Therefore, the structure of the hanger for hanging the interior material can be simplified, Can be reduced.

In addition, since the cost can be reduced, the cost of the construction interior material can be reduced.

Hereinafter, a construction interior material and a manufacturing method thereof according to a preferred embodiment of the present invention will be described.

Building interior material according to the present invention is made by mixing melamine as a binder, mineral filler, and a small amount of water together to make a mixture, and cut into polyester-based flame retardant yarn to a length of 1.5 ~ 2.5cm Then the pressurized dough is made into a plate shape.

Although only the above-described materials can be used, the building interior material pursued by the present invention can be obtained, but carboxyl methyl cellulose sodium as a thickener to increase the viscosity in order to improve the formability of the product and to improve the quality of the product, It is preferable to mold by adding an additive consisting of a release agent for the molded product to be separated from the mold well, a polyvinyl alchole (PVA) to add elasticity and elasticity to the product, and a flame retardant to increase the flame retardancy to the product.

The flame retardant yarn used in the present invention may generally be used as it is, commercially available flame retardant yarns, for example, polyester-based flame retardant yarns produced by a company such as JR Corporation.

When polyester-based flame retardant polymerizes a polyester resin, a flame retardant is polymerized to produce a flame-retardant polyester resin and then spun to produce yarn, or a flame retardant master batch is prepared in advance. Flame retardant master batches are made by mixing a certain amount of polyester yarn to produce, then spinning and producing yarn.

In the present invention, such a flame retardant yarn is used to cut the length of the straight form, such as a common thread in the size of 1.5 ~ 2.5cm, this length is used to cut the length so that the flame retardant yarn is well mixed with other materials, manufacturing process of the product Not only can this simple and higher molding effect, but also higher flame retardant effect can improve product quality.

In addition, the flame retardant yarn is preferably used in the range of 20 ~ 30 denia, when using less than 20 denia has a disadvantage that the mixture of melamine and flame retardant and water when mixed with the water is not mixed properly.

In addition, when 30 denier or more is used, the threads are thicker than necessary, so that the mixing is not properly performed, and there may be problems such as cracking after molding and fragile of the finished product.

The melamine serves to form a certain shape by acting as a binder that combines the flame retardant yarn and the filler.

On the other hand, since the filler is made of a mineral, it exhibits a sufficient flame retardant function in itself, and also plays a role of a filler, thereby maintaining the shape of the product itself when forming the product and smoothing the surface.

In the present invention, the filler is used by mixing wollastonite (CaOSiO ₂ ) and magnesium hydroxide in order to pursue eco-friendliness, which is an original purpose.

The building interior material of the present invention made of a combination of such materials can have sufficient strength as a building interior material even if the thickness is about 1 to 1.5 mm, and evenly mixes flame retardant yarn, melamine resin and filler with a small amount of water to form a dough. The mixing operation is easy, and the drying time can be greatly reduced because the moisture content mixed in the dough kneaded with flame retardant yarn is reduced, and the molding state of the panel can be improved during the molding operation.

On the other hand, the pigment is added to the raw material of the melamine in advance to obtain the desired color. Therefore, in the present invention, the pigment may be added to the raw material of the melamine, or the pigment may be added separately to obtain a desired color.

Here, the pigment used is an inorganic pigment, which is generally opaque and insufficient in concentration compared to an organic pigment, but has good light resistance and heat resistance and is insoluble in organic solvents. Also, the price is low and the usage is large.

In the present invention, such an inorganic pigment is used for expressing the color of a necessary building interior material, and since the basic color of the flame retardant resin and melamine can not obtain the required color of the building interior material, The molded product is subjected to a separate process such as coating various films or coloring. In the present invention, the desired color is immediately obtained while the production process is being performed.

Looking at the specific method of making the building interior of the present invention made of the configuration as described above, first to mix the flame retardant 50 to 100 parts by weight with respect to 20 to 50 parts by weight of water to make a flame retardant aqueous solution.

The flame retardant used in the present invention may be used as it is commonly distributed in the market, for example, ethylene vinyl acetate (ethylene vinyl acetate) and may be composed of a mixture of aluminum, water, ammonium poststate, bentonite.

The composition of the flame retardant used in the present invention is 30 to 40% by weight, bentonite 30 to 40% by weight, aluminum 6 to 7% by weight, ammonium phosphate 3 to 4% by weight, and the rest with ethylene vinyl acetate (ethylene vinyl acetate) Is done.

In addition, the flame retardant is to improve the flame retardancy of the product, the flame retardancy can be secured to some extent by the mineral filler alone, but to add a flame retardant to ensure a certain flame retardancy of the product.

Then, the molding material to maintain the shape of the plate after molding to the flame retardant aqueous solution (CaOSiO ₂ ) 250-350, magnesium hydroxide 100-150 parts by weight is mixed to form a filler mixture almost no moisture.

Next, 200 to 250 parts by weight of the melamine powder as a binder in the filler mixture, 4 to 6 parts by weight of silicone as a release agent for separating the molded product from the mold, and carboxyl as a thickener to increase the viscosity of the mixture. 6-8 parts by weight of methyl cellulose sodium, 6-10 parts by weight of polyvinyl alchole (PVA), which adds elasticity to the product, is added to make a highly viscous mixture.

The thickener is intended to increase the viscosity of the mixture so that it spreads well when molding, and the release agent is to make it easy to separate when forming the product after forming in a heating molding machine, PVA adds elasticity or elasticity to the product It is to prevent phenomena such as being easily broken or broken in the finished product state, and the flame retardant is to add flame retardancy to the product, although the mineral filler itself has flame retardancy due to the properties of the material, but further increases the flame retardancy by adding a flame retardant material. I can do it.

And evenly mix the 70 to 100 parts by weight of the polyester-based flame retardant yarn 1.5 to 2.5cm in length in the mixture to make the dough less water.

When the flame retardant yarn is added in a small amount in the above process, it is preferable to mix the flame retardant yarns evenly as a whole by forcibly mixing using a mechanical stirrer to improve the quality of the final product.

Aged dough as described above can be aged after about 12 to 24 hours before molding into the molding machine, then molding, so that the mixing of the dough becomes more dense, so that the tissue of the product after the molding is tight and the tissue is dense The effect can be obtained.

If the flame retardant yarn and melamine, filler and water are properly mixed together with the above conditions, the water does not flow down and the flame retardant yarn is evenly contained, so that it is mixed evenly in the state of injeolmi or flour dough. The product can be molded immediately without going through the drying process. Therefore, it is possible to drastically shorten the working time than using a long flame retardant yarn or using a flame retardant cotton that is agglomerated in a cotton state.

That is, in the present invention, by using a piece of flame retardant yarn can be made dough even if the content of water is small, if the water in the above composition ratio of 20 parts by weight or less of water, the content of water is too small to mix well 50 If the weight part or more, the water content is high, there is a problem that a separate drying process.

Therefore, when the water content is in the range of 20 to 50 parts by weight, the total moisture content of the mixture is 5 to 10%, and when this water content is reached, the molding time is not lengthened due to the moisture and the defect rate of the work during the press molding is achieved. It can be reduced, and above all, the work efficiency is greatly improved since there is no need for a separate drying process.

Then, the dough made through the kneading step is put into a heating molding machine and subjected to a pressurizing process of pressurizing at a pressure of 400 to 600 t / cm 2 for about 5 to 8 seconds at a temperature of 140 to 160 ° C.

Then, the upper mold of the heating molding machine is lifted by 2-3 mm to discharge the gas generated during pressurization, and the pressurizing process of pressing the upper mold again to pressurize is repeated 3 to 4 times to completely discharge the gas.

And finally, the pressing step for 40 ~ 60sec is subjected to a heat forming step to be completely compressed.

This press-molded product is not completely hardened and can be bent, so when placed on a horizontal stand at room temperature and cooled and dried, it is hardened in a horizontal state to obtain a finished product in a horizontal state.

The finished product made through this process is about 1.5 ~ 2mm thick.

If the pressing pressure is low in the above-mentioned pressing process, the product will not be densified and it will be difficult to obtain a clean and complete product. If the gas produced by moisture evaporated during the press molding is not discharged, And a complete product can not be obtained.

Therefore, it is a very important process to pressurize the pressure of the press and to remove the gas by lifting the upper mold during press molding.

As described above, according to the present invention, when the building interior material of the present invention is bonded by pressing a light and tough polyester-based flame retardant piece with melamine resin, the tissue becomes hard and not easily broken, so as a thin interior material Not only can it exhibit sufficient strength, but it also has sufficient flame resistance as a building interior material.

In addition, the building interior material according to the present invention can greatly reduce the weight, it is possible to simplify the structure of the hanger for hanging the interior material, as a result it is possible to obtain the effect of reducing the load of the building.

Claims (5)

Mixing and kneading a mixture of water and a flame retardant, magnesium hydroxide or at least one of wollastonite, a mineral filler, a binder melamine, a mold release agent, a thickener, an elastic PVA, and a piece of polyester flame retardant yarn, Being made; The composition ratio of the composition is 50 to 100 parts by weight of a flame retardant composed of a mixture of ethylene vinyl acetate and aluminum, water, ammonium phosphate, and bentonite with respect to 20 to 50 parts by weight of water, and to maintain a plate shape after molding. 250 to 350 parts by weight of wollastonite (CaOSiO ₂ ) as a filler and 100 to 150 parts by weight of magnesium hydroxide, 200 to 250 parts by weight of melamine powder as a binder, 6 to 8 parts by weight of carboxymethyl cellulose sodium as a thickener, and silicone 4 as a release agent. ~ 6 parts by weight, 6 ~ 10 parts by weight of polyvinyl alchole (PVA) as an elastic material, and 70 ~ 100 parts by weight of polyester flame retardant yarn of 1.5 ~ 2.5cm in length
delete According to claim 1, wherein the constituents of the flame retardant is 30 to 40w% of water, 30 to 40w% of bentonite, 6 to 7w% of aluminum, 3 to 4w% of ammonium phosphate, and the other is ethylene vinyl acetate Architectural interior materials
A flame retardant mixing step of making a flame retardant aqueous solution by mixing 50 to 100 parts by weight of a flame retardant made of a mixture of ethylene vinyl acetate and aluminum, water, ammonium phosphate, and bentonite with respect to 20 to 50 parts by weight of water at room temperature;
A filler mixing step of forming a filler mixture having almost no moisture by mixing 250 to 350 parts by weight of wollastonite (CaOSiO ₂ ) and 100 to 150 parts by weight of magnesium hydroxide as a molding filler to maintain a plate shape after molding in the aqueous solution of the flame retardant;
200 to 250 parts by weight of the melamine powder as a binder in the filler mixture, and 4 to 6 parts by weight of silicone as a release agent that allows the molded product to be separated from the mold, and 6 to 6 carboxymethyl cellulose sodium as a thickener to increase the viscosity of the mixture. 8 parts by weight, an additive mixing step of adding 6-10 parts by weight of a polyvinyl alchole (PVA) that adds elasticity to a product to make a high viscosity mixture,
Kneading step of uniformly mixing 70 ~ 100 parts by weight of polyester flame retardant yarn of 1.5 ~ 2.5cm in length to the mixture to make a dough less water;
Pressing step of spreading the dough made through the kneading step into a heating molding machine and pressurized at a pressure of 400 ~ 600t / ㎠ for 5-8 seconds at a temperature of 140 ~ 160 ℃;
A gas discharge step of discharging the gas completely during lifting by pressing the upper mold of the heating mold by 2 to 3 mm and repeating the pressing process of pressing the upper mold again for 3 to 4 times to completely discharge the gas;
Finally, the manufacturing method of the building interior material comprising a molding step of pressing by pressing for 40 ~ 60 seconds to form a complete compression
The method of claim 4, further comprising a maturing step of aging the dough kneaded with flame retardant yarn mixed between the kneading step and the pressing step for about 12 to 24 hours.