WO2015137570A1 - Method for manufacturing functional board by using flame-retardant mixed fiber - Google Patents

Abstract

The present invention relates to a method for manufacturing a functional board by using a flame-retardant mixed fiber and, particularly, to a method for manufacturing a functional board, by using a flame-retardant mixed fiber, which is obtained by: mixing, in a fixed ratio, flame-retardant treated natural cotton, flame-retardant treated natural bast fiber including hemp, jute, flax, and kenaf, or coir fiber, and one thermoplastic resin fiber selected from polypropylene fiber, acrylic fiber, EVA fiber, polyethylene fiber and nylon fiber; opening and beating out the mixed fiber and laminating the same so as to form a non-woven fabric of the mixed fiber; passing the non-woven fabric through a drying chamber so as to simultaneously dry and preheat the same; applying pressure thereto with a heat press so as to shape a board of the mixed fiber; and forming an ornamental protective layer on the surface of the shaped board.

Description

[Correction 19.08.2014 based on Rule 26] Manufacturing method of functional board using flame retardant mixed fiber

The present invention relates to a method for producing a functional board using a flame retardant mixed fiber, and specifically, natural hemp fiber or palm fiber and polypropylene fiber, acrylic including flame retardant natural cotton and flame retardant hemp, jute, flax, and sheep A non-woven fabric of mixed fibers, which is selected from among fibers, EVA fibers, and polystyrene fibers and nylon fibers, mixed, opened, and laminated with a predetermined ratio, is passed through a drying chamber, preheated at the same time as drying, and pressed by a heat press. The present invention relates to a method for producing a functional board using a flame retardant mixed fiber formed by molding a mixed fiber board and forming a decorative protective layer on the molded board surface.

The natural cotton fire retarded by the above method means that 20-25 parts by weight of ammonium monophosphate is added to 100 parts by weight of 5% aqueous ammonia solution, and 3 to 7 parts by weight of boron is added to the solution completely dissolved in the temperature range of 50 to 70 ° C. After dissolving, adding 0.4 parts by weight of anionic surfactant, 1 part by weight of fluorine-based water repellent, and 3 parts by weight of acrylic phosphate-based capping agent, immersed in natural cotton in a flame-retardant composition for immersion of cotton fiber and stirred for 10-20 minutes. It is a flame retardant natural cotton that is extracted by dehydrating natural cotton with water content of 50-60%, and dehydrated with water content of 50-60%, and dried to less than 10% of water content.

Flame retardant trifiber was dissolved by adding 30 parts by weight of ammonium phosphate to 100 parts by weight of 3% aqueous ammonia solution and adding 8 parts by weight of boric acid to a solution completely dissolved in a temperature range of 50 to 70 ° C. 0.5 parts by weight of anionic surfactant to 4 parts by weight of a fluorine-based water repellent was added to the solution to immerse the natural fiber cut into 5 cm to 10 cm in a completely dissolved flame retardant composition soaked in 5 to 10 minutes and dried to less than h 10% in 5 to 10 minutes. It can be called flame retardant trifibers made by burning.

In addition, the thermoplastic resin fiber can be used as the thermoplastic resin spun into the thermoplastic resin as it is, and the thermoplastic resin fiber can be used as it is to impart flame retardant, 0.5 to 1.5 parts by weight of flame retardant is added to 100 parts by weight of thermoplastic resin to impart flame retardancy One flame retardant thermoplastic resin fiber can be used.

In addition, the method of forming decorative protection on the surface of the molded mixed fiber board can be formed by coating and curing the thermosetting resin solution to a certain thickness on the surface of the molded mixed fiber board, and forming the decorative patterned thin film sheet by plywood bonded to the plywood. It is also possible to disperse the thermoplastic synthetic resin particles or pallets on the board surface and heat-bond them.The synthetic resin particles or pallets can be colored or batched with masterbatch or pellets added with permeate or pigment.They are also reactive to thermosetting resins or thermoplastic resins. , Flame retardant, additive flame retardant may be added in 0.5 to 1.5 parts by weight.

The functional board using the flame retardant mixed fiber is very light and moldable, so it can be formed into flat surface as well as curved surface and wave shape. The surface layer is dense, so that the support layer is reinforced with the decorative protective layer, and the back layer is absorbed by the muscle muscle. It is a functional board for eco-friendly building materials that has insulation, insulation, and dustproofing and does not harm the human body.

Conventional boards belonging to the technical field of the present invention include glass fiber boards, rock wool fiber boards, wood chipboards, gypsum boards, boards in which synthetic resin foams are inserted between wood plywood, vermiculite boards, reed particles or wood powder boards as a binder. Various boards have been used as building materials boards.

However, glass fiber board and rock wool fiber board have heat insulation and heat insulation function, but when the debris particles which are easily cut come into contact with human body, it causes skin disease and it is subject to regulation except for industrial use. Wood chip board and plaster board are adhesive Since the binder is a water-soluble adhesive or an oil-soluble adhesive by molding using a binder, such as a water-soluble adhesive, when exposed to moisture or oil, the original bond strength decreases, causing swelling or breakage at the contact portion. Debris can easily fall off, damaging the aesthetics.

In addition, sandwich type boards in which a synthetic resin hard foam is inserted are excellent in sound insulation, heat insulation, and thermal insulation dustproofing, but lack heat resistance. In particular, a synthetic resin hard foam such as styrofoam starts to soften at 70 ° C, and as the temperature rises, the original form collapses, and when it reaches 100 ° C, it starts to melt and melts completely at 120 ° C, thus losing its original shape. This loss prevents use for walls such as high temperature drying chambers and thermal barrier boards.

In addition, the board for building materials made of synthetic resins, especially thermoplastic resins, is a building material board with high defect rate after construction because the thermoplastic synthetic resin, which is the main material, is sensitive to heat and the fluidity increases as the temperature rises. have.

Fiber accounts for more than 90%, and many hollows are formed in the fiber, and the front edge is twisted to improve the defects of natural cotton while incorporating the advantages of natural cotton with excellent insulation, heat insulation, sound absorption, and dust resistance. By mixing natural hemp fiber or palm fiber, reinforcement of stiffness, which is a weak point of natural cotton, and reduction of volume reduction rate, improvement of tensile strength and dimensional stability, and also strong binding between fiber yarns by thermal fusion of the mixed fiber. The present invention provides a method of manufacturing a functional board using a flame retardant mixed fiber which can obtain various boards of planar, curved, corrugated, and uneven shape by adding thermoplastic fibers which give effects and thermoformability.

Fiber accounts for more than 90%, and many hollows are formed in the fiber, and the front edge is twisted to improve the defects of natural cotton while incorporating the advantages of natural cotton with excellent insulation, heat insulation, sound absorption, and dust resistance. By mixing natural hemp fiber or palm fiber, reinforcement of stiffness, which is a weak point of natural cotton, and reduction of volume reduction rate, improvement of tensile strength and dimensional stability, and also strong binding between fiber yarns by thermal fusion of the mixed fiber. The present invention provides a method of manufacturing a functional board using a flame retardant mixed fiber which can obtain various boards of planar, curved, corrugated, and uneven shape by adding thermoplastic fibers which give effects and thermoformability.

The mixed fiber functional board prepared according to the present invention is very light and has excellent tensile strength, compressive strength and flame retardancy, and excellent thermal insulation, sound absorption, heat insulation, and dustproof function. It can be molded into various forms such as wave form, bending form, etc., so it can be easily installed on the inner wall of a curved shape, steel cylinder, and corner of structure, and it is a board with excellent construction adaptability. It is a functional board that uses natural materials as an address material and can be called a functional board for environmentally friendly building materials.

The present invention is a flame retardant natural cotton and a flame retardant natural hemp fiber having a tensile strength and stiffness (stiffness) or a mixed fiber mixed with a certain ratio of the palm fiber and thermoplastic synthetic resin fibers in a ratio and laminated to a carding machine The mixed fiber nonwoven fabric is passed through a drying chamber and preheated at the same time as drying, and then pressurized with a press preheated to a high temperature to obtain a board of mixed fiber formed by thermoforming and forming a decorative protective layer on the surface layer of the board. As a manufacturing method of the board to explain this in detail by process,

1 step process to obtain mixed fibers by mixing at a weight ratio of 40-45% by weight of fire-retardant natural cotton, 45-50% of retarded natural hemp or palm fiber and 8-12% by weight of thermoplastic resin fiber A two-step process of forming a mixed fiber nonwoven fabric by laminating a homogeneous mixed cotton thin film layer with a carding machine, a three-step process of passing the mixed fiber nonwoven fabric through a dryer and preheating it simultaneously with drying, and preheating the mixed fiber nonwoven fabric at 120 to 180 ° C. Flame-retardant mixing comprising a five-step process of forming a decorative protective layer on the surface of the mixed fiber board by thermally forming a board of the mixed fiber by thermoforming for 20 to 40 seconds with a pressure of 20-30kgf / ㎠ It relates to a method for producing a functional board using fibers.

In the above method, the flame retardant cotton and flame retardant natural ginseng fiber are flame retarded cotton treated with the flame retardant composition liquid for cotton fiber immersion mentioned in the above-mentioned background art, and the natural ginseng fiber is similarly treated with the flame retardant composition for natural ginseng immersion. It is softened natural hemp fiber and natural hemp fiber contains hemp, jute, flax, and hemp fibers. The flame retarded palm fiber is a flame retarded palm fiber treated with a flame retardant composition for dipping natural ginseng. In addition, the thermoplastic synthetic resin fiber can be selectively used polypropylene fiber, acrylic fiber, EVA fiber, polystyrene fiber, polyamide fiber, and in the case of using a high melting point polyester fiber, the fiber yarn coated with the EVA resin In order to increase the overall flame retardancy of the functional board, as the flame retardant in 100 parts by weight of each thermoplastic synthetic resin, as the flame retardant, heptic acid, tetrabrophthalic anhydride, tatra-chlorophthalic anhydride, and as an additive flame retardant, antimony trioxide, zinc borate, toritricrecredil It is also possible to use thermoplastic synthetic resin fibers spun by adding 0.5 to 1.5 parts by weight of one or more flame retardants selected from phosphates.

In the three-step process, the internal temperature of the dryer is dried by air heated to a temperature lower than the board forming temperature by 20 ° C., the drying is preheated to the temperature of the softening temperature of each thermoplastic synthetic fiber yarn, and the moisture content of the mixed fiber passed through the dryer is 8 It is less than%.

Actual temperature of the dryer or board forming temperature of the actual dryer can be said to be variable according to the melting point of the thermoplastic resin fiber, and the pressing pressure in the molding process can lower the melting point temperature of each thermoplastic synthetic fiber fiber to 20 ~ 30 ℃.

In addition, since the nonwoven fabric of mixed fibers has thermoforming by the addition of thermoplastic synthetic fiber yarn, it can be molded into various forms such as flat boards, curved boards, corrugated boards, and uneven boards.

In addition, the temperature of the press can be adjusted in the range of 120 ~ 180 ℃ according to the type of thermoplastic resin fibers, yellowing phenomenon occurs after the board molding at a temperature of 180 ℃ or more, select a short time in the range of 20 ~ 30 seconds of the press pressure time. Can be adjusted to some extent but should not exceed 180 ° C.

In the above method, the mixed fiber nonwoven fabric laminated to the carding machine has a thickness of about 50 mm, which is press-pressed in accordance with four processes. The thickness of the mixed fiber board is molded into a thickness ranging from 10 mm to 12 mm and has a weight of 1.8 kg / m 2. Therefore, the apparent specific gravity of 0.15 g / cm 3 to 0.18 g / cm 3 can be said to be an extremely lightweight wall board.

In addition, since the bottom surface of the mold used in the 4th process is maintained only at a press that is pressurized without additional heat, heat is only applied to the surface of the mixed fiber nonwoven fabric during the pressurization time for 20 to 30 seconds. The difference between the surface structure and the back layer structure of the mixed fiber board is formed. In other words, the surface layer structure of the mixed fiber is dense and hard, and it has sex muscle tissue toward the back side of the board, which makes the surface layer of the mixed fiber harder, which can strongly fix the decorative protection plate formed on the surface layer, and improves the supportability. In order to achieve dimensional stability, the back layer makes the structure sparse and preserves many hollows in the fibrous tissue, thereby reducing the rate of reduction of thermal insulation, sound absorption, heat insulation, and dustproofing functions due to molding.

In step 5, there are various methods of forming a decorative protective layer on the surface of the mixed fiber board. One of the methods is to spray an epoxy resin and an unsaturated polyester resin solution onto the mixed fiber board to smooth the surface layer. By curing, it is possible to form a decorative protective layer. Above, epoxy resin has very small reaction shrinkage due to hardening, does not generate volatiles, secures dimensional stability, and has excellent water resistance, chemical resistance, wear resistance, adhesiveness and heat resistance. . The chain unsaturated polyunsaturated polyester main solution is 100 parts by weight of a resin solution in which an unsaturated polyester resin is dissolved in one vinyl monomer selected from styrene, α methyl styrene, vinyl acetate, methacrylic acid ester, and diaryl phthalate, It is an unsaturated polyester resin solution prepared by adding 2 parts by weight of a polymerization catalyst selected from methyl ethyl ketone peroxad, 0.5 parts by weight of cobalt naphthenic acid and 0.5 to 1.5 parts by weight of a flame retardant as a reaction accelerator.

The flame retardant added above can greatly improve the flame retardancy as the addition of the flame retardant as one flame retardant selected from flame retardants added to the thermoplastic synthetic resin fibers.

Another method of forming a decorative protective layer on the surface of the mixed fiber board is to uniformly disperse the particles or pallets of polystyrene ABS, AS, and methacrylic resins, which are thermoplastic values, containing a flame retardant and an antistatic agent on the surface of the mixed fiber board. By fusing with a hot pressing plate, a decorative protective layer can be obtained, a concave-convex pattern can be formed on the decorative protective layer, and various patterns can be printed. Here, the synthetic master batch particles or the pallets added to the thermoplastic resin master batch are made by adding 0.5 to 1.5 parts by weight of a flame retardant and 1 to 1.5 parts by weight of an antistatic material with respect to 100 parts by weight of thermoplastic synthetic resin. The antistatic agent is selected from flame retardants, and an antistatic agent selected from elegan and chemistak is added.

In addition, another method of forming a decorative protective layer on the surface of the mixed fiber board is 100 parts by weight of ocher, 10 parts by weight of pulp, and 5 parts by weight of milk casein, 10 weight of alginate extracted from seaweed (half), a natural adhesive. It is a method of forming a decorative protective layer by carrying out the adhesive coating of the colloid material gelatinized by adding to 50 weight part of aqueous solution of%.

In addition, as a method of forming a decorative protective layer, there are a decorative protective layer bonded to a plywood bonded with veneer on the surface of the mixed fiber board, and a method of forming a decorative protective layer by adhering the chip board to the surface layer.

In order to clearly implement the technical configuration of the present invention and to examine the effects thereof, an embodiment will be given to find out the functions and properties of the flame retardant mixed fiber board which is a core material in the functional manufacturing method of the present invention.

Example (1)

Fire retardant cotton 42% by weight, flame retardant hemp fiber 50% by weight Fire retardant polypropylene resin fiber 8 kg by weight of 1.8 kg per square meter of laminated, carded and laminated flame retardant mixed fiber Was passed through a drying chamber maintained at 130 ℃ was molded for 20 seconds by pressing press maintained at 150 ℃ to prepare a flame retardant mixed fiber board (A) of 1m × 1m × 1.2mm.

Example (2)

Test results as shown in Table (1) were obtained through the physical property test with the flame-retardant mixed fiber board (A) prepared in Example (1).

Table 1 Tensile and bursting strength test results of Sample A Test Items Test property value Remarks The tensile strength Longitudinal 1400 (144.9) N / 5cm (kg5 / 5cm) Width 1300 (131.4) N / 5cm (kg5 / 5cm) Bursting strength 6,350KPα

* 1: Tensile strength is the result of testing by KS K 0521: 2006, CR.E strip method by FITI test institute.

Note 2: Bursting strength is the result of testing by KS K 0351: 2006, Hydraulic method by FITI Testing Institute.

Example (3)

The flame retardant mixed fiber board (A) manufactured in Example (1) was commissioned by the FITI Testing Institute and the results of the test by the mechanical burner method (Table 2) were in accordance with the test standards of the Law Test Act on the Installation and Stability Management of Fire Protection Facilities. Indicated.

TABLE 2 Flame retardant (flame retardant) test result of sample (A) Classification Test Items / Test standard Test value of sample (A) Remarks Afterflaming time (S) Within 10 (S) ○ Residual Time (S) Within 30 (S) ○ Bullet area (㎠) Within 50 (㎠) 30.2 Carbonization Length (cm) Within 20 (㎠) 7.4 Judgment - pass

Example (4)

The weight of the sample A was 1.8 kg as a result of measuring the apparent specific gravity of the sample A (1 m x 1 m x 1.2 mm). It was 0.15 g / cm <3> when the apparent specific gravity was converted into the volume and weight of the sample (A).

It can be said to be a mixed fiber board which is lighter than any other board except at least a board made of a synthetic resin foam.

The functional board made of flame-retardant mixed hemp oil produced by the above method is an extremely lightweight board for building materials, has excellent tensile strength, compressive strength and flame retardancy, and has excellent thermal insulation, sound absorption, insulation, and dustproof function. It can be formed into various forms such as flat, curved, semi-circular, wave form, and bent, so that it can be applied to curved inner wall steel columns, structure edges, etc. It is also an eco-friendly board because it is made of natural cotton, natural hemp fiber or palm fiber.

Claims (11)

One-step process of mixing at a weight ratio of 40 to 45% by weight of flame retarded natural cotton, 45 to 50% by weight of flame retarded natural ginseng or palm fiber and 8 to 12% of thermoplastic resin fiber A two-step process of forming a mixed fiber nonwoven fabric by modifying the mixed fiber and loading the homogeneous mixed fiber thin film layer on the other side with a carding machine Three-stage process to pass mixed fiber nonwoven fabric through drying chamber and preheat simultaneously with drying Four-step process of forming mixed fiber board by thermoforming preheated mixed fiber nonwoven fabric for 20 ~ 40 seconds under 20 ~ 30kgf / ㎠ pressure with heat press keeping the temperature of 120 ~ 180 ℃ A method of manufacturing a functional board using a flame retardant mixed fiber comprising a five-step process of forming a decorative protective layer on the surface of the mixed fiber. The method of claim 1, wherein the thermoplastic resin fiber is a thermoplastic synthetic resin fiber selected from polypropylene fiber, acrylic fiber, EVA fiber, and polystyrene fiber. The method of claim 1, wherein the thermoplastic synthetic resin fiber is a thermoplastic resin fiber which is spun by adding 0.5 to 1.5 parts by weight of a flame retardant to 100 parts by weight of thermoplastic resin. The method of manufacturing a functional board using a flame retardant mixed fiber according to claim 1, wherein in forming the mixed fiber board, the surface structure is compactly formed and the back surface is sparsely formed. The method according to claim 1, wherein the decorative protective layer is a decorative protective layer formed by spraying an epoxy resin solution and an unsaturated polyester resin solution on the surface of the mixed fiber board to smooth and then harden the functional board using a flame retardant mixed fiber. Way The decorative protective layer according to claim 1, wherein the decorative protective layer is a decorative protective layer formed by uniformly dispersing particles or pallets of a thermoplastic resin containing a flame retardant and an antistatic agent on a surface of a mixed fiber board and fusion-bonding them with a hot pressing plate. Manufacturing method of functional board using flame retardant mixed fiber The decorative protective layer according to claim 1, wherein the decorative protective layer is mixed with a gelatinized material by adding 10 parts by weight of ocher pulp and 5 parts by weight of milk casein to 50 parts by weight of an aqueous solution of 10% by weight of alginate extracted from seaweed which is a natural adhesive. A method of manufacturing a functional board using a flame retardant mixed fiber characterized in that the decorative protective layer is adhesively coated on the surface of the fiber board. 7. The method of claim 6, wherein the thermoplastic resin is polystyrene, ABS, or AS methacryl resin. 10. The functional board using a flame retardant mixed fiber according to claim 6, wherein the thermoplastic resin master batch is a master batch melt-extruded by adding 0.5 to 1.5 parts by weight of a flame retardant and 1 to 1.5 parts by weight of an antistatic agent to 100 parts by weight of thermoplastic resin. Manufacturing method. The flame retardant of claim 3 and claim 6 is a reactive flame retardant and is at least one flame retardant selected from antimony trioxide, zinc borate and toris triccrephosphate as a flame retardant with a heptate, tetradraphthalic anhydride and tetracrophthalic anhydride. Method for producing a functional board using a flame retardant mixed fiber characterized in that. The method of manufacturing a functional board using flame retardant mixed fibers according to claim 9, wherein the antistatic agent is elecan or chemistatdo.