WO2008130132A1

WO2008130132A1 - Anti-flammable board and manufacturing method thereof

Info

Publication number: WO2008130132A1
Application number: PCT/KR2008/002156
Authority: WO
Inventors: Seok Kyu Yoon
Original assignee: IK Corp
Current assignee: IK Corp
Priority date: 2007-04-18
Filing date: 2008-04-17
Publication date: 2008-10-30
Anticipated expiration: 2009-10-18
Also published as: KR100828949B1

Abstract

An anti-flammable board and a manufacturing method thereof are disclosed. The method for manufacturing an anti- flammable board comprises forming a coating layer for forming micropores, on a surface of a bead impregnated with a foaming agent and a fire retardant agent, forming a plurality of foam particles by expanding the bead, wherein a predetermined steam pressure is applied to expand the bead, forming a board having the micropores formed between the plurality of foam particles, by welding the plurality of foam particles, injecting a fire retardant solution into the micropores, and drying the board. Here, the beads are coated with a coating layer containing an inorganic fire resistant material and then expanded to form foam particles, and the content of a foaming agent in the foam particle and the pressure of a steam applied to the foam particle are adjusted to ensure pores between the foam particles, so that a fire retardant solution can be sufficiently injected into the pores, thereby improving the fire resistance, insurability and intensity of the anti-flammable board.

Description

ANTI-FLAMMABLE BOARD AND MANUFACTURING

METHOD THEREOF

Technical Field

[1] The present invention relates to an anti- flammable board and a manufacturing method thereof. Background Art

[2] Styrofoam is being commonly used in an insulator and sandwich boards for building walls. However, they are vulnerable to a fire because the styrofoam has no fire resistance.

[3] In order to overcome this problem have been introduced an insulating styrofoam coated with a fireproof paint and an insulating styrofoam of which foam beads are coated with a fireproof paint before expanded.

[4] However, the fireproof paint does not permeate through the inside of the styrofoam so that when the styrofoam is sliced, the cross section becomes bare of the fireproof paint. Also, the styrofoam with coated particles may lose the fireproof paint during a expansion process, or the foam beads may melt from heat in a fire.

[5] Therefore, there is an attempt to inject a fire retardant solution into a molded styrofoam, but it has a drawback that the styrofoam is not filled with the fire retardant solution sufficiently and uniformly. Disclosure of Invention Technical Problem

[6] The present invention provides an anti-flammable board with high fire resistance as well as high intensity and a manufacturing method thereof by filling the anti- flammable board with a fire retardant solution sufficiently and uniformly. Technical Solution

[7] According to one aspect of the present invention, a method for manufacturing an anti-flammable board is provided, which comprises: forming a coating layer for forming micropores, on a surface of a bead impregnated with a foaming agent and a fire retardant agent; forming a plurality of foam particles by expanding the bead, wherein a predetermined steam pressure is applied to expand the bead; forming a board having the micropores formed between the plurality of foam particles, by welding the plurality of foam particles; injecting a fire retardant solution into the micropores; and drying the board.

[8] The method may further comprises, prior to said forming the board, maturing the foam particles so that the content of the foaming agent ranges from 3.9 % to 4. 5 %, wherein said forming the board comprises: applying to the foam particles a steam pressure between 0.30 and 0.60 kgf/cm for between 4.5 and 10 seconds; and applying to the foam particles a steam pressure between 0.35 and 0.60 kgf/cm for between 3.5 and 6.5 seconds.

[9] A diameter of the foam particle may range from 2.5mm to 5.0mm, and a weight ratio to the board of an inorganic material contained in the fire retardant solution may range from 60 to 80 %.

[10] Said drying evaporates the fire retardant solution so that the inorganic material is left, and in the case of a fire, the anti-flammable board melts but the inorganic material maintains a honeycomb-like structure, preventing an infiltration of heat and flame by blocking air from the outside.

[11] Posterior to said drying, the anti-flammable board is composed of the board, a weight percent of which is in the range from 20 to 40 %, and the inorganic material, a weight percent of which is in the range from 60 to 80 %.

[12] According to another aspect of the present invention is provided an anti-flammable board manufactured by using a plurality of foam particles, wherein a coating layer for creating micropores is formed on a surface of a bead impregnated with a foaming agent and a flame retardant agent, and the bead is expanded to form the foam particles, which comprises: a board formed by welding the plurality of foam particles so that the micropores are formed between the plurality of foam particles; and a fire retardant solution injected into the micropores; wherein a diameter of the foam particle ranges from 2.5mm to 5.0mm, and a weight ratio of the inorganic material contained in the fire retardant solution to the board ranges from 60 to 80 %.

[13] Additional aspects, features, and advantages will be elucidated from the following drawings, claims, and specification.

[14]

Advantageous Effects

[15] According to a preferable embodiment of the present invention, beads are coated with a coating layer containing an inorganic fire resistant material and then expanded to form foam particles, and the content of a foaming agent in the foam particle and the pressure of a steam applied to the foam particle are adjusted to ensure pores between the foam particles, so that a fire retardant solution can be sufficiently injected into the pores, thereby improving the fire resistance, insulatability and intensity of the anti- flammable board. Brief Description of the Drawings

[16] Fig.l is a flowchart illustrating a manufacturing method of an anti-flammable board according to an embodiment of the present invention. [17] Fig.2 illustrates a side view of a drilling apparatus forming injection holes in a board.

[18] Fig.3 is a cross sectional view of a board having injection holes.

[19] Fig.4 is a cross sectional view of injecting a fire retardant solution with a nozzle.

[20] Fig.5 is a cross sectional view of a prior art board.

[21] Fig.6 is a cross sectional view of the board in Fig.5 filled with a fire retardant solution . [22] Fig.7 is a cross sectional view of a board manufactured by the method illustrated in

Fig.l. [23] Fig.8 is a cross sectional view of the board in Fig.7 filled with a fire retardant solution.

[24] Fig.9 illustrates a burning test.

[25] Fig.10 and Fig.11 illustrate a result of a burning test for an anti- flammable board manufactured by the method illustrated in Fig.l. [26] Fig.12 illustrate a result of a burning test for a conventional anti-flammable board.

Mode for the Invention [27] Hereinafter, embodiments of the present invention is described with reference to the accompanied drawings. Same reference numerals designate the same or corresponding parts throughout the drawings and repeated description on them is omitted. [28] [29] Fig.1 is a flowchart illustrating a manufacturing method of an anti-flammable board according to an embodiment of the present invention. [30] First, on a surface of a bead impregnated with a foaming agent and a fire retardant agent is formed a coating layer comprising an inorganic fire retardant material SlO.

The bead impregnated with a forming agent and a fire retardant agent may be obtained by adding a foaming agent to a styrene monomer and polymerizing them. Other various methods may also be used to impregnate a bead with a foaming agent. [31] A coating layer may be formed on these beads by using an inorganic fire retardant material. Such a coating can prevent the generation of blocking, shorten molding time, and enhance the moldability, and demoldability. [32] Also, the coating layer may be water resistable, ensuring water tolerance, reducing the sensitiveness of the beads to steam, and, after expansion, and facilitating an injection of a fire retardant solution by lowering a friction coefficient of foam particles and also providing micropores. [33] Next, the beads are expanded to form a plurality of foam particles S20. When a steam is applied to the beads impregnated with a foaming agent, the foaming agent expands the beads, forming the foam particles. [34] Here, the foam particle may preferably have a diameter in the range from 2.5mm to

5.0mm. When the diameter is smaller than 2.5mm, pores become smaller and a friction coefficient of the surface becomes higher, hindering the injection of a fire retardant solution. When the diameter is larger than 5.0mm, the friction coefficient and the strength become too lower, increasing a fragility.

[35] In order to form the foam particles having such a preferable diameter, the pressure of a steam and the length of time over which the steam is applied may be adjusted.

[36] By using the above foam particles, a predetermined form of board is formed S40.

Before forming the board, the foam particles may be matured S30.

[37] The foam particles are matured to reduce the amount of the residual foaming agent in the foam particles. The maturation process may be performed by putting the foam particles in a well ventilated room for a predetermined time.

[38] Through this maturation, the content of the foaming agent may be reduced to from

3.9 % to 4.5 %. When the content of the foaming agent exceeds 4.5 %, the foam particles may be too strongly welded, discouraging the formation of pores. When the content is lower than 3.9 %, the welding between the foam particles may become loose, thereby lowering the intensity of the board.

[39] The length of maturation time may be adjusted in order to adjust the content of the foaming agent in the foam particles.

[40] Next, a steam is provided to the plurality of foam particles to form a predetermined form of board S40. Since the foam particles still contain the foaming agent, when a steam is applied to the foam particles in a mold, the foam particles show a tendency to reexpand. Due to this tendency, the foam particles are welded with each other, producing a board corresponding to a shape of the mold.

[41] Here, a steam having a pressure in the range from 0.30 to 0.60 kgf/cm may be applied for from 4.5 to 10 seconds S41, and then a steam having a pressure in the range from 0.35 to 0.60 kgf/cm may be applied for from 3.5 to 6.5 seconds S42. Unless the above condition is satisfied, the size of the pore between the foam particles is too small to inject the fire retardant solution sufficiently, or the pore is too large that the strength of the board may not be guaranteed.

[42] Then, a fire retardant solution is injected into the pores disposed amid the plurality of foam particles S50. A process for filling the board with the fire retardant solution is briefly described with reference to Figs.2 through 4.

[43] Fig.2 illustrates a side view of a drilling apparatus forming injection holes in a board. Fig.3 is a cross sectional view of a board having injection holes. Fig.4 is a cross sectional view of injecting a fire retardant solution with a nozzle. In Figs.2 through 4 are illustrated a drilling apparatus 110, a roller part 112, a slotting pin 114, projections 116, a board 120, foam particles 122, injection holes 124, pores 126, and a nozzle 130. [44] Firstly, the injection holes 124 are drilled in the board 120 S51. As shown in Fig.4, the injection holes 124 may be created on either side of the board 120. If necessary, the injection holes 124 may also be formed on one side of the board 120.

[45] These injection holes 124 may be drilled by the drilling apparatus 110 shown in

Fig.2.

[46] The roller part 112 is rotatable, and along the circumference of the roller part 112 are disposed a plurality of slotting pins 114 at predetermined intervals, through which the board 120 passes, so that the injections holes 124 can be created on a surface of the board 120.

[47] The roller part 112 may rotate by means of a motor, or spontaneously due to a transportation force of the board 120 applied to the slotting pin 114.

[48] The slotting pins 114 may be formed plurally along the circumference of the roller part 112 at predetermined intervals. Each slotting pin 114 may be projected perpendicularly to an axis of the roller part 112, and the length and the thickness of the slotting pin 114 may correspond to the depth and the width of the injection hole 124.

[49] The projection 116 is formed at an end of the slotting pin 114 in an opposite direction to a rotating direction, which prevents the slotting pin 124 from pressing a rear side of the injection hole 124 while the slotting pin 114 is pulled out from the board by the rotation.

[50] Fig.4 shows the board 120 having the injection holes 124 created by the above method.

[51] Although the above embodiment proposes the drilling apparatus 110 as shown in

Fig.3, other diverse means, a blade(not shown), e.g., may be employed as a means for forming the injection hole 124.

[52] Meanwhile, in the case that the board 120 has injection holes 124 on either side, the injection holes 124 may have the same depth, which can simplify the process forming the injection holes 124 and prevent a change in a function of the board 120 even if the board 120 is turned over during the manufacturing process.

[53] Then, a fire retardant solution is injected to the board 120 S52. The solution may be filled in the pores 126 and the injection holes 124. The nozzle 130 may be employed for the injection. By contacting the nozzle 130 with one or both sides of the board 120 and pressing the nozzle 130, the fire retardant solution can be injected into the pores 126 within the board 120 and the pores 126 neighboring the injection holes 124. The injection holes 124 are created before injecting the fire retardant solution, so that a surface resistance of the board 120 can be lowered, thereby facilitating the injection of the solution.

[54] The fire retardant solution may be comprised of an inorganic material. When the inorganic solution is injected, the foam particles 122 comprised of a organic material can be sealed by an inorganic diaphragm, blocking out moisture and air from the outside and preventing a leakage of the foaming agent contained in the foam particles 122, so that the strength and insulation efficiency can be maintained. The inorganic diaphragm itself can also serve as an insulator, improving the insulation efficiency.

[55] Here, the fire retardant solution may contain silica and other absorbent materials.

Absorptive properties of the silica can reduce gas emissions such as carbon monoxide, carbon dioxide from combustion.

[56] Next, the fire retardant solution exposed on a surface of the board 120 may be removed S53. A roller(not shown) may be employed for the removing after the solution is injected sufficiently into the board 120 with the nozzle 130.

[57] In order to remove the fire retardant solution exposed on the surface of the board

120, the board 120 may be compressed with the roller to a predetermined depth, discharging surplus solution, which can be recycled.

[58] However, in the case that the board 120 is compressed with the roller, the width of the board 120 may be changed. Therefore, when the board 120 with an exact width and thickness is desired, the exposed solution may be removed without compressing the board 120.

[59] Next, a minus pressure is applied to the board 120 S54. This aims to separate the fire retardant solution into water and fire retardant inorganic components, thereby improving a drying efficiency of the board 120.

[60] More specifically, this allows the water having a lower density to leave out of the board 120 while the fire retardant inorganic components having a higher density remain in the board 120. This reduces a drying time, which is usually extended due to a high heat capacity of the water.

[61] Next, the fire retardant solution exposed on the surface of the board 120 may be removed S55. After the fire retardant solution is separated by the minus pressure, the surface of the board 120 is processed again. In the case that the board 120 is compressed with the roller, the width of the board 120 may be changed. Therefore, when the board 120 with an exact width and thickness is desired, the exposed solution may be removed without compressing the board 120.

[62] Through the above method, the fire retardant solution is injected to the board 120, and then the board 120 is dried S60. Drying the board 120 can prevent a leakage of the fire retardant solution or the fire retardant inorganic components from the board 120.

[63] A microwave may be applied to the board 120 for the drying. The microwave causes water molecules to vibrate, which induces an evaporation of the water.

[64] However, when the board 120 is filled with water vapors generated due to a heating of the microwave, increasing the humidity within the board 120, the drying efficiency may be deteriorated. Therefore, the water vapors within the board 120 may be discharged to the outside.

[65] After the drying is completed, a weight ratio of the inorganic components within the board 120 may range from 60 % to 80%. When the weight ratio is smaller than 60 %, the fire resistance may drop, but when the ratio is larger than 80%, it is hard to handle the product and the intensity may deteriorate.

[66] Fig.5 is a cross sectional view of a prior art board. Fig.6 is a cross sectional view of the board in Fig.5 injected with a fire retardant solution. Fig.7 is a cross sectional view of a board manufactured by the method in Fig.l. Fig.8 is a cross sectional view of the board in Fig.7 injected with a flame retardant solution.

[67] Referring to Figs.5 and 6, it can be seen that a conventional board does not have enough pores and a fire retardant solution is not injected sufficiently and uniformly.

[68] On the other hand, Figs. 7 and 8 show that a board manufactured according to the present embodiment has enough pores and a flame retardant solution is injected sufficiently and uniformly.

[69] An effect of this improvement can be shown from Figs.9 through 12. Fig.9 illustrates a burning test. Fig.10 and Fig.l 1 illustrate a result of a burning test for an anti-flammable board manufactured by a method in Fig.l. Fig.12 illustrates a result of a burning test for a conventional anti- flammable board.

[70] In order to prove the fire resistance of the board, a burning test was conducted in which a fire was applied directly to an anti-flammable board manufactured by the present embodiment, as shown in Fig.9.

[71] As a result, it can be seen from Fig.10 that, in the case of the anti-flammable board manufactured by the present embodiment, the foam particles applied to a fire melt, but the inorganic material neighboring the melted particles maintained a honeycomb-like structure. Therefore, this inorganic material kept heat and flame from infiltrating, allowing the board to remain almost unchanged as shown in Fig.11.

[72] On the other hand, it can be shown from Fig.12 that, in the case of a conventional board, the board could not keep a fire from infiltrating, so that the shape and the width of the board were changed. Industrial Applicability

[73] Although the present invention is described by referring to one of preferable embodiments, it will be appreciated by those skilled in the art that changes may be made without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.

Claims

[1] A method for manufacturing an anti-flammable board, the method comprising: forming a coating layer for forming micropores, on a surface of a bead impregnated with a foaming agent and a fire retardant agent; forming a plurality of foam particles by expanding the bead, wherein a predetermined steam pressure is applied to expand the bead; forming a board having the micropores formed between the plurality of foam particles, by welding the plurality of foam particles; injecting a fire retardant solution into the micropores; and drying the board.

[2] The method of Claim 1, prior to said forming the board, further comprising maturing the foam particles so that the content of the foaming agent ranges from

3.9 % to 4. 5 %, wherein said forming the board comprises: applying to the foam particles a steam pressure between 0.30 and 0.60 kgf/cm for between 4.5 and 10 seconds; and applying to the foam particles a steam pressure between 0.35 and 0.60 kgf/cm for between 3.5 and 6.5 seconds.

[3] The method of Claim 1 or 2, wherein a diameter of the foam particle ranges from

2.5mm to 5.0mm, and a weight ratio to the board of an inorganic material contained in the fire retardant solution ranges from 60 to 80 %.

[4] The method of Claim 1 or 2, wherein said drying evaporates the fire retardant solution so that the inorganic material is left, and in the case of a fire, the anti- flammable board melts but the inorganic material maintains a honeycomb-like structure, preventing an infiltration of heat and flame by blocking air from the outside.

[5] The method of Claim 4, wherein, posterior to said drying, the anti-flammable board is composed of the board, a weight percent of which is in the range from 20 to 40 %, and the inorganic material, a weight percent of which is in the range from 60 to 80 %.

[6] An anti-flammable board manufactured by using a plurality of foam particles, wherein a coating layer for creating micropores is formed on a surface of a bead impregnated with a foaming agent and a flame retardant agent, and the bead is expanded to form the foam particles, the anti-flammable board comprising: a board formed by welding the plurality of foam particles so that the micropores are formed between the plurality of foam particles; and a fire retardant solution injected into the micropores; wherein a diameter of the foam particle ranges from 2.5mm to 5.0mm, and a weight ratio of the inorganic material contained in the fire retardant solution to the board ranges from 60 to 80 %.