WO2009151162A1

WO2009151162A1 - Fire prevention panel manufacturing method for fold-up

Info

Publication number: WO2009151162A1
Application number: PCT/KR2008/003298
Authority: WO
Inventors: Kwangsoo Jung; Insoo Kim
Original assignee: Individual
Current assignee: Individual
Priority date: 2008-06-12
Filing date: 2008-06-12
Publication date: 2009-12-17
Anticipated expiration: 2010-12-12

Abstract

Disclosed herein is a method for manufacturing a prefabricated fireproof panel, and more particularly to a method capable of manufacturing a light-weight, environment- friendly, prefabricated fireproof panel, having high elasticity, high strength, excellent fireproof properties and high thermal insulation properties, using expandable minerals such as perlite and vermiculite in a continuous process.

Description

FIRE PREVENTION PANEL MANUFACTURING METHOD FOR FOLD-UP

Technical Field

[1] The present invention relates to a method for manufacturing a prefabricated fireproof panel, and more particularly to a method capable of manufacturing a light-weight, environment-friendly, prefabricated fireproof panel, having high elasticity, high strength, excellent fireproof properties and high thermal insulation properties, using expandable minerals such as perlite and vermiculite in a continuous process. Background Art

[2] Generally, panel materials which are used as interior building materials are mostly made of flammable materials, and when a fire breaks out, the interior building materials become a burning media which emits harmful toxic gases and rapidly spreads the fire to adjacent structures. For this reason, building panels having fireproof materials therein have recently been frequently installed even in general-purpose buildings.

[3] Due to severe environmental conditions to which are subjected the fireproof panels, the materials from which they could be constructed would necessarily be very limited, and these days ceramics, steel sheets or expanded resins, which can resist temperatures higher than 1000 ⁰C, are mainly being used. However, these materials have low thermal resistance with the exception of the ceramic materials, and thus when these materials are exposed to high temperatures for longer than a given time, they are melted. In addition, the ceramic materials have good thermal resistance but are disadvantageous in that they have low strength and poor moldability.

[4] Furthermore, the above mentioned fireproof panels consist mainly of a structure in which a honeycomb spacer is placed in fireproof sheets which are connected with a metal material. Such a structure has problems in that, when it is exposed to high heat conditions, it is severely distorted, and a gap between the panels is formed, such that fire and high heat leak to the outside without being blocked.

[5] Particularly, fireproof panels, manufactured by soaking asbestos and chemical fireproof additives in water and drying the soaked materials, are sensitive to changes in the weather. Thus, these fireproof panels have many problems in that the inside thereof collects moisture with the passage of time, and thus, when they are used for a long period of time, the appearance thereof is deteriorated, the strength thereof is remarkably reduced, materials harmful to the himan body are emitted from the panels, and the fireproof performance thereof is remarkably deteriorated. Disclosure of Invention Technical Problem

[6] Accordingly, the present invention has been made in order to solve the above- described problems occurring in the prior art, and it is an object of the present invention to provide a method for manufacturing a prefabricated fireproof panel, in which a light-weight, environment- friendly prefabricated fireproof panel, having high elasticity, high strength, excellent fireproof properties and high thermal insulation properties can be manufactured using expandable minerals, such as perlite and vermiculite, in a continuous process in order to greatly increase the productivity measure of the panel. Technical Solution

[7] To achieve the above object, the present invention provides a method for manufacturing a prefabricated fireproof panel, the method comprising the steps of: heating each of perlite, vermiculite and fibrous sepiolite to expand them a given nurber of times; mixing 40 wt% of the expanded perlite and 35 wt% of the expanded vermiculite, which have a size of more than 5 mm, with 5 wt% of fibrous sepiolite powder, obtained by grinding the expanded fibrous sepiolite, 3 wt% of graphite, 2 wt% of quick lime, 15 wt% of woody fiber, adding given amounts of sodiun silicate and aluninun hydroxide to the mixture, adding water to the mixture in an amount about 2.5 times the weight of the mixture, and heating the mixture solution at 60-70 ⁰C so as to cause a chemical reaction; mixing 10 wt%, based on the total weight of the heated mixture, of an inorganic adhesive with the mixture in a mixer, and extruding the resulting mixture in an extruder at a pressure of 5.5 kg/cm²; depositing the extruded mixture on a panel cover and primarily pressing the deposited mixture; and secondarily pressing the primarily pressed mixture on a dry-hot-air molding roller line, heated to 160 ⁰C, at a pressure of 35 kg/cm², so as to impart the necessary thickness to a fireproof panel.

[8] Preferably, the perlite is expanded about 12 times by heating it to 1100 ⁰C, and the vermiculite is expanded about 40 times by heating it to 600 ⁰C.

[9] Preferably, the panel cover has formed therein a plurality of through holes having a shape of prominences and depressions.

Advantageous Effects [10] As described above, according to the present invention, a light-weight, environment- friendly prefabricated fireproof panel, having high elasticity, high strength, excellent fireproof properties and high thermal insulation properties, can be manufactured using expandable minerals, such as perlite and vermiculite, in a continuous process in order to greatly increase the productivity measure of the panel. In addition, the fireproof panel according to the present invention does not cause environmental contamination when it is discarded after use, and the present invention is a very useful invention which can improve the effectiveness and reliability of the fireproof panel. Best Mode for Carrying Out the Invention

[11] Hereinafter, a preferred embodiment of the present invention will be described in detail.

[12] A prefabricated fireproof panel, which is manufactured in a continuous process according to the present invention, is included in a panel cover made of a metal material and is manufactured in the following manner using, as raw materials, the expandable minerals perlite, vermiculite, and fibrous sepiolite, which is light such that it floats on water, woody fiber, graphite, quick lime, sodium silicate and sodiun hydroxide, and as an adhesive, an inorganic adhesive.

[13] Among the expandable minerals, the perlite, having strength, is heated to 1100 ⁰C to expand it 12 times (specific gravity of 0.18), and the vermiculite, having flexibility, is heated to 600 ⁰C to expand it 40 times (specific gravity of 0.05).

[14] Then, based on a total weight of 100 wt%, 40 wt% of the expanded perlite and 35 wt% of the expanded vermiculite, which have a size of more than 5 mm, are mixed with 5 wt% of fibrous sepiolite powder, obtained by grinding the expanded fibrous sepiolite, 3 wt% of graphite, 2% of quick lime and 15 wt% of woody fiber. Given amounts of sodiun silicate and aluminum hydroxide are added to the mixture, and water is added to the mixture in an amount about 2.5 times the weight of the mixture. The resulting mixture is heated at 60-70 ⁰C to cause a chemical reaction.

[15] Then, 10 wt%, based on the weight of the mixture, of the inorganic adhesive is mixed with the mixture and extruded in an extruder at a pressure of 5.5 kg/cm². Then, the mixture is deposited on a panel cover, which is made of a steel sheet and includes a plurality of holes formed therethrough, the holes having a shape of prominences and depressions and a diameter of 8 mm. The deposited material is primarily pressed, and then secondarily pressed on a dry-hot-air molding roller line at 160 ⁰C at a pressure of 35 kg/cm² so as to impart necessary thickness to a fireproof panel. In this way, the lightweight, environment- friendly prefabricated fireproof panel, having high elasticity, high strength, excellent fireproof properties and high thermal insulation properties, can be manufactured with a desired dimension in a continuous process.

[16] The fireproof panel, manufactured according to the above-described method, is shipped as a product, after being tested at 1300-1800 ⁰C for 1-3 hours in order to examine whether the panel is deformed.

[17] Meanwhile, the perlite that is used in the present invention is obsidian formed when volcanic rocks are rapidly cooled. When the perlite is heated to a high temperature, water contained in the perlite evaporates, and the perlite expands so that it becomes a fine, porous white mineral. The perlite has a neutral pH and contains little or no nutrients, and weeds, seeds, germs and noxious insects do not inhabit the perlite.

[18] Also, the vermiculite that is used in the present invention is a mineral produced by the weathering or hydrothermal alteration of biotite and is divided, according to quality, into vermiculite gold and vermiculite silver. It contains water molecules bound therein, and thus when it is heated to a high temperature, innunerable pores are formed therein due to air bubbles formed during the evaporation of water in the mineral, and it expands to a volune 40-50 times that of the raw ore.

[19] The environment- friendly perlite and vermiculite are three-layered mica- like minerals and contain water between the layers thereof. Thus, when they are heated, dehydration between the layers thereof occurs, and they thermally expand, so that they serve as a thermally insulating, soundproof inorganic material having innunerable pores therein.

[20] The aluminum hydroxide that is used in the present invention has a specific gravity of 2.423 and naturally occurs as gibbsite or diaspore. It is produced as a white colloidal precipitate when ammonia water is added to an aqueous solution of aluninun. When it is heated to about 300 ⁰C, it loses its water molecule. It is an amphoteric hydroxide, which reacts with alkali to form aluminate and reacts with acid to form a salt thereof.

[21] Also, a compound of sodiun silicate and aluminun hydroxide is gelled when it is brought into contact with water. It is used as a raw material for preparing aluminum oxide, which is an absorbing agent, an ion exchanger or a packing agent for chromatography. When it is combined with an extender or fibrous sepiolite powder, the waterproof properties thereof are increased, and it is used as an additive for preparing waterproof cloth and as an antacid.

[22] Moreover, when the graphite and quick lime that are used in the present invention are heated together with water, a material required for the manufacture of the panel is produced and this material serves as a fireproof, waterproof and sound isolation material.

[23] In addition, the reason why the plurality of through holes are formed in the panel cover made of a steel sheet according to the present invention is because, when the mixture is supplied and hardened on the panel cover, it can adhere closely to the panel cover by using the through hole portions without being separated from the panel cover.

Claims

[1] A method for manufacturing a prefabricated fireproof panel, the method comprising the steps of: heating each of perlite, vermiculite and fibrous sepiolite to expand them a given nutrber of times; mixing 40 wt% of the expanded perlite and 35 wt% of the expanded vermiculite, which have a size of more than 5 mm, with 5 wt% of fibrous sepiolite powder, obtained by grinding the expanded fibrous sepiolite, 3 wt% of graphite, 2 wt% of quick lime, 15 wt% of woody fiber, adding given amounts of sodium silicate and aluminum hydroxide to the mixture, adding water to the mixture in an amount about 2.5 times the weight of the mixture, and heating the mixture solution at 60-70 ⁰C so as to cause a chemical reaction; mixing 10 wt%, based on the total weight of the heated mixture, of an inorganic adhesive with the mixture in a mixer, and extruding the resulting mixture in an extruder at a pressure of 5.5 kg/cm²; depositing the extruded mixture on a panel cover and primarily pressing the deposited mixture; and secondarily pressing the primarily pressed mixture on a dry-hot-air molding roller line, heated to 160 ⁰C, at a pressure of 35 kg/cm², so as to impart necessary thickness to a fireproof panel.

[2] The method of Claim 1, wherein the perlite is expanded about 12 times by heating it to 1100 ⁰C, and the vermiculite is expanded about 40 times by heating it to 600 ⁰C.

[3] The method of Claim 1, wherein the panel cover has formed therein a plurality of through holes having a shape of prominences and depressions.