KR102197209B1 - Fireproof board and manufacturing method thereof - Google Patents

Abstract

The present invention provides a fireproof board having excellent flame retardancy and a method of manufacturing the same, which is formed so as to withstand fire while having excellent light weight, workability and durability.
In addition, the present invention provides a fireproof board and a method of manufacturing the same, which can be widely used as a fireproof insulation material for preventing fire with a significantly improved fire resistance by reducing the stress concentration phenomenon caused by heat when exposed to high temperature heat while having a thinner thickness. .

Description

Fireproof board and its manufacturing method {FIREPROOF BOARD AND MANUFACTURING METHOD THEREOF}

The present invention relates to a fireproof board and a method of manufacturing the same, and more particularly, to a fireproof board and a method of manufacturing the same with improved flame retardancy by reducing the stress concentration phenomenon to disperse the stress when exposed to high temperature heat while having excellent durability and flame retardancy. About.

In general, refractory insulating materials are not burnt and can withstand high-temperature combustion gases or chemical reactions sufficiently, and are collectively referred to as the entire material used for the purpose of suppressing the transfer of heat as much as possible. Insulation systems or fires to save energy consumption It is used as a building material to prevent

In general, the insulating raw material is classified into inorganic materials such as asbestos, glass wool, rock wool, ceramic fiber, diatomaceous earth, pearlite, and organic materials including carbonized cork, styrene foam, urethane foam, and hard rubber.

Organic materials have low flame retardancy compared to inorganic materials and are very vulnerable to fire and heat, but they are used for reasons of light weight, workability and economy, whereas inorganic materials have excellent flame retardancy and can withstand fire and heat, but have poor workability. Therefore, conventionally, a heat-insulating composite material obtained by mixing an inorganic material and an organic material has been manufactured and used.

It discloses an integrated fireproof board of Korean Patent No. 10-1019513. When the inorganic binder is coated on the organic heat insulating material as described above, there is a limit in flame retardancy. In addition, when exposed to high temperatures, cracks occur at points where stress is concentrated, and there is a limitation in that the fire resistance is significantly lowered.

Korean Patent Registration No. 10-1019513

The present invention was conceived to solve the above-described problems, and the problem to be solved by the present invention is that it has excellent durability and flame retardancy, and at the same time, the stress concentration phenomenon caused by heat is alleviated when exposed to high temperature heat, thereby improving flame retardancy having remarkably excellent fire resistance. It is to provide a fireproof board and a manufacturing method thereof.

In order to solve the above problems, the present invention comprises: a first non-combustible material layer and a second non-combustible material layer including an inorganic binder, a micro-crack inducing agent, and an inorganic flame retardant; And a flame-retardant material layer formed between the first and second non-flammable material layers, wherein the flame-retardant material layer provides a fire-resistant board in which a flame-retardant member is coated with a flame retardant.

According to a preferred embodiment of the present invention, the flame-retardant material layer and the second non-flammable material layer may be further stacked by repeating 1 to 5 times as a repeating unit.

According to a preferred embodiment of the present invention, the microcrack-inducing agent may be styrofoam or pulp.

According to a preferred embodiment of the present invention, the flame retardant is from the group consisting of expanded graphite, aluminum hydroxide, magnesium hydroxide, borax, APP, sodium bicarbonate, melamine, iron oxide, sodium silicate, calcium carbonate, magnesium carbonate, dolomite and hydrotalcite. It may be any one or more selected.

According to a preferred embodiment of the present invention, the first non-combustible material layer and the second non-combustible material layer may each contain 0.5 to 10% by weight of a microcrack inducing agent.

According to a preferred embodiment of the present invention, the flame retardant member of the flame retardant layer may be at least one selected from the group consisting of styrofoam, urethane, paper honeycomb, nonwoven fabric, or polyester sound absorbing plate.

According to a preferred embodiment of the present invention, the fireproof board may satisfy all of the following conditions (a) and (b).

(a) 0.5 ≤ A/B ≤ 1.4

(A: Total thickness of the flame retardant layer included in the fireproof board B: Total thickness of the fireproof board)

(b) 0.030 ≤ P ≤ 0.042

(P: Thermal conductivity of fireproof board according to the measurement method specified in KS L 9016 (W/mK))

According to a preferred embodiment of the present invention, the fireproof board may further satisfy the following condition (c).

(c) 1.0 ≤ X ≤ 7.0

(X: Heat release rate of fireproof board according to the measurement method specified in KS F ISO 5660 (MJ/m ² ))

In addition, the present invention comprises the steps of (1) forming a first flame retardant layer coated with a flame retardant on at least one surface of the flame retardant member; And (2) forming a first non-combustible material layer and a second non-combustible material layer on both sides of the fire-retardant member from a non-combustible composition for producing a fire-resistant board including an inorganic binder, a micro-crack inducing agent, and an inorganic flame retardant. Provides.

According to a preferred embodiment of the present invention, after the step (2) (3) forming a second flame retardant layer on the second non-flammable material layer; And (4) forming a third non-flammable material layer on the second flame-retardant material layer, and repeating steps (3) to (4) 1 to 9 times.

The present invention provides a fireproof board having excellent light weight, workability, and durability, as well as excellent fire resistance and improved flame retardancy, and a method for manufacturing the same.

In addition, the present invention has a thinner thickness, but when exposed to high temperature heat, the stress concentration phenomenon caused by heat is relieved, resulting in remarkably improved fire resistance, and a fireproof board with improved flame retardancy, which can be widely used as a fireproof insulating material for preventing fire, and its manufacture. Provides a way.

1 is a structural diagram of a fireproof board according to a preferred embodiment of the present invention.
2 is a structural diagram of a multilayer fireproof board according to an embodiment of the present invention.
3 is a structural diagram of a fireproof board on which a steel plate is laminated according to a preferred embodiment of the present invention.
4 is a structural diagram of a fireproof board in which a protective layer and a heat insulating layer are laminated according to a preferred embodiment of the present invention.
5 is a graph measuring the thermal conductivity of a fireproof board according to an embodiment of the present invention.
6 is a graph measuring the heat release rate of the fireproof board according to an embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those of ordinary skill in the art can easily implement the present invention.

As described above, the conventional fireproof board was able to satisfy the effects of light weight, workability, and durability, but its flame retardancy decreases, and when exposed to high temperature heat, a relatively large crack occurs at the point where the stress is concentrated, so that the fire resistance is remarkable. There was a limit of deterioration.

Accordingly, the present invention comprises: a first non-combustible material layer and a second non-combustible material layer including an inorganic binder, a micro-crack inducing agent, and a flame retardant; And a flame-retardant material layer formed between the first and second non-flammable material layers, wherein the flame-retardant material layer provides a fire-resistant board in which a flame-retardant member is coated with a flame retardant.

Through this, since the present invention is in the form of a multi-layered non-combustible material layer and a flame-retardant material layer is excellent in light weight, workability and durability, and at the same time, there is an effect of excellent flame retardancy because it does not burn easily. In addition, in the present invention, when exposed to high-temperature heat due to the micro-crack-inducing agent included in the first and second non-combustible material layers, a large number of micro-cracks are generated, thereby reducing the stress concentration phenomenon caused by heat, resulting in huge cracks. It is possible to prevent ignition according to the effect of remarkably improving the flame resistance. In addition, there is an advantage of providing a fireproof board with significantly improved fire resistance and flame retardancy with a thinner thickness. Due to these characteristics, there is an advantage that can be widely used as an energy consumption saving and fire prevention insulation material.

Specifically, Figure 1 is a structural diagram of a fireproof board according to an embodiment of the present invention. Referring to the drawing, the first non-combustible material layer (1) and the second non-combustible material layer (3) are formed, and a flame-retardant material layer (2) is formed therebetween, so that the fireproof board 100 of the present invention is formed in a multilayered form. It can be seen that it is formed.

First, the first non-combustible material layer 1 and the second non-combustible material layer 3 including an inorganic binder, a micro-crack inducing agent, and a flame retardant will be described.

The non-combustible material layers 1 and 3 of the present invention contain an inorganic binder and a micro-crack inducing agent. In other words, the non-combustible material layers (1, 3) contain an inorganic binder that exhibits excellent durability against high temperatures and a micro-crack-inducing agent that exhibits fire resistance, and has excellent durability and fire resistance, so it can be widely used as an insulating material and prevent fire. It also has a suitable effect.

The inorganic binder exhibits a function as a binder through the interaction of an inorganic substance and water, and may be mixed with a micro-crack inducing agent and other additives to improve durability and heat insulation.

The inorganic binder may be any one or more selected from the group consisting of cement, gypsum, clay, silicate and phosphate, but more preferably, an inorganic binder commonly available in the relevant technical field may be used. It may be any one or more selected from the group consisting of cement, gypsum, sodium silicate, alumina silicate, calcium silicate and phosphate, more preferably any one or more selected from the group consisting of cement, gypsum, sodium silicate and phosphate. In addition, silica sand may be mixed and used. As the cement, hydraulic cements or pre-hardened cements such as Portland cement, alumina cement, and mixed cement (blast furnace slag cement, fly ash cement, silica cement, etc.) may be used, or silica sand may be mixed and used.

According to a preferred embodiment of the present invention, the non-combustible material layers 1 and 3 of the present invention may include 70 to 90% by weight of an inorganic binder.

The micro-crack inducing agent is a material that is oxidized at a high temperature included in the non-combustible material layers (1, 3), and plays a role in causing a number of micro-cracks when exposed to high temperatures, and stress concentration due to heat is alleviated due to micro-cracks. Fire resistance can be remarkably improved since it can prevent huge cracks from occurring. If the micro-crack inducing agent is not included, when exposed to high-temperature heat, a huge crack is generated due to the phenomenon that the stress due to heat is concentrated in the layer coated with the inorganic material, and accordingly, a large crack is formed inside the non-combustible material layers (1, 3). Since ignition proceeds to the flame retardant layer 2 or other non-flammable material layer, there may be a problem in that fire resistance is remarkably deteriorated.

The microcrack inducing agent may be any one or more selected from the group consisting of pulp and styrofoam. When the material is used as a micro-crack inducing agent, fire resistance and flame retardancy can be improved by alleviating stress concentration due to heat due to micro-cracks.

According to a preferred embodiment of the present invention, the microcrack inducing agent may be included in an amount of 0.5 to 20% by weight, more preferably 0.5 to 10% by weight. If the microcrack inducing agent is contained in an amount of less than 0.5% by weight, the fire resistance may be deteriorated because the stress concentration caused by heat cannot be sufficiently relieved, and if the mile microcrack inducing agent exceeds 20% by weight, The fire resistance may be deteriorated due to cracks.

The flame retardant is a formulation capable of imparting flame retardancy, and the non-flammable material layers 1 and 3 may include a flame retardant to impart flame retardancy to the fireproof board 100 of the present invention.

The flame retardant adds a flame retardant substance by chemical reaction and affects strength maintenance and moldability. The flame retardant can be widely used as a reactive flame retardant, an additive flame retardant to which a flame retardant material is added, and as the additive flame retardant, not only organic flame retardants such as halogen-based, phosphorus-based, nitrogen-based, and composite-based, but inorganic flame retardants can be used without limitation. . Preferably, any one or more selected from the group consisting of expanded graphite, aluminum hydroxide, magnesium hydroxide, borax, APP, sodium bicarbonate, melamine, iron oxide, sodium silicate, calcium carbonate, magnesium carbonate, dolomite and hydrotalcite may be used.

Meanwhile, the non-combustible material layers 1 and 3 may further include a heat resistant agent. In this case, there is an advantage that can further improve heat resistance. The heat-resistant agent may be any one or more selected from the group consisting of alumina, silica, clay, and zircon, and may use a material commonly used in the relevant technical field.

In addition, the non-combustible material layers 1 and 3 of the present invention may further include an inorganic foaming agent. The inorganic foaming agent is an additive for including air bubbles in the non-combustible material layers 1 and 3, and by adding it, light weight, heat insulation, buffering property, sound insulation, and the like can be imparted.

In addition, the non-combustible material layers 1 and 3 of the present invention may further contain other additives within a range that does not harm the physical properties desired by the present invention. Preferably, the other additives may be any one or more selected from the group consisting of a caking agent, a water reducing agent, and an acrylic resin.

In this way, the fireproof board of the present invention can achieve the desired heat resistance and flame retardancy only when the non-combustible material layer (1, 3) is included. Specifically, when using styrofoam (EPS) as a flame-retardant member, it is possible to supplement the fire-resistant properties with a non-combustible material layer (1, 3), and when rock wool or glass is used as a flame-retardant member, it is prevented from becoming too thick. In order to do so, heat resistance and flame retardance may be improved by including the non-combustible material layers 1 and 3. In addition, even when other flame-retardant members that are fragile by heat such as fire are used, heat resistance and flame retardancy can be improved by using the non-combustible material layers 1 and 3.

Next, the flame retardant layer 2 formed between the first non-combustible material layer 1 and the second non-combustible material layer 3 will be described.

The flame retardant layer 2 includes a flame retardant member, and the flame retardant member is coated with a flame retardant. Accordingly, the fireproof board 100 including the flame retardant layer 2 has an effect of remarkably improving fire resistance.

The flame-retardant member may be a material commonly used as a heat insulating material and a flame-retardant member in the relevant technical field, but is preferably selected from the group consisting of styrofoam (EPS), urethane, paper honeycomb, non-woven fabric, rock wool, glass or polyester sound-absorbing plate. It may be any one or more, more preferably any one or more selected from the group consisting of styrofoam (EPS) and urethane, and more preferably styrofoam (EPS).

When using styrofoam (EPS) as a flame retardant member, heat resistance and flame retardancy can be remarkably improved. In addition, by coating at least one surface of the styrofoam (EPS) with a flame retardant, effects such as light weight, heat insulation, cushioning and sound insulation may be implemented.

Meanwhile, the flame retardant is a formulation capable of imparting flame retardancy, and a flame retardant including the same may be coated on at least one surface of the flame retardant member to impart flame retardancy to the fireproof board 100 of the present invention.

The flame retardant adds a flame retardant substance by chemical reaction and affects strength maintenance and moldability. The flame retardant can be widely used as a reactive flame retardant, an additive flame retardant to which a flame retardant material is added, and as the additive flame retardant, not only organic flame retardants such as halogen-based, phosphorus-based, nitrogen-based, and composite-based, but inorganic flame retardants can be used without limitation. . Preferably, any one or more selected from the group consisting of expanded graphite, aluminum hydroxide, magnesium hydroxide, borax, APP, sodium bicarbonate, melamine, iron oxide, sodium silicate, calcium carbonate, magnesium carbonate, dolomite and hydrotalcite may be used.

The flame retardant may be coated on at least one surface of the flame retardant member, and preferably may be coated on all surfaces of the flame retardant member. In addition, when applied, the content may be coated on the surface of the flame retardant member to an extent that can form a flame retardant layer with improved flame retardancy, but preferably, the weight ratio of the flame retardant member: the flame retardant may be coated in a ratio of 1:1 to 1.2.

Meanwhile, in the fireproof board 100 of the present invention, the first non-combustible material layer 1 per pyeong of the flame-retardant material layer 2 may be formed in an amount of 400 to 1600 g, and preferably the first non-combustible material layer per pyeong of the flame-retardant material layer 2 ( 1) may be formed of 600 ~ 1200g, more preferably the flame retardant layer 2 per pyeong of the first non-flammable material layer may be formed of 700 ~ 1000g. This is consistent with the description of the content of the second non-flammable material layer 3 per pyeong of the flame-retardant material layer 2. If the first non-combustible material layer is formed in an amount less than the above range, the fire resistance performance may be deteriorated due to an increase in the rear surface temperature. If the first non-combustible material layer is formed in an amount exceeding the above range, the construction There may be a problem that flows down during the time.

In addition, the fireproof board 100 of the present invention has a structure in which a flame retardant layer 2 is formed between the first non-combustible material layer 1 and the second non-combustible material layer 3, through which it is exposed to high temperature heat. In this case, the first non-combustible material layer (1) and the second non-combustible material layer (3) has the advantage that it is difficult to enter the flame-retardant material layer (2) because the stress concentration phenomenon is alleviated so that large cracks do not occur and only a number of fine cracks are formed. have. Accordingly, not only the fire resistance is remarkably improved, but also the flame retardancy of the flame retardant layer 2 is maximized.

According to a preferred embodiment of the present invention, the flame-retardant material layer 2 and the second non-flammable material layer 3 may be further stacked by repeating 1 to 5 times as a repeating unit. The'repeating unit' means a repeating unit.

Specifically, FIG. 2 is a structural diagram of a multilayer fireproof board 200 according to a preferred embodiment of the present invention. Referring to the above drawing, it means that the flame retardant layer (2) and the second non-combustible material layer (3) are repeatedly stacked once as a repeating unit. 2 It means that only the non-combustible material layer 3 is repeatedly stacked once more so that two more layers of the flame-retardant material layer 2'and the non-combustible material layer 3'are laminated. At this time, it can be seen that the fireproof board becomes a multilayer fireproof board 200 formed of five layers.

Likewise, it means that the flame retardant layer (2) and the second non-combustible material layer (3) are repeatedly stacked twice as a repeating unit, meaning that only the flame-retardant material layer (2) and the second non-combustible material layer (3) are repeated twice more. It means laminating, and the fireproof board will be formed in 7 layers. That is, in the fireproof board of the present invention, a non-combustible material layer (3, 3')-a flame-retardant material layer (2, 2') is repeated, but a non-combustible material layer (1, 3') is present on the outermost side of the fireproof board. I can.

When the fireproof board of the present invention is formed in a multi-layered structure, fireproof performance is improved, and a temperature transmitted to the rear surface in the event of a fire can be blocked, thereby preventing burns in contact with the body.

On the other hand, the thickness of the fireproof board 100 of the present invention may be 45.1 to 76 mm in the case of no repeating of the repeating units described above, and may be thickened by 45.5 to 68 mm each time the repeating unit is increased once. In addition, the thickness of the non-combustible material layers 1, 3, and 3 ′ may be 0.05 to 8 mm, respectively, and the thickness of the flame-retardant material layers 2 and 2 ′ may be 45 to 60 mm. That is, the present invention has the effect of providing a fireproof board that satisfies excellent flame retardancy and fire resistance with only a thinner thickness.

In addition, FIG. 3 is a structural diagram of a fireproof board on which a protective layer 4 is stacked according to a preferred embodiment of the present invention. As can be seen from the drawings, a protective layer 4 may be further included on at least one of the outer surfaces of the non-combustible material layer of the fireproof board 100 of the present invention. In this way, when the protective layer 4 is further included, the durability of the fireproof board can be improved, and thus, there is an advantage that it can be used as various insulating materials.

Meanwhile, the protective layer 4 may be formed by laminating a material layer commonly used in the relevant technical field, but may be preferably an iron plate.

Further, according to a preferred embodiment of the present invention, a heat insulating layer 5 may be further included on at least one surface of the first and second non-combustible material layers 1 and 3. At this time, at least one surface of the non-combustible material layer (1, 3) means the outer surface of the non-combustible material layer (1, 3) forming the outermost side of the fireproof board and the inner surface of the non-combustible material layer (1, 3) in contact with the fire-retardant material layer. It means at least one side. In addition,'at least one surface' means any one or more of the inner surface of the first non-combustible material layer, the outer surface of the first non-combustible material layer, the inner surface of the second non-combustible material layer, and the outer surface of the second non-combustible material layer. That is, the heat insulating layer 5 may be formed on one or more of the outer and inner surfaces of the non-combustible material layers 1 and 3.

In this way, when the heat insulating layer 5 is further included, heat insulating properties and heat resistance may be improved, and at the same time, cracks and collapse of the non-combustible material layer may be prevented.

According to a preferred embodiment of the present invention, the heat insulating layer 5 may be formed of one or more layers selected from the group consisting of a glass fiber layer and an aluminum foil layer. That is, the heat insulating layer 5 may be a glass fiber layer made of glass fiber, an aluminum foil layer made of aluminum foil, or a laminated glass fiber layer and an aluminum foil layer.

Meanwhile, in relation to the protective layer 4, the heat insulating layer 5 is preferably formed inside the protective layer 4. That is, when formed on the outer surfaces of the non-combustible material layers (1, 3), after the heat insulating layer (5) is formed on the outer surface of the non-combustible material layer (1, 3), the protective layer (4) on the heat insulating layer (5) It is preferably formed.

In this regard, FIG. 4 is a structural diagram of a fireproof board in which a protective layer and a glass fiber layer are stacked according to a preferred embodiment of the present invention. Referring to FIG. 4, it can be seen that when the heat insulating layer 5 is formed on the outer surfaces of the non-combustible material layers 1 and 3, the protective layer 4 forms the outermost surface of the fireproof board. Through this, it is possible to prevent cracking and collapse of the non-combustible material layer, and at the same time, there is an effect of improving the durability of the fireproof board.

On the other hand, when the fireproof board of the present invention is formed in a'multilayer', the fireproof board may further include at least one heat insulating layer 5. That is, for a plurality of non-combustible material layers (1, 3, 3'?) included in a'multi-layered' structure, a heat insulating layer 5 may be formed on at least one surface of the non-combustible material layers.

In addition, when more than one heat insulating layer 5 is formed, the heat insulating layers 5 may each independently be any one or more selected from the group consisting of a glass fiber layer and an aluminum foil layer. For example, when the heat insulating layer 5 is formed in two places on the fireproof board, one place may be a glass fiber layer and the other may be formed of an aluminum foil layer, and both places may be a glass fiber layer or an aluminum foil layer. It can also be formed only.

According to a preferred embodiment of the present invention, the fireproof board 100 may satisfy all of the following conditions (a) and (b). The fireproof board 100 of the present invention may have significantly improved flame retardancy even with only a thinner thickness by satisfying the thermal conductivity while satisfying the thickness range of the following conditions.

(a) 0.5 ≤ A/B ≤ 1.4

(A: Total thickness of the flame retardant layer included in the fireproof board B: Total thickness of the fireproof board)

(b) 0.030 ≤ P ≤ 0.042

(P: Thermal conductivity of fireproof board according to the measurement method specified in KS L 9016 (W/mK))

The condition (a) may be preferably 0.6 ≤ A/B ≤ 1.35. Further, the condition (b) may preferably be 0.033≦P≦0.040, more preferably 0.035≦P≦0.038. If P does not satisfy the above range, the thermal conductivity is excessively high and the flame retardancy may be deteriorated.

According to another preferred embodiment of the present invention, the fireproof board 100 may further satisfy the following condition (c). Through this, it is possible to provide a fireproof board having excellent insulation, flame retardancy and heat resistance.

(c) 1.0 ≤ X ≤ 7.0

(X: Heat release rate of fireproof board according to the measurement method specified in KS F ISO 5660 (MJ/m ² ))

The condition (c) may preferably be 2.0≦X≦6.0, and more preferably 2.0≦X≦4.0.

Furthermore, the present invention provides a first non-combustible material from a non-combustible composition for manufacturing a fire-resistant board including (1) forming a first flame-retardant material layer (2) coated with a flame-retardant member and (2) an inorganic binder, a micro-crack inducing agent, and an inorganic foaming agent. It provides a fireproof board manufacturing method comprising; forming a layer (1) and a second non-combustible material (3) layer on both sides of the flame-retardant member.

Hereinafter, it will be described in detail except for the content overlapping with the above.

First, a description will be given of the step of (1) forming the first flame retardant layer 2 in which the flame retardant member is coated with a flame retardant.

In the step (1), the flame retardant coating method for the flame retardant member may be a method commonly used in the relevant technical field, but preferably, a method of coating by injecting a flame retardant to at least one surface of the flame retardant member or flame retardant member There is a method of manufacturing a flame retardant member through a molding process after coating the beads with a flame retardant before foaming the beads for manufacture. More preferably, the latter method can be used.

The method of coating by injecting a flame retardant onto at least one surface of the preformed flame retardant member has the advantage of improving the flame retardancy by injecting a simple process and injecting a sufficient amount of flame retardant.

In addition, the method of manufacturing a flame retardant member through a molding process after coating the beads with a flame retardant before foaming the beads for manufacturing the flame retardant member can evenly coat the flame retardant on the beads, and the type and amount of the flame retardant can be easily adjusted. There is an advantage.

Meanwhile, the method of manufacturing the flame retardant layer 2 may be performed in a two-component process or a one-component process. The two-component process may preferably perform a foaming process after coating a bead for manufacturing a flame retardant member with a flame retardant. Thereafter, when performing the mixing and drying process, after spraying the organic adhesive, the mold injection and molding process may be performed. In addition, the one-component process may be performed in the same manner as the two-component process, but the organic adhesive may not be sprayed.

Next, (2) forming a first non-combustible material layer (1) and a second non-combustible material layer (3) on both sides of the flame-retardant member from a non-combustible composition for manufacturing a fireproof board including an inorganic binder, a microcracks inducing agent and a flame retardant. Explain.

In the step (2), the non-combustible composition may be applied to both sides of the flame-retardant material layer to form a first non-combustible material layer (1) and a second non-combustible material layer (3). In this case, the non-flammable composition may be applied by a method commonly used in the art, but preferably, a roll-to-roll process or a blade process may be performed.

Meanwhile, according to a preferred embodiment of the present invention, after step (2), (3) forming a heat insulating layer on at least one surface of the first non-combustible material layer and the second non-combustible material layer; may be further performed. The step (3) may be performed in a way that the heat insulating material forming the heat insulating layer can be evenly attached to at least one side of the non-combustible material layer, but preferably, after applying the non-flammable composition for producing a fireproof board on both sides of the flame retardant layer, it is not dried. It may be formed by attaching a heat insulator in the state, or may be formed by disposing the heat insulator before applying the non-combustible composition for producing a fireproof board and then applying a non-combustible composition for producing a fireproof board. In the former case, a heat insulating layer is formed on the outer surface of the non-combustible material layer. In the latter case, a heat insulating layer is formed on the inner surface of the non-combustible material layer.

In the case of applying a non-combustible composition for manufacturing a fireproof board on both sides of the flame retardant layer and then attaching the insulation material in a non-dried state, drying is performed after moisture is absorbed into the insulation material, so that it can be more easily attached to the non-combustible material layer. There is.

In addition, after step (2), (4) forming a second flame retardant layer on the second non-combustible material layer and (5) forming a third non-flammable material layer on the second flame retardant layer are further performed, Steps (4) to (5) may be repeated 1 to 9 times.

The step of forming the second flame retardant layer (2') in step (4) is the same as the step of forming the first flame retardant material layer (2) in step (2) and the same method and conditions. In addition, the step of forming the third non-combustible material layer (3') in step (5) includes the steps of forming the first non-combustible material layer (1) and the second non-combustible material layer (2) in the step (1) and the method of performing And the conditions are the same. In addition, by repeating steps (3) to (4) 1 to 9 times, the multilayer fireproof board 200 can be manufactured as described above.

As a result, the fireproof board and its manufacturing method of the present invention are excellent in light weight, workability, and durability, and at the same time, they are not easily burned, and thus have excellent flame retardancy. In addition, in the present invention, when exposed to high temperature heat due to a micro-crack inducing agent, a number of micro-cracks are generated, thereby reducing the stress concentration phenomenon caused by heat. It works.

In addition, the fireproof board according to the present invention can be used to manufacture a standard fireproof board by sintering and cutting a product, so that it can be widely used as an energy consumption saving and fire prevention insulation material.

Hereinafter, the present invention will be described in more detail through specific examples.

Example One

35% by weight of cement, 35% by weight of silica sand, 10% by weight of magnesium carbonate, and 10% by weight of pulp were mixed to prepare a non-combustible composition for forming a non-combustible material layer. Meanwhile, a coating solution containing a flame retardant was prepared by mixing 35% by weight of ethylene vinyl acetate (EVA), 40% by weight of a flame retardant, 5% by weight of a phase change material, and 20% by weight of water. After coating the styrofoam beads with the coating solution, a foaming process was performed. Then, a two-component process in which an organic additive is injected while performing a mixing and drying process was performed, and then a mulde injection and molding process were performed to prepare a flame retardant layer. At this time, the coating was applied at a weight ratio of styrofoam: flame retardant of 1:1.2. The composition for forming a non-combustible material layer was applied to both sides of the flame-retardant material layer through a roll-to-roll process or a blade-type process to prepare a fireproof board.

Example 2

It was carried out in the same manner as in Example 1, except that a one-component process in which an organic additive is not injected when performing the mixing and drying process instead of the two-component process.

Example 3

It was carried out in the same manner as in Example 1, except that 25% by weight of water was mixed without including a phase change material.

Example 4

After preparing the flame retardant layer and before applying the composition for forming a non-flammable material layer, it was carried out in the same manner as in Example 1, except that aluminum foil layers were laminated on both sides of the flame retardant layer.

Example 5

After preparing the flame retardant layer and before applying the composition for forming a non-flammable material layer, it was carried out in the same manner as in Example 1, except that glass fiber layers were laminated on both sides of the flame retardant layer.

Comparative example One

It was carried out in the same manner as in Example 1, except that the phase change material and pulp were not included.

Experimental example 1-Flame propagation measurement

remind Flame propagation properties were measured by the method specified in ASTM E-2058 for the fireproof board test bodies manufactured through Examples 1 to 3 and Comparative Examples, and the results are shown in Tables 1 and 2 below.

Experimental example 2 - Heat release rate Measure

The heat release rate was measured by the method specified in KS F ISO 5660-1:2008 for the fireproof board test specimens manufactured through Examples 1 to 3 and Comparative Examples. The heat release rate is shown in Table 1 and Table 2 below, the values repeatedly measured 1 to 3 times per each example.

Experimental example 3-Gas hazard measurement

Gas hazards were measured by the method specified in KS F 2271:2016 for the refractory board test specimens manufactured through Examples 1 to 3 and Comparative Examples. The measurement measures the average behavior stop time of the experimental white rats, and the values measured repeatedly 1 to 3 times per example are shown in Tables 1 and 2 below.

Experimental example 4-measurement of thermal conductivity

The heat conductivity was measured by the method specified in KS L 9016 for the refractory board test specimens prepared in Examples 1, 4 and 5 above. The measured values are shown in Tables 1 and 3 below.

Experimental example 5- Of flame retardant layer Thermal conductivity measurement

Thermal conductivity was measured for the flame retardant layer prepared through Examples 1 to 3 and Comparative Examples by the method specified in KS L 9016. Measurements were repeated in 1 to 3 times per example, and the measured values are shown in Tables 1 and 2 below.

[Table 1]

[Table 2]

[Table 3]

Referring to Table 1, in Example 1 including a micro-crack inducing agent, sustained combustion heat and heat release rate have values suitable for disaster prevention. Through this, it can be seen that when the micro-crack inducing agent is included, it is possible to prevent the occurrence of huge cracks, so that the fire resistance is excellent and the flame propagation property is low, so that the possibility of use as an insulating material that needs fire prevention is high. In addition, it can be seen that the average behavior stop time of the experimental white rats is 14 minutes or more, indicating that they have excellent fire resistance properties. That is, in the present invention, it can be seen that all experimental examples related to the flame retardant grade 2 test are excellent.

In addition, referring to Tables 1 and 2, the heat release rates and gas hazards of Examples 1 and 2 have excellent values. On the other hand, in the case of Example 3, the heat release rate is higher than 6.0 MJ/m ² . In addition, in the case of the comparative example, the heat release rate was 8.0 MJ/m ² or more and the gas epidemic was remarkably high, indicating that it is not suitable for disaster prevention.

On the other hand, Figure 5 is a graph measuring the thermal conductivity of the fireproof board according to an embodiment of the present invention, Figure 6 is a graph measuring the heat release rate of the fireproof board according to an embodiment of the present invention. The heat release rate corresponding to each example of FIG. 6 refers to an average value of repeated measured values. Referring to the drawings and Table 1, the fireproof board of the present invention not only exhibits a low heat release rate, but also exhibits a low thermal conductivity of about 0.045 W/mK. It can be seen that the heat conductivity of the fireproof board itself has a value of about 0.045W/mK compared to that of the heat conductivity value measured only the flame retardant layer has a value of about 0.030 to 0.040W/mK. That is, the fireproof board of the present invention is a heat insulating material having excellent flame retardancy and fire resistance.

In addition, Examples 4 and 5 further include an aluminum foil layer and a glass fiber layer, respectively. The thermal conductivity of Example 4 and Example 5 was 0.043 W/mK and 0.044 W/mK, respectively, which was lower than that of Example 1.

Claims (12)

A first non-combustible material layer and a second non-combustible material layer comprising an inorganic binder, a micro-crack inducing agent, and a flame retardant; And
Includes; a flame retardant layer formed between the first non-combustible material layer and the second non-combustible material layer,
In the flame retardant layer, the flame retardant member is coated with a flame retardant,
The first non-combustible material layer and the second non-combustible material layer each contain 0.5 to 10% by weight of a microcrack inducing agent,
The microcrack inducing agent is strofoam or pulp,
An insulating layer is formed on at least one surface of the first and second non-combustible material layers, and the insulating layer is at least one layer selected from the group consisting of a glass fiber layer and an aluminum foil layer. Fireproof board made of.
The method of claim 1,
A fireproof board, characterized in that the fire-retardant material layer and the second non-combustible material layer as a repeating unit are repeatedly stacked 1 to 5 times.
delete The method of claim 1,
The flame retardant is any one or more selected from the group consisting of expanded graphite, aluminum hydroxide, magnesium hydroxide, borax, APP, sodium bicarbonate, melamine, iron oxide, sodium silicate, calcium carbonate, magnesium carbonate, dolomite, and hydrotalcite. Fireproof board.
delete The method of claim 1,
The flame retardant member of the flame retardant layer is a fireproof board, characterized in that at least one selected from the group consisting of styrofoam, urethane, paper honeycomb, non-woven fabric, glass, asbestos or polyester sound absorbing plate.
delete The method of claim 1,
A fireproof board, characterized in that it satisfies all of the following conditions (a) and (b).
(a) 0.5 ≤ A/B ≤ 1.4
(A: Total thickness of the flame retardant layer included in the fireproof board B: Total thickness of the fireproof board)
(b) 0.030 ≤ P ≤ 0.042
(P: Thermal conductivity of fireproof board according to the measurement method specified in KS L 9016 (W/mK))
The method of claim 8,
Fireproof board, characterized in that it further satisfies the following condition (c).
(c) 1.0 ≤ X ≤ 7.0
(X: Heat release rate of fireproof board according to the measurement method specified in KS F ISO 5660 (MJ/m ² ))
(1) forming a first flame retardant layer in which the flame retardant member is coated with a flame retardant; And
(2) forming a first non-combustible material layer and a second non-combustible material layer on both sides of the flame-retardant member from a non-combustible composition for producing a fire-resistant board containing an inorganic binder, a micro-crack inducing agent and a flame retardant
The method of claim 10,
After step (2) above,
(3) forming a heat insulating layer on at least one surface of the first non-combustible material layer and the second non-combustible material layer; further comprising a fireproof board manufacturing method.
The method of claim 10,
After step (2) above
(4) forming a second flame retardant layer on the second nonflammable material layer; And
(5) forming a third non-combustible material layer on the second flame-retardant material layer; further performing,
Fireproof board manufacturing method, characterized in that the steps (4) to (5) are repeated 1 to 9 times.

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