KR101795750B1

KR101795750B1 - Composition for flame retardant, flame retardant polystyrene foam and manufacturing method of the same

Info

Publication number: KR101795750B1
Application number: KR1020150079300A
Authority: KR
Inventors: 강범형
Original assignee: 강범형
Priority date: 2015-06-04
Filing date: 2015-06-04
Publication date: 2017-11-08
Also published as: KR20160143137A

Abstract

The present invention relates to a flame retardant composition capable of improving miscibility and flame retardancy and being easily applied to a manufacturing process to ensure high durability, a flame retardant styrofoam using the flame retardant composition, and a method for producing the flame retardant styrofoam.

Description

FIELD OF THE INVENTION [0001] The present invention relates to a flame retardant composition, a flame retardant styrofoam,

The present invention relates to a flame retardant composition, a flame retardant styrofoam and a method for producing the same. More particularly, the present invention relates to a flame retardant composition capable of improving miscibility and flame retardancy and being easily applied to a manufacturing process to ensure high durability, flame retardant styrofoam using the flame retardant composition, and a method for producing the flame retardant styrofoam.

Expandable polystyrene (EPS) is a porous material that is widely used as an insulation material because it has excellent insulation effect and is light and easy to form. In particular, sandwich panels, which are made of Styrofoam core and which are coated with iron plates on both sides, are light and have excellent insulation effect. They are widely used as construction materials because they can be constructed quickly and at a low cost. In addition, the Exterior Insulating and Finishing System (EIFS), which is a styrofoam insulation applied to the exterior wall of the building, and the drivit method, which is easy to construct, It is widely used in residential and commercial buildings.

However, styrofoam is a combustible material and is very weak to heat. When it exceeds 70 ° C, it deforms and generates a lot of toxic gas and collapses structure in case of fire. In particular, the vertically installed styrofoam acts as a flashlight to spread the flame.

Therefore, researches on flame retardants that can be added to raw material resins to exhibit flame retardancy have been actively conducted. At present, halogen-based flame retardants are the most abundant, while phosphorus and nitrogen-based ones are widely used in non-halogen based flame retardants. [0003] Brominated flame retardants which are inexpensive and have a high flame retardant effect are widely used in the above halogen-based flame retardants, and HBCD (hexabromocyclododecane) is the most widely used brominated flame retardant applied to styrofoam.

However, some of the above brominated flame retardants have been used for a long time since their carcinogenicity and hepatotoxicity are known, and other types of brominated flame retardants currently used also have a bad influence on the development of children's brain.

In order to replace such a brominated flame retardant, a nitrogen-based flame retardant or a phosphorous flame retardant has been developed and applied as a non-halogen flame retardant. However, the flame retardant performance is significantly lowered or the cost is higher than that of a brominated flame retardant. Accordingly, development of a flame retardant that is excellent in flame retardancy and is safe and inexpensive has been desired.

The present invention is to provide a flame retardant composition capable of improving miscibility and flame retardancy and being easily applied to a manufacturing process to ensure high durability.

The present invention also provides a flame retardant styrofoam using the flame retardant composition.

The present invention also provides a method for producing the flame-retardant styrofoam.

In this specification, a ceramic hollow body; And an inorganic binder having a viscosity of from 5000 to 100000 CP at 20 캜.

In this specification, polystyrene expanded particles; And a flame retardant composition bonded to the surface of the polystyrene expanded particles.

The present invention also provides a method for producing a flame-retardant styrofoam comprising a foaming step of heat-treating a mixture of the expandable polystyrene resin and the flame retardant composition.

The present invention also provides a method for producing a flame retardant styrofoam comprising the step of heat treating a mixture of polystyrene expanded particles and the flame retardant composition.

Hereinafter, the flame retardant composition, the flame retardant styrofoam and the method for producing the flame retardant composition according to a specific embodiment of the present invention will be described in detail.

According to one embodiment of the invention, a ceramic hollow body; And an inorganic binder having a viscosity of from 5000 cP to 100000 cP at 20 캜.

The inventors of the present invention have found that when the above-mentioned specific flame retardant composition is used, the use of an inorganic binder having a specific viscosity makes it easy to blend the ceramic hollow body with an inorganic binder and exhibits a high level of bonding strength when applied to a substrate surface or the like It was confirmed through experiments that the coating or molding was easy to accomplish according to the present invention and the invention was completed.

In addition, since the inorganic binder is flame retardant, it is difficult to be applied solely in general coating and molding processes since it is weak to water. However, by adding a ceramic hollow body to the inorganic binder, the water resistance of the flame retardant composition is improved , It is possible to form a strong bonding force with the base material surface when coating the base material surface, and durability can be ensured in coating and molding processes.

When the inorganic binder is coated on the surface of the substrate, the flame retardant composition exhibits flame retardancy for a certain period of time while being bulged when the flame is applied. The flame retardant composition obtained by mixing the inorganic binder and the ceramic hollow body is coated on the substrate surface, The flame retardancy can be further improved by forming a hard film through chemical reaction while increasing the swelling degree by about two times as compared with the case where only the inorganic binder is coated.

Specifically, the flame retardant composition may include an inorganic binder having a viscosity of at least 5000 cP and less than 100000 cP at 20 ° C. As described above, the inorganic binder has flame retardancy, and it is possible to impart an adhesive force upon coating the base material surface while ensuring easy mixing with the ceramic hollow body through viscosity.

Since the viscosity of the inorganic binder contained in the flame retardant composition satisfies a viscosity of 5000 cP or more and less than 100000 cP, it is easy to mix the ceramic hollow body and the inorganic binder, When applied, it may be easy to form a coating layer as it exhibits an appropriate level of bonding strength.

If the viscosity of the inorganic binder is excessively increased to 100000 cP or more, it is difficult to mix the inorganic binder and the ceramic hollow body, and thus the production of the flame retardant composition may be unfavorable. On the other hand, when the viscosity of the inorganic binder is reduced to less than 5000 cP, there is a limit in application because the water content is high and the adhesive force is weak.

The inorganic binder may include liquid sodium silicate. The liquid sodium silicate is also referred to as water glass, and when lit, it can exhibit flame retardancy as it swells.

The liquid sodium silicate may have a molar ratio of 2.4 to 2.6 according to the following formula (1).

[Equation 1]

Molar ratio = {SiO ₂ (wt.%) / Na ₂ O (wt.%) X 1.032}

The liquid sodium silicate may include, for example, 30 to 40% by weight of the silicon dioxide (SiO ₂ ) and 10 to 20% by weight of sodium oxide (Na ₂ O) Can be in the range of 2.4 to 2.6. The liquid sodium silicate may be classified into one to four KS standards according to the molar ratio, and the liquid sodium silicate satisfying the molar ratio of 2.4 to 2.6 corresponds to two KS standards.

When the molar ratio calculated by Equation (1) is reduced to less than 2.4, as the viscosity of the inorganic binder increases, it is difficult to blend the inorganic binder and the ceramic hollow body, so that the manufacturing process of the flame retardant composition may be unfavorable. On the other hand, when the molar ratio calculated by the above-mentioned formula (1) is increased to more than 2.6, there is a limit to be difficult to apply because the water content is high and the adhesion is weak.

In addition, the flame retardant composition may include a ceramic hollow body. The ceramic hollow body may be made water resistant by the binding force with the inorganic binder in a state of being mixed with the inorganic binder in the flame retardant composition. Further, even when coated on the surface of the substrate, the inorganic binder can be firmly bonded to the surface of the substrate so that the inorganic binder can be firmly bonded to the coating layer.

The ceramic hollow body may have a core-shell structure including a core including nitrogen gas or carbon dioxide gas and a shell including silica or alumina. Accordingly, the ceramic hollow body is exposed to the external surface by a ceramic material such as silica or alumina, and is excellent in compatibility with the inorganic binder, and has a strong bonding force with the inorganic binder.

Although the example of the ceramic hollow body is not limited to a large extent, senescosphere can be preferably used. The senospheres are spherical particles produced in the combustion process of coal, and the senospheres may have a diameter of 100 mesh to 1000 mesh, or 500 mesh to 1000 mesh. Accordingly, the senescospher particles may be included in an amount of 20 to 90 parts by weight based on 100 parts by weight of the inorganic binder.

The average diameter of the senosphere particles is 100 mesh to 400 mesh. Through the grinding process, the senesphere particles having a diameter of 500 mesh to 1000 mesh can be produced. When the diameter of the senosphere particles is reduced to 500 mesh to 1000 meshes, the content of the senosphere particles in the flame retardant composition can be increased, and more excellent flame retardancy can be ensured. For example, the content of the senosphere particles may be 60 to 80 parts by weight based on 100 parts by weight of the inorganic binder.

The Senosphere is a porous inorganic material containing 40 to 60% by weight of silicon dioxide (SiO ₂ ) and 30 to 50% by weight of aluminum oxide (Al ₂ O ₃ ), and a hollow containing nitrogen gas or the like is formed therein , And a specific gravity of 0.5 to 1.0. The Senosphere can be obtained inexpensively and recycles industrial wastes. Therefore, the flame retardant composition is environmentally friendly and economical compared to conventional non-halogen flame retardants.

The flame retardant composition may include 20 to 90 parts by weight, or 60 to 80 parts by weight of the ceramic hollow body based on 100 parts by weight of the inorganic binder. If the content of the ceramic hollow body is less than 20 parts by weight based on 100 parts by weight of the inorganic binder, it may be difficult to sufficiently realize the effect of improving the water resistance, durability and flame retardancy of the flame retardant composition due to reduction of the ceramic hollow body.

On the other hand, if the content of the ceramic hollow body is more than 90 parts by weight based on 100 parts by weight of the inorganic binder, mixing of the inorganic binder and the ceramic hollow body becomes difficult and moldability in coating, And the durability of the product may be reduced due to the breakage of the product after molding.

The flame retardant composition may comprise a ceramic hollow body and an inorganic binder having a viscosity of at least 5000 cP and less than 100000 cP at 20 캜.

The flame retardant composition may be formed on a substrate to impart flame retardancy to the substrate. Examples of the substrate include, but are not limited to, a foamed resin such as polystyrene foam, polyolefin foam, melamine foam and urethane foam, wood (MDF), rubber foam, synthetic rubber foam, The material can be used without limitation, and examples of the method of forming the flame retardant composition on the substrate are not limited, and various coating and mixing methods known in the art can be used without limitation.

On the other hand, according to another embodiment of the present invention, polystyrene expanded particles; And a flame retardant composition of one embodiment bonded to the surface of the polystyrene expanded particles.

The flame retardant styrofoam has no warping, is easy to be processed by a curved line or hot wire, has water resistance, is flame retardant, generates less toxic gas, and can be extinguished itself without spreading flame upon fire.

The flame-retardant styrofoam can be used as a filler or a molding aid for thermoplastic resin molding with excellent flame retardancy higher than the heat-resistant temperature originally of the foamed resin, and is well mixed with the cement product to be lightly weighted and effective in providing heat insulation. Can be used as insulation.

The polystyrene expanded particles are spherical particles produced by foaming a polystyrene resin impregnated with a foaming agent, and may have a particle diameter of 2 mm to 100 mm, or 3 mm to 50 mm, or 3 mm to 10 mm.

The surface of the polystyrene expanded particles may be bonded to the flame retardant composition of one embodiment. The content of the flame retardant composition includes the above-mentioned contents in relation to the above embodiment. Examples of the method of bonding the flame retardant composition of the present invention to the surface of the polystyrene expanded particles are not limited. For example, the method of mixing the polystyrene expanded particles with the flame retardant composition, or mixing the unfoamed polystyrene resin with the flame retardant composition And then foaming the polystyrene resin.

The flame-retardant styrofoam may include 20 to 180 parts by weight, or 40 to 160 parts by weight of the ceramic hollow body based on 100 parts by weight of the polystyrene foam. If the content of the ceramic hollow body is excessively reduced to less than 20 parts by weight based on 100 parts by weight of the polystyrene foam, it may be difficult to sufficiently realize the water resistance, durability and flame retardancy improvement effect of the flame retardant composition due to the reduction of the ceramic hollow body.

On the other hand, if the ceramic hollow body content is excessively increased to more than 180 parts by weight based on 100 parts by weight of the polystyrene foam, mixing of the inorganic binder and the ceramic hollow body becomes difficult, and the molding in the process of compounding, The durability can be reduced, such as cracking of the product after molding.

The flame-retardant styrofoam may include 120 to 240 parts by weight, 180 to 220 parts by weight, or 190 to 210 parts by weight of the inorganic binder based on 100 parts by weight of the polystyrene foam. If the content of the inorganic binder is excessively reduced to less than 120 parts by weight based on 100 parts by weight of the polystyrene foam, mixing of the inorganic binder and the ceramic hollow body becomes difficult, and the formability in the processes such as compounding, foaming and compression molding is reduced And the durability of the product may be reduced due to the breakage of the product after molding.

On the other hand, if the content of the inorganic binder is excessively increased to more than 240 parts by weight based on 100 parts by weight of the polystyrene foam, shrinkage may occur during the secondary foam molding, cutting is difficult, product cost may increase, and the efficiency of the process may decrease.

According to another embodiment of the present invention, there is provided a method of manufacturing a flame-retardant styrofoam comprising a foaming step of heat-treating a mixture of a foamable polystyrene resin and a flame retardant composition of the embodiment.

The inventors of the present invention have found that by using the specific flame retardant styrofoam production method described above, it is possible to reduce the size of the mixing apparatus and to minimize the amount of the flame retardant composition by mixing the flame retardant composition with a finer size polystyrene resin before the foaming step of the polystyrene resin And confirmed that the existing manufacturing facility can be used as it is, and confirmed the invention and completed the invention.

In addition, even if the foaming agent is mixed with the flame retardant composition before the foaming step and the foaming agent composition is subjected to the foaming and compression molding process, the flame retardant composition on the surface of the foam of the polystyrene foam can be prevented by the ceramic hollow body and the inorganic binder contained in the flame retardant composition As durability is maintained in a strongly bonded state, the water resistance and flame retardancy of the finally produced flame retardant styrofoam can be improved.

The content of the flame retardant composition, the ceramic hollow body and the inorganic binder includes the above-mentioned contents in relation to the above embodiment.

Specifically, the foamable polystyrene resin is a polystyrene resin that has not been foamed, and includes a polystyrene resin and a blowing agent impregnated in the inside of the polystyrene resin, and is capable of foaming by the subsequent foaming step.

The foamable polystyrene resin may include 2 to 10 parts by weight of the foaming agent per 100 parts by weight of the polystyrene resin. Examples of the foaming agent include, but are not limited to, propane, butane, hexane, pentane, heptane, , Methylene chloride, ethyl chloride, methylene chloride, dimethyl ether, diethyl ether, methyl ethyl ether, nitrogen, carbon dioxide, argon or a mixture of two or more of these may be used. Further, the expandable polystyrene resin may further contain a flame retardant or the like as an additive.

The expandable polystyrene resin may have a shape of spherical polystyrene particles having a particle diameter of 0.5 mm to 1.5 mm. The spherical polystyrene particles having a particle diameter of 0.5 mm to 1.5 mm have a small particle size and can minimize the amount of the inorganic binder and the ceramic hollow body to be mixed for binding to the surface of the polystyrene particles and can reduce the size of the mixing apparatus .

Examples of the method for producing the expandable spherical polystyrene particles are not particularly limited, but for example, a suspension polymerization method or a compounding method can be used. Examples of the suspension polymerization method include suspension polymerization of a styrene monomer on a water-based reaction medium, or suspension polymerization of a styrene monomer and at least one comonomer; And a suspension polymerization method including the step of adding the foaming agent during the suspension polymerization, or after the suspension polymerization, before starting the suspension polymerization.

Examples of the compounding method include: compounding a styrene-based polymer and then cutting the resultant mixture while extruding to produce styrene-based polymer particles; And adding a foaming agent to the styrene-based polymer particles.

The density of the expandable polystyrene resin may be from 14 g / l to 20 g / l.

The mixture may include 20 to 180 parts by weight of the ceramic hollow body based on 100 parts by weight of expandable polystyrene resin. If the content of the ceramic hollow body is less than 20 parts by weight based on 100 parts by weight of the expandable polystyrene resin, it may be difficult to sufficiently realize the effect of improving the water resistance, durability and flame retardancy of the flame retardant composition due to reduction of the ceramic hollow body.

On the other hand, if the content of the ceramic hollow body is excessively increased to more than 180 parts by weight based on 100 parts by weight of the expandable polystyrene resin, mixing of the inorganic binder and the ceramic hollow body becomes difficult, The moldability may be reduced, and the durability may be reduced, for example, the product is broken after molding.

The mixture may contain 120 to 240 parts by weight, or 180 to 220 parts by weight of the inorganic binder based on 100 parts by weight of expandable polystyrene resin. If the content of the inorganic binder is excessively reduced to less than 120 parts by weight based on 100 parts by weight of the expandable polystyrene resin, mixing of the inorganic binder and the ceramic hollow body becomes difficult and moldability in the processes of compounding, foaming, And the durability of the product may be reduced due to the breakage of the product after molding.

On the other hand, if the content of the inorganic binder is excessively increased to more than 240 parts by weight based on 100 parts by weight of the expandable polystyrene resin, there is a shrinkage phenomenon during the secondary foaming molding, cutting is difficult, product cost is increased, .

Examples of the method of mixing the expandable polystyrene resin, the ceramic hollow body and the inorganic binder are not limited and various mixing techniques widely used in the technical field related to the mixing of the resin composition may be used without limitation.

Meanwhile, the heat treatment may be carried out at a temperature of 50 ° C to 200 ° C or 100 ° C to 110 ° C for 20 seconds to 200 seconds. In the foaming step, foaming of the expandable polystyrene resin contained in the mixture proceeds, and a polystyrene foam expanded in volume as compared with the expandable polystyrene resin may be produced.

In the mixture before the foaming step, the inorganic binder and the ceramic hollow body may be bonded to the surface of the foamable polystyrene resin, and the bond may be maintained on the surface of the foamed polystyrene foam produced after the foaming step.

The foaming step may be carried out under a pressure of 0.05 kg / cm 2 to 1 kg / cm 2, or 0.1 kg / cm 2 to 0.5 kg / cm 2, or 0.1 kg / cm 2 to 0.4 kg / cm 2.

The foaming step in which the mixture is heat-treated at a temperature of 50 ° C to 200 ° C, or 100 ° C to 110 ° C for 20 seconds to 200 seconds may be carried out in a dry condition or a wet condition, but preferably in a wet condition. Examples of the wet condition include steam. Specifically, a method of contacting steam with a steam having a temperature of 50 to 200 占 폚 and a pressure of 0.05 to 1 kg / cm2 may be used. Examples of the steam are not limited to a wide variety, and various materials widely used in a wet process can be used without limitation.

As described above, after the foaming step is conducted under the wet condition, the foaming treatment may further include drying the foamed mixture for 1 hour to 2 hours.

Further, after the foaming step, the foamed mixture may further be heat-treated at a temperature of 80 to 250 ° C or 100 to 120 ° C for 20 seconds to 200 seconds. The additional heat treatment process may be conducted at a pressure of 1 kg / cm 2 to 50 kg / cm 2, or 5 kg / cm 2 to 20 kg / cm 2, or 6 kg / cm 2 to 7 kg / cm 2.

Thus, compression molding of the foamed mixture can be performed. Specifically, the foamed foamed particle and the mixture of the flame retardant composition can be foamed together with compression to produce styrofoam having a certain shape. Although the compression molding method is not limited to a specific example, for example, a method may be used in which the foamed mixture is placed in a molding machine having a predetermined shape, followed by heat treatment and compression.

The step of heat-treating the mixture at 80 ° C to 250 ° C, or 100 ° C to 120 ° C for 20 seconds to 200 seconds may also be carried out under dry conditions or wet conditions, but preferably under wet conditions. Examples of the wet condition include steam. Specifically, a method of bringing a vapor having a temperature of 80 to 250 占 폚 and a pressure of 1 to 50 kg / cm2 into contact with the mixture may be used. Examples of the steam are not limited to a wide variety, and various materials widely used in a wet process can be used without limitation.

As described above, after the compression molding step is carried out under the wet condition, it may further include drying for 40 to 80 hours.

According to another embodiment of the present invention, there is provided a method for manufacturing a flame-retardant styrofoam comprising the step of heat-treating a mixture of the polystyrene expanded particles and the flame retardant composition of the first aspect.

Said flame retardant composition. The content of the ceramic hollow body and the inorganic binder includes the above-mentioned contents in relation to the above embodiment.

That is, before the step of heat-treating the mixture of the polystyrene expanded particles and the flame retardant composition of the first aspect, foaming the expandable polystyrene resin may be further included. The content of the expandable polystyrene resin includes the above-mentioned contents in the flame retardant styrofoam production method of the other embodiment.

The step of foaming the expandable polystyrene resin may include a step of heat-treating the expandable polystyrene resin at a temperature of 50 ° C to 200 ° C or a temperature of 100 ° C to 110 ° C for 20 seconds to 200 seconds. In the foaming step, foaming of the expandable polystyrene resin proceeds, and a polystyrene foam expanded in volume as compared with the expandable polystyrene resin may be produced.

The step of foaming the expandable polystyrene resin may be carried out under a pressure of 0.05 kg / cm 2 to 1 kg / cm 2, or 0.1 kg / cm 2 to 0.5 kg / cm 2, or 0.1 kg / cm 2 to 0.4 kg / cm 2.

The foaming of the expandable polystyrene resin may be carried out in a dry condition or a wet condition, but preferably in a wet condition. Examples of the wet condition include steam. Specifically, a method of contacting steam with a temperature of 50 to 200 占 폚 and a pressure of 0.05 to 1 kg / cm2 to the expandable polystyrene resin may be used. Examples of the steam are not limited to a wide variety, and various materials widely used in a wet process can be used without limitation.

As described above, after the foaming step is carried out under the wet condition, it may further include drying for 1 to 2 hours.

The mixture may include 20 to 180 parts by weight of the ceramic hollow body based on 100 parts by weight of polystyrene expanded particles. If the content of the ceramic hollow body is excessively reduced to less than 20 parts by weight based on 100 parts by weight of the polystyrene expanded particles, it may be difficult to fully realize the water resistance, durability and flame retardancy improvement effect of the flame retardant composition due to the reduction of the ceramic hollow body.

On the other hand, when the content of the ceramic hollow body is excessively increased to more than 180 parts by weight based on 100 parts by weight of the polystyrene expanded particles, it is difficult to mix the inorganic binder and the ceramic hollow body, The moldability may be reduced, and the durability may be reduced, for example, the product is broken after molding.

The mixture may contain 120 to 240 parts by weight, or 180 to 220 parts by weight of the inorganic binder based on 100 parts by weight of polystyrene expanded particles. If the content of the inorganic binder is excessively reduced to less than 120 parts by weight based on 100 parts by weight of the polystyrene expanded particles, mixing of the inorganic binder and the ceramic hollow body becomes difficult and moldability in the processes of compounding, foaming, And the durability of the product may be reduced due to the breakage of the product after molding.

On the other hand, when the content of the inorganic binder is excessively increased to more than 240 parts by weight based on 100 parts by weight of the polystyrene expanded particles, shrinkage occurs in the secondary foam molding, cutting is difficult, product cost increases, .

Examples of the method of mixing the polystyrene expanded particles, the ceramic hollow body and the inorganic binder are not limited, and various mixing techniques widely used in the art relating to the mixing of the resin composition may be used without limitation.

In the heat treatment step, the mixture may be heated at a temperature of 80 to 250 DEG C, or 100 to 120 DEG C for 20 to 200 seconds. The heat treatment step may be performed at a pressure of 1 kg / cm 2 to 50 kg / cm 2, or 5 kg / cm 2 to 20 kg / cm 2, or 6 kg / cm 2 to 7 kg / cm 2.

According to the present invention, it is possible to provide a flame retardant composition capable of improving miscibility and flame retardancy and being easily applied to a manufacturing process to ensure high durability, flame retardant styrofoam using the flame retardant composition, and a method for producing the flame retardant styrofoam.

Fig. 1 shows the flame retardancy evaluation result (a) of the styrofoam used as the base material and the flame retardancy evaluation result (b) of the styrofoam formed with the flame retardant coating layer of Example 1.
Fig. 2 shows the flame retardancy evaluation result (a) of the general wood used as the substrate and the flame retardancy evaluation result (b) of the general wood having the flame retardant coating layer of Example 1 formed therein.
Fig. 3 shows the flame retardancy evaluation result (a) of the rubber foam used as the base material and the flame retardancy evaluation result (b) of the rubber foam having the flame retardant coating layer of Example 1 formed.
Fig. 4 shows the result (a) of the flame retardancy evaluation of the synthetic rubber foamed foam used as the base material and the evaluation result (b) of the flame retardancy of the synthetic rubber foamed foam in which the flame retarded coating layer of Example 1 is formed.
Fig. 5 shows the result (a) of the flame retardancy evaluation of the isofine foam used as the substrate and the evaluation result (b) of the flame retardancy of the isofine foam with the flame retardant coating layer of Example 1. Fig.
Fig. 6 shows the flame retardancy evaluation result (a) of the paper used as the base material and the flame retardancy evaluation result (b) of the paper on which the flame retardant coating layer of Example 1 was formed.
Fig. 7 shows the flame retardancy evaluation results of the flame retardant styrofoam prepared in Example 2. Fig.
Fig. 8 shows the flame retardance evaluation results of the flame retardant styrofoam prepared in Example 3. Fig.
Fig. 9 shows the flame retardance evaluation results of the flame retardant styrofoam prepared in Example 4. Fig.
Fig. 10 shows the flame retardance evaluation results of the flame retardant styrofoam prepared in Example 5. Fig.
Fig. 11 shows the flame retardancy evaluation results of the flame-retardant styrofoam prepared in Example 6. Fig.
Fig. 12 shows the flame retardancy evaluation results of the flame-retardant styrofoam produced in Comparative Example 1. Fig.
13 shows the flame retardance evaluation result of the flame-retardant styrofoam produced in Comparative Example 2. Fig.
Fig. 14 shows the flame retardancy evaluation results of the flame-retardant styrofoam produced in Comparative Example 3. Fig.
15 shows the flame retardance evaluation results of the flame-retardant styrofoam produced in Comparative Example 4. Fig.
16 shows the flame retardance evaluation results of the flame-retardant styrofoam produced in Comparative Example 5. Fig.

The invention will be described in more detail in the following examples. However, the following examples are illustrative of the present invention, and the present invention is not limited by the following examples.

< Example One: Flame retardant Preparation of composition >

Seno sphere particles (200mesh) 40g and water glass (KS standard two kinds: silicon dioxide (SiO ₂₎ 34 to 36% by weight of sodium (Na ₂ O) 14 to 15% by weight, ferric oxide (Fe ₂ O ₃ oxide) 0.05 wt. % Or less, water insoluble content 0.2 wt% or less / viscosity 5000 cP or more) were mixed to prepare a flame retardant composition.

The above flame retardant composition was coated on the base material shown in Table 1 and then heated with a gas lighter for 30 seconds to evaluate flame retardancy. The results are shown in Table 2 below.

For reference, the substrate to which the above flame retardant composition was not applied was heated for 30 seconds in a lighter, and flame retardancy was evaluated.

Flame retardancy evaluation result of substrate materials Flammability evaluation Styrofoam When the lighter is heated for about 2 seconds, the styrofoam is melted and burned, and black smoke is generated (Fig. 1 (a)). Plain wood (MDF) When the lighter is heated for 10 seconds or longer, the fire begins to start, and black smoke is generated (Fig. 2 (a)). Foam EPDM (rubber foam) When the lighter is turned on for about 20 seconds, the flame starts to burn, and black smoke is generated (Fig. 3 (a)). Foam EVA (synthetic rubber foam) When the lighter is burned for about 10 seconds, the fire starts to start, and black smoke is generated (Fig. 4 (a)). Foamed PS (iso-pink foam) 5 (a)), the black smoke is generated (Fig. 5 (a)). Paper (200g art paper) Lighter burning When heated for about 20 seconds, starts to ignite, black smoke occurs (Fig. 6 (a))

The substrate on which the flame retardant composition of Example 1 was formed and the flame retardancy evaluation result materials Flammability evaluation Styrofoam Bubbles are generated after about 10 seconds, and they are foamed but not burnt (Fig. 1 (b)). Plain wood (MDF) Bubbles are generated after about 10 seconds, and they are foamed but not burnt (Fig. 2 (b)) Foam EPDM (rubber foam) Bubbles are generated after about 10 seconds, and they are foamed but not burnt (Fig. 3 (b)) Foam EVA (synthetic rubber foam) Bubbles are generated after about 10 seconds, and they are foamed but not burnt (Fig. 4 (b)) Foamed PS (iso-pink foam) After about 10 seconds, bubbles are generated, and they are foamed but not burnt (Fig. 5 (b)) Paper (200g art paper) Bubbles are generated after about 10 seconds, and they are foamed but not burnt (Fig. 6 (b))

As shown in Table 1, it can be confirmed that the substrate before the flame retardant composition is applied is burned and black smoke is generated while it is heated for 30 seconds in the lighter flame.

On the other hand, as shown in Table 2, in the case of a base material coated with a flame retardant composition containing Senosphere particles and water glass, bubbles are generated in the flame retardant composition layer during heating for about 30 seconds in a lighter, It is confirmed that it is possible to secure a high flame retardancy.

< Example 2 to 6: Preparation of Flame Retardant Styrofoam>

Polystyrene (SH Energy Chem. SB 2,000: 1.1 mm in diameter) beads containing 94% by weight of a polystyrene resin and 6% by weight of pentane, water glass (2 kinds of KS standards) and senosphere particles were dispersed in an amount of . Then, the mixture was placed in a steam stirrer and heat-treated at a temperature of 105 ° C and a pressure of 0.2 kg / cm 2 for 80 seconds to be firstly foamed, followed by drying in air for 1 hour. The dried primary foamed styrofoam was placed in a steam molding machine and subjected to heat treatment at a temperature of 120 ° C and a pressure of 6.5 kg / cm 2 for 80 seconds, followed by secondary compression foaming and drying for about 2 days to prepare flame retardant styrofoam.

< Example 7: Preparation of Flame Retardant Styrofoam>

Polystyrene (SH Energy 2,000, diameter: 1.1 mm) containing 94% by weight of polystyrene resin and 6% by weight of pentane was placed in a steam stirrer and heat-treated for 80 seconds with steam at a temperature of 105 ° C and a pressure of 0.2 kg / After primary foaming, it was dried in air for 1 hour. Water glass (two kinds of KS standards) and senosphere particles were mixed in the dried primary foamed styrofoam in the contents shown in Table 3 in a stirrer. Then, the mixture was placed in a steam molding machine and heat-treated for 80 seconds at a temperature of 120 ° C and a pressure of 6.5 kg / cm 2, followed by secondary compression foaming and drying for about 2 days to prepare flame retardant styrofoam.

&Lt; Comparative Examples 1 to 7: Preparation of Flame Retardant Styrofoam &

As shown in the following Table 4, flame retardant styrofoam was prepared in the same manner as in Examples except that the water glass used in the reaction (KS standard 2 kinds) and the content of the senosphere particles were different.

< Experimental Example >

Using the flame-retardant styrofoam obtained in Examples 2 to 6 and Comparative Examples 1 to 7, specimens having a width of 10 cm, a length of 5 cm and a thickness of 2 cm were prepared and heated for 30 seconds with a gas lighter to evaluate flame retardancy.

The compositions of the flame retardant styrofoam of the above Examples and Comparative Examples and the results of the experimental examples are shown in Tables 3 to 6 below.

The flame retardant styrofoam composition of the examples division Polystyrene (g) Senosphere (g) Water glass (g) Senosphere diameter Example 2 60 50 120 200mesh Example 3 60 70 120 200mesh Example 4 60 30 120 200mesh Example 5 60 80 120 800mesh Example 6 60 90 120 800mesh Example 7 60 50 120 200mesh

Flame retardant styrofoam composition of Comparative Example division Polystyrene (g) Senosphere (g) Water glass (g) Additive (g) Senosphere diameter Comparative Example 1 60 - - - 200mesh Comparative Example 2 60 50 - - 200mesh Comparative Example 3 60 - 120 50 (talc) 200mesh Comparative Example 4 60 50 - 120 (PVA) 200mesh Comparative Example 5 60 - 120 50 (zeolite) 200mesh Comparative Example 6 60 50 150 - 200mesh Comparative Example 7 60 120 120 - 800mesh
Example 1: Experimental Example 1 of Flame Retardant Styrofoam division Flammability evaluation Formability evaluation Example 2 Slightly burned on initial heating but no longer burning with no smoke (Figure 7) Good Example 3 Slightly burned during initial heating but no continuous burning with no smoke (Figure 8) Good Example 4 Slight burning at initial heating but no smoke and no continuous burning (FIG. 9) Good Example 5 Good (Figure 10) Good Example 6 Good (Figure 11) Good

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Comparative Example Experimental Example 1 of Flame Retardant Styrofoam division Flammability evaluation Formability evaluation Comparative Example 1 Bad (Figure 12) - Comparative Example 2 13) - Comparative Example 3 Bad (Figure 14) - Comparative Example 4 Bad (Figure 15) - Comparative Example 5 16) Bad Comparative Example 6 Good (Figure 17) Bad Comparative Example 7 Bad (Figure 18) Bad

As shown in Table 5, styrofoam prepared by mixing Senospore particles and water glass together with polystyrene beads shows excellent flame retardancy and moldability. Particularly, in Examples 5 and 6 in which the diameters of the senosphere particles were further reduced, it was confirmed that the polystyrene beads and the Senospore water glass coating were well coated, the senescospher could be contained in a larger amount, and the flame retardancy and formability were further improved I could.

On the other hand, as shown in Table 6, the polystyrene beads were produced by using Comparative Example 1 in which senescosphere and water glass were not mixed, Comparative Examples 3 and 5 in which no senospheres were used, and Comparative Examples 2 and 4 in which no water glass was used In the case of the styrofoam, it was confirmed that the flame retardancy was poor and the combustion of styrofoam could not be prevented.

The flame retardancy and the moldability of the styrofoam produced may be influenced by the mixing ratio of the Senosphere particles and the water glass, and it has been confirmed that the optimum mixing ratio is satisfied in the case of the above embodiment.

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Claims

Ceramic hollow body; And an inorganic binder having a viscosity of at least 5000 cP and less than 100000 cP at 20 DEG C,
The ceramic hollow body includes a senosphere having a diameter of 500 mesh to 1000 mesh,
Wherein the inorganic binder comprises liquid sodium silicate,
And 60 to 80 parts by weight of the ceramic hollow body based on 100 parts by weight of the inorganic binder,
Wherein the liquid sodium silicate is a flame retardant composition having a molar ratio of 2.4 to 2.6 according to the following formula:
[Equation 1]
Molar ratio = {SiO ₂ (wt.%) / Na ₂ O (wt.%) X 1.032}.

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The method according to claim 1,
Wherein said ceramic hollow body has a core-shell structure comprising a core comprising nitrogen gas or carbon dioxide gas and a shell comprising silica or alumina.

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Polystyrene expanded particles; And
The flame retardant composition of claim 1, which is bonded to the surface of the polystyrene expanded particles.

10. The method of claim 9,
Wherein the polystyrene expanded particles have a particle diameter of 2 mm to 100 mm.

10. The method of claim 9,
And 20 to 180 parts by weight of the ceramic hollow body based on 100 parts by weight of the polystyrene expanded particles.

10. The method of claim 9,
And 120 parts by weight to 240 parts by weight of the inorganic binder based on 100 parts by weight of the polystyrene foam.

And a foaming step of heat-treating a mixture of the foamable polystyrene resin and the flame retardant composition of claim 1.

14. The method of claim 13,
Wherein the expandable polystyrene resin comprises a polystyrene resin and a foaming agent.

15. The method of claim 14,
Wherein the foaming agent is contained in an amount of 2 to 10 parts by weight based on 100 parts by weight of the polystyrene resin.

14. The method of claim 13,
Wherein the expandable polystyrene resin has a particle shape with a particle diameter of 0.5 mm to 1.5 mm.

14. The method of claim 13,
Wherein the mixture comprises 20 to 180 parts by weight of the ceramic hollow body based on 100 parts by weight of the expandable polystyrene resin.

14. The method of claim 13,
Wherein the mixture comprises 120 parts by weight to 240 parts by weight of the inorganic binder based on 100 parts by weight of the expandable polystyrene resin.

Comprising the step of heat treating a mixture of polystyrene expanded particles and the flame retardant composition of claim 1.

20. The method of claim 19,
Wherein the polystyrene expanded particles have a particle size of 2 mm to 100 mm.