KR100933974B1 - Manufacturing method of non-combustible thermosetting steel sheet finish for partition and door - Google Patents

Abstract

The present invention relates to a method for manufacturing a non-combustible thermosetting resin steel plate partition and a door finishing material, comprising the steps of: (a) impregnating a shape paper with melamine resin and drying it in a dryer to form an impregnated paper layer; (b) impregnating the glass fiber nonwoven fabric with a phenolic resin containing calcium carbonate and drying in a dryer to form a phenolic resin impregnated glass fiber nonwoven layer; And (c) laminating an impregnated paper layer, a glass fiber nonwoven fabric layer, and a steel sheet layer from above, and then forming the non-combustible thermosetting resin steel sheet partition and door finishing material comprising the step of forming in a hot press.

Description

Process for preparing finish material used in partition and door comprising incombustible thermosetting resin and steel plate}

The present invention relates to a partition and a door finishing material consisting of a non-combustible thermosetting resin and a steel sheet and a method of manufacturing the same.

Conventional partition and door finishing materials are heat-pressurized (combined with melamine resin impregnated with melamine resin, and phenol resin impregnated paper with kraft paper impregnated with phenol resin containing black dye). It is manufactured by molding (compact type), or by combining several layers of melamine resin impregnated paper and phenol resin impregnated paper, and then attaching a particle board (PB) to a melamine sheet formed at high temperature and high pressure to treat the finishing material on both sides (PB type). .

However, these conventional dividers and door finishing materials have the biggest disadvantage of burning well in case of fire as the biggest vulnerability.

As another conventional partition and door finishing material, the finishing material (AL honeycomb type) bonded to the aluminum honeycomb coated color steel sheet has the advantage of not burning well, but since the surface is painted, it is easily scratched and the surface is damaged. It is difficult to restore after installation.

Accordingly, it is an object of the present invention to provide a partition, a door finishing material, and a method of manufacturing the same, having non-flammability and excellent various physical properties.

The present invention to achieve the above object, (a) impregnated in the melamine resin and then dried in a dryer to form an impregnated paper layer; (b) impregnating the glass fiber nonwoven fabric with a phenolic resin containing calcium carbonate and drying in a dryer to form a phenolic resin impregnated glass fiber nonwoven layer; And (c) laminating an impregnated paper layer, a glass fiber nonwoven fabric layer, and a steel sheet layer from above, and then forming the non-combustible thermosetting resin steel sheet partition and door finishing material comprising the step of forming in a hot press.

In the step (a), the basis weight of the paper is 60 to 135 g / ㎡, the impregnated amount of melamine resin is 45 to 65% by weight relative to the basis weight of the paper, the temperature of the dryer is preferably 90 to 130 ℃.

In the step (b), the basis weight of the glass fiber nonwoven fabric is 45 to 110 g / m 2, the calcium carbonate content is 30 to 90% by weight based on the total weight of the phenolic resin, and the impregnation amount of the phenol resin is 30 to 90 relative to the basis weight of the glass fiber nonwoven fabric. It is weight% and it is preferable that the temperature of a dryer is 100-150 degreeC.

In the step (c), the temperature is 120 to 165 ° C. in a hot press, a holding time of 20 to 60 minutes, a unit pressure of 35 to 70 kgf / cm 2, and a cooling time of 20 to 60 minutes. .

In the present invention, the glass fiber nonwoven layer may be laminated at least one or more.

In order to prevent bending of the finishing material in the present invention, a phenol resin-impregnated glass fiber nonwoven fabric layer may be further laminated under the steel sheet layer.

In addition, the present invention provides a non-combustible thermosetting resin steel plate partition and a door finishing material produced according to the above-described method.

According to the present invention, the non-combustible thermosetting steel sheet finishing material, which supplements the disadvantages of the conventional thermosetting resin finishing material and the disadvantages of the aluminum honeycomb finishing material, has about 1/3 lighter weight than the conventional compact type finishing material and is not burned. Compared to the wood type finishing materials, the non-flammable function does not have a tendency to blow even when eroded or infiltrated with water, and it can create interiors with various designs and colors as compared to the aluminum honeycomb color steel plate type finishing materials. As it exhibits the strength of the surface (chemical resistance, abrasion resistance, impact resistance, hot water resistance, light resistance, etc.) which is the greatest advantage of melamine resin, it is a partition material or door inside a building of a multi-use facility such as the subway station where many people come and go frequently. It can be used as a finishing material.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

1 is a cross-sectional view of a non-combustible thermosetting resin steel sheet divider and a door finishing material according to the present invention, which is composed of an impregnated paper layer 10, a glass fiber nonwoven fabric layer 20, and a steel sheet layer 30 from above.
The present invention can be used not only for non-combustible thermosetting resin steel plate partitions and door finishing materials, but also for fire doors.

The impregnated paper layer 10 is impregnated with melamine resin. As the pattern paper, it is preferable to use a pattern paper having a basis weight of 60 to 135 g / m 2 engraved with a pattern. As melamine resin, 100 parts by weight of a fast-setting resin, 3 parts by weight of polyvinyl alcohol (PVA), 10 to 15 parts by weight of water, 5 to 10 parts by weight of methyl alcohol, 0.1 to 0.2 parts by weight of surfactant, 0.5 to 1.0 parts by weight of curing agent And melamine resins composed of 0.2 to 0.3 parts by weight of silicone oil.

The fast curing resin is a resin produced by a common melamine resin manufacturing method, which is prepared by mixing melamine powder and formalin in a ratio of 3: 4.

PVA 3 parts by weight is added to improve the adhesive strength to the fast-drying resin, but when the PVA addition amount is added below 3 parts by weight, there is a problem that the adhesive strength of the resin is reduced, and when more than 3 parts by weight is added, the adhesive gels This will occur.

Water is added to the quick-drying resin, where water has a function of completely dissolving the PVA by hydrogen bonding with PVA to form a hydrogen bond. If the amount is less than 10 parts by weight, since the concentration of the resin is high and it becomes difficult to impregnate the paper, it is preferable to add 10 to 15 parts by weight of water with respect to 100 parts by weight of the fast curing resin.

It is necessary to add methyl alcohol in order to control the viscosity and stability of the resin. If the amount of methyl alcohol is more than 10 parts by weight, the viscosity of the melamine resin is low, resulting in a decrease in adhesion strength with the solids after impregnation. 5 If the weight is less than 5 parts by weight of the melamine resin is too high impregnation when impregnated and the resin is not stable because it is preferable to add 5 to 10 parts by weight of methyl alcohol.

The surfactant is added so that the impregnation can be made more effectively. If the amount is added in excess of 0.2 parts by weight, the surfactant rises to the surface of the resin layer, causing a problem of lowering the surface gloss. When the impregnability is lowered, a problem occurs, so that the amount of the surfactant added is preferably 0.1 to 0.2 parts by weight.

The curing agent plays a role of promoting the curing of the resin, and when added in excess of 1.0 part by weight, the curing time is too fast, so that the resin is not stable, and cracks are generated on the surface of the product, and 0.5 parts by weight. If it is added less than 0.5 to 1.0 parts by weight is preferable because the curing time is delayed to cause a problem that the surface strength of the product is lowered.

The adhesive according to the general plywood manufacturing process takes about 60 to 70 minutes to fully cure, but the fast-curing resin used in the present invention is completely completed in about 20 to 25 minutes by adjusting the molar ratio of the additive and adding a curing agent. It will harden.

In addition, the silicone oil is added to make it easier to separate the product heat-compressed using the above resin in the press. If the amount of silicone oil exceeds 0.3 parts by weight, the surface of the product contains a large amount of oil The problem of lowering the gloss occurs, and if less than 0.2 parts by weight, the product sticks to the press hard plate so that it does not fall well, it is preferable to add 0.2 to 0.3 parts by weight of silicone oil.

The impregnated shape paper is impregnated so that the amount of melamine resin is 45 to 65% by weight (5 to 10% by weight of volatile matter) relative to the basis weight of the shape paper, and the impregnated shape paper is dried in a dryer at 90 to 130 ° C.

If the impregnated amount of the melamine resin in the shape paper is less than 45% by weight, there is a problem that the adhesive strength of the impregnated paper is reduced, and if the amount exceeds 65% by weight, the impregnation time is delayed, so the impregnated amount of melamine resin is 45 to Impregnation to 65% by weight is preferred.

After impregnating the shape paper, it goes through a drying process. If the drying temperature exceeds 130 ℃, the shape paper may be deformed. If the drying temperature is lower than 90 ℃, the drying time is delayed and too much volatile matter is present in the adhesive. It is preferable that the drying temperature is dried at 90 to 130 ° C. because the presence of the adhesive force decreases.

The glass fiber nonwoven fabric layer 20 is impregnated with a phenol resin of a glass fiber nonwoven fabric. As the glass fiber nonwoven fabric, it is preferable to use a nonwoven fabric having a basis weight of 45 to 110 g / m 2 made of glass fibers. The phenol resin impregnation liquid may include 30 to 43 parts by weight of phenol resin, 20 to 24 parts by weight of 37% formalin, 5 to 10 parts by weight of 91% paraform, 20 to 30 parts by weight of methanol, 10 to 12 parts by weight of 25% ammonia, 98 Impregnation solution composed of 2 to 3 parts by weight of% caustic soda may be used.

The calcium carbonate content is preferably 30 to 90% by weight based on the total weight of the phenol resin. Flame retardant impregnation prepared by adding calcium carbonate shows excellent flame retardant effect. That is, when a fire occurs, calcium carbonate contained in the impregnated paper is decomposed by high temperature to generate carbon dioxide, and the carbon dioxide thus produced has fire extinguishing ability. At this time, the calcium carbonate has a disadvantage in that the flame retardancy of the impregnated glass fiber nonwoven fabric is not sufficiently improved when added to less than 30% by weight relative to the total weight of the phenolic resin impregnation liquid, when the addition amount exceeds 90% by weight phenol resin impregnation It is not easy to mix with the liquid, there is a problem that workability is poor and impregnation is difficult.

In particular, gypsum, tetrabromobisphenol-A and the like may be added to the phenol resin instead of calcium carbonate.

As for gypsum, it is preferable to use the phenol resin impregnation liquid added 30 weight part-60 weight part with respect to 100 weight part of phenol resin impregnation liquid compositions. When gypsum is applied, the flame retardancy of the resin may be improved due to the gypsum component. If the amount is less than 30 parts by weight, the flame retardancy may not be sufficiently improved. If the amount exceeds 60 parts by weight, the resin may not be easily dispersed. Not only are they not uniformly dispersed within, but the impregnation is not easy due to the precipitation of gypsum.

Tetrabromo bisphenol A is added by dissolving 10 to 30 parts by weight in methanol to 100 parts by weight of the phenol resin impregnation solution. The tetrabromobisphenol A is added to give flame retardancy, there is a problem that the sufficient effect is not obtained when the addition amount is less than 10 parts by weight, and if the addition amount exceeds 30 parts by weight it will not be easily dissolved in methanol In addition, it is preferable to add tetrabromobisphenol A within the above range because the problem of the impregnation is not made properly because the concentration of the prepared impregnation solution is high.

The glass fiber nonwoven fabric is impregnated such that the impregnated amount of the phenol resin is 30 to 90% by weight (1.5 to 5.0% by weight of volatile matter) relative to the basis weight of the glass fiber nonwoven fabric, and the glass fiber nonwoven fabric is dried in a dryer at 100 to 150 ° C.

When impregnating the glass fiber nonwoven fabric so that the impregnation amount of the phenolic resin is less than 30% by weight, there is a problem in that the adhesive strength is lowered. Impregnation to 90% by weight is preferred.

After impregnating the glass fiber nonwoven fabric, the drying process is carried out. If the drying temperature exceeds 150 ° C, the glass fiber nonwoven fabric may be deformed. If the drying temperature is less than 100 ° C, the drying time is delayed, Since too much volatile matter is present, the problem of deterioration in adhesive strength occurs, and the drying temperature is preferably dried at 100 to 150 ° C.

The glass fiber nonwoven layer 20 may be laminated at least one or more.

As the steel plate layer 30, a general steel sheet having a thickness of 0.4 to 1.5 mm can be used. Instead of the steel sheet, various metal materials such as nonferrous metals such as aluminum can be used.

As shown in FIG. 1, the impregnated paper layer 10, the glass fiber nonwoven fabric layer 20, and the steel sheet layer 30 are laminated from above, and then molded in a hot press. After molding at a temperature of 120 to 165 ° C., a holding time of 20 to 60 minutes, a unit pressure of 35 to 70 kgf / cm 2, and then cooling to a cooling time of 20 to 60 minutes, the molding is preferable.

In the step of forming the laminate, when the molding temperature is less than 120 ℃, there is a problem in that the adhesion force is lowered and peeling of each layer occurs, and if the temperature exceeds 165 ℃, there is a problem that the deformation of each layer is caused, so 120 ℃ It is preferable to mold at 165 degreeC. If the pressurization condition is less than 35 kgf / cm 2, there is a problem in that the adhesion force is lowered and peeling of each layer occurs. It is preferable to set it as 70 kgf / cm <2>. If the pressurization time is less than 20 minutes, there is a problem in that the adhesive force is lowered and peeling of each layer occurs, and if the pressurization time exceeds 60 minutes, the pressurization time is 20 minutes to 60, since the deformation of each layer is caused by long exposure under high temperature. It is preferable to make it into minutes. It is preferable to cool to room temperature over 20 to 60 minutes after thermoforming and then demold.

In addition, in order to prevent bending of the finishing material, a phenol resin-impregnated glass fiber nonwoven fabric layer may be additionally laminated under the steel plate layer 30 (not shown).

Hereinafter, the present invention will be described in detail through the following Examples and Test Examples.

EXAMPLE

Melamine resin was prepared by mixing 100 parts by weight of a quick-drying resin, 3 parts by weight of PVA, 15 parts by weight of water, 10 parts by weight of methyl alcohol, 0.2 parts by weight of surfactant, 1.0 part by weight of curing agent, and 0.3 part by weight of silicone oil. The impregnated paper layer was prepared by impregnating the melamine resin impregnating solution so that the impregnated amount of the melamine resin was 55%, and drying the impregnated impregnated paper in a drier at 110 ° C.

Next, 35 parts by weight of phenol resin, 22 parts by weight of 37% formalin, 7 parts by weight of 91% paraform, 23 parts by weight of methanol, 11 parts by weight of 25% ammonia, 2 parts by weight of 98% caustic soda, 100 parts by weight of calcium carbonate, After preparing the phenol resin impregnation solution, the phenol resin impregnation solution was impregnated with a glass fiber nonwoven fabric such that the impregnation amount of the phenol resin was 60% by weight, and the impregnated glass fiber nonwoven fabric was dried in a dryer at 130 ° C. to form a glass fiber nonwoven fabric layer. Prepared.

Next, the impregnated paper layer, the glass fiber nonwoven fabric layer and the steel sheet layer (thickness 0.48 mm general steel sheet) were laminated from above, and then formed in a thermostatic press at a temperature of 140 ° C., a holding time of 40 minutes, and a unit pressure of 50 kgf / cm 2, followed by cooling. By cooling by molding for 40 minutes, a non-combustible thermosetting resin sheet finish for partitions and doors was produced.

Comparative Example 1

Compact type finishing material manufactured by heat-pressure molding a combination of melamine resin impregnated paper impregnated with melamine resin and phenol resin impregnated paper impregnated with phenol resin containing black dye.

Comparative Example 2

PB type finish made by attaching particle board (PB) to melamine sheet formed at high temperature and high pressure by combining several layers of melamine resin impregnated paper and phenol resin impregnated paper

Comparative Example 3

Al honeycomb finish with bonded colored steel sheet on aluminum honeycomb

[Test Example]

The finishes of Examples and Comparative Examples 1 to 3 were compared to the quality and performance according to KS M 3332 and KS F 2271, the results are shown in Table 1. At this time, KS M 3332 is a thermosetting resin high pressure decorative plate test method, KS F 2271 is a test method for flame retardancy of the interior materials and structures of buildings.

Test Items Example Comparative Example 1 Comparative Example 2 Comparative Example 3 Test Methods Flame retardant Flame retardant class 1 Not flame retardant Not flame retardant Flame retardant class 1 KS F 2271 surface Color, design various Color, design various Color, design various Not diverse and uniform KS M 3332 Wear resistance Wear value over 500 Wear value over 400 Wear value over 200 100 wear or less KS M 3332 Water-resistant No defect No defect Blown out No defect KS M 3332 Chemical resistance (pollution resistance) No change in acid and alkali No change in acid and alkali No change in acid and alkali Discolored by acid and alkali KS M 3332 Impact resistance No cracks on more than 100 face sheets No cracks on more than 100 face sheets No cracks on more than 100 face sheets Cracks on the face KS M 3332 Scratch resistance No defect No defect No defect Easy to scratch KS M 3332 Light resistance Lab color difference 2.6 Lab color difference 3.0 Lab color difference 3.0 Lab color difference 3.6 KS M 3332 Cigarette resistance 110 seconds or more More than 85 seconds More than 85 seconds 85 seconds or less KS M 3332 Lightweight Example = Comparative Example 3> Comparative Example 2> Comparative Example 1

As can be seen in Table 1, the finishing material according to the present invention has the advantage that it is about 1/3 lighter than conventional compact type finishing materials and does not burn. It does not have a tendency to blow out when it penetrates, and it can create interiors with various designs and colors compared to the color steel sheet-type finish coated on aluminum honeycomb, and it has abrasion resistance, hot water resistance, chemical resistance, impact resistance, scratch resistance, Excellent physical properties such as light resistance and cigarette resistance.

1 is a cross-sectional view of a non-combustible thermosetting resin steel plate partition and a door finishing material according to the present invention.

[Description of Symbols for Main Parts of Drawing]

10: impregnated stratum

20: glass fiber nonwoven fabric layer

30: steel plate layer

Claims (7)

(A) impregnated in the form of 60 to 135 g / ㎡ of the shape paper in the melamine resin 45 to 65% by weight relative to the weight of the paper, and then dried in a dryer of 90 to 130 ℃, the melamine resin 100 parts by weight of the melamine resin 3 parts by weight of polyvinyl alcohol (PVA), 10 to 15 parts by weight of water, 5 to 10 parts by weight of methyl alcohol, 0.1 to 0.2 parts by weight of surfactant, 0.5 to 1.0 parts by weight of curing agent and 0.2 to 0.3 parts by weight of silicone oil. Forming an impregnated paper layer using melamine resin; (b) impregnating a glass fiber nonwoven fabric having a basis weight of 45 to 110 g / m 2 in 30 to 90% by weight of phenolic resin relative to the basis weight of the glass fiber nonwoven fabric, and then drying it in a dryer at 100 to 150 ° C., wherein the phenolic resin is phenol 30 to 43 parts by weight of resin, 20 to 24 parts by weight of 37% formalin, 5 to 10 parts by weight of 91% paraform, 20 to 30 parts by weight of methanol, 10 to 12 parts by weight of 25% ammonia, 2 to 3 parts by weight of 98% caustic soda Forming a phenolic resin-impregnated glass fiber nonwoven fabric layer using a phenolic resin which is composed of 30 parts by weight and contains 30 to 90% by weight of calcium carbonate based on the total weight; And (c) laminating the impregnated paper layer of (a), at least one glass fiber nonwoven fabric layer of (b), a steel sheet layer, and a glass fiber nonwoven fabric layer of (b) from above, and then the temperature is 120 to 165 캜 in a hot press. Method for producing a non-combustible thermosetting resin steel sheet finishing material for the partition and the door comprising the step of forming a holding time of 20 to 60 minutes, a unit pressure of 35 to 70 kgf / ㎠, cooling to 20 to 60 minutes of cooling time. delete delete delete delete delete A non-combustible thermosetting resin steel sheet finishing material for partitions and doors comprising (a) an impregnated paper layer, at least one sheet of (b) a glass fiber nonwoven fabric layer, a steel sheet layer, and (b) a glass fiber nonwoven fabric layer from above according to the method of claim 1.

Images