KR20170025983A - Sandwich Panel Containing Polyester Resin Foam - Google Patents

Abstract

The present invention relates to a sandwich panel, and a sandwich panel according to the present invention includes: a resin foam having improved flame retardancy and compressive strength; And improved thermal stability and elastic properties.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a sandwich panel comprising a polyester resin foam,

The present invention relates to a sandwich panel comprising a resin foam.

A sandwich panel is a special plywood that is sandwiched between different kinds of materials and glued together. In general, the surface plate is made of a material having high strength such as a plastic plate, an aluminum plate, a stainless steel plate and a metal plate, and the core material is made of paper, wood, foam plastic, etc. in consideration of thermal insulation, have.

This sandwich panel is one of the building materials used for the space division or the outer wall, which is applied to the wall in the construction period or the already constructed buildings, and the application range of the sandwich panel is expanded due to the advantages such as simplicity of construction and shortening of the construction period .

As a conventional main material constituting the resin foam of the conventional sandwich panel, there is known a nonflammable inorganic foam using an inorganic filler such as calcium carbonate and zinc oxide and a vinyl chloride resin as a binder. However, The filler is used in an excess amount of about 4 to 18 times the added weight of the vinyl chloride resin, so that it is impossible to foam by a conventional method, so that the equipment for kneading and foam molding is very difficult, Require a cumbersome procedure, which has been taken directly from the market due to the lack of economics of the lightweight nonflammable products.

Therefore, development of a sandwich panel including a resin foam having excellent flame retardancy, moisture resistance, mechanical strength and processability, light weight, nonflammability, excellent bonding with different materials and excellent workability and economic efficiency is desperately required have.

United States Patent Number 5000991.

It is an object of the present invention to provide a sandwich panel comprising a polyester resin foam and an adhesive resin and having improved fire stability and compressive strength.

According to an aspect of the present invention,

Resin foams;

A first plate formed on one surface of the resin foam;

A second plate formed at a position opposite to the first plate with respect to the resin foam; And

And an adhesive dispersed between the first plate, the second plate, and the resin foam,

The resin foam has a water absorption of 1 g / 100 cm < ² > as measured in accordance with KS M IOS 7214 And a sandwich panel satisfying the following general formula (1) is provided.

[Formula 1]

X / Y ≥ 1.5

X represents the compressive strength (N / cm ² ) of the resin foam layer according to KS M ISO 844, and Y represents the density (kg / m ³ ) of the resin foam layer according to KS M ISO 845.

Further, according to the present invention,

Applying an adhesive resin to the surface of the polyester resin foam;

Bonding the panel to the surface to which the adhesive resin is applied using a pressure roller; And

And cutting the continuous product in which the resin foam and the panel are integrated into a unit size,

The resin foam had a water absorption of 0.8 g / 100 cm < ² > on the basis of KS M IOS 7214 Or less, and satisfies the following general formula (1).

[Formula 1]

X / Y ≥ 1.5

X represents the compressive strength (N / cm ² ) of the resin foam layer according to KS M ISO 844, and Y represents the density (kg / m ³ ) of the resin foam layer according to KS M ISO 845.

INDUSTRIAL APPLICABILITY The sandwich panel according to the present invention comprises: a resin foam having improved flame retardancy and compressive strength; And fire stability and elasticity properties are greatly improved.

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail.

It is to be understood, however, that the invention is not to be limited to the specific embodiments, but includes all modifications, equivalents, and alternatives falling within the spirit and scope of the invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

The terms first, second, etc. may be used to describe various elements, but the elements should not be limited by terms. Terms are used only for the purpose of distinguishing one component from another.

The terminology used in this application is used only to describe a specific embodiment and is not intended to limit the invention. The singular expressions include plural expressions unless the context clearly dictates otherwise.

In the present invention, the terms "comprising" or "having ", and the like, specify that the presence of a feature, a number, a step, an operation, an element, a component, But do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or combinations thereof.

Therefore, the configurations shown in the embodiments described herein are merely the most preferred embodiments of the present invention and are not intended to represent all of the technical ideas of the present invention. Therefore, various equivalents And variations.

Hereinafter, the sandwich panel according to the present invention will be described in detail.

In the sandwich panel according to the present invention,

Resin foams;

A first plate formed on one surface of the resin foam;

A second plate formed at a position opposite to the first plate with respect to the resin foam; And

And an adhesive dispersed between the first plate, the second plate, and the resin foam,

The resin foam has a water absorption of 1 g / 100 cm < ² > as measured in accordance with KS M IOS 7214 Or less, and the following general formula (1) can be satisfied.

[Formula 1]

X / Y ≥ 1.5

X represents the compressive strength (N / cm ² ) of the resin foam layer according to KS M ISO 844, and Y represents the density (kg / m ³ ) of the resin foam layer according to KS M ISO 845.

Specifically, absorption of a resin foam according to the present invention is to KS M 7214 standard IOS 1 g / 100cm ² or less, 0.7 g / 100cm ² 0.6 g / 100 cm < ² > 0.01 to 0.5 g / 100 cm ² or 0.1 to 0.4 g / 100 cm ² Lt; / RTI > When the amount of absorption of the resin foam is within the above range, there is an advantage that it can be easily stored outside.

Specifically, the density to compressive strength ratio of the resin foam according to the present invention may range from 1.5 to 3, 1.6 to 2.5, or 1.7 to 2. The resin foam according to the present invention can realize a resin foam having a high expansion ratio and high strength at the same time by satisfying the density-to-density ratio of compressive strength within the above range. This means that, in the resin foam according to the present invention, the foaming agent is well trapped in the resin foam layer, and the pores are not bonded to each other but the closed cells are formed independently, and excellent heat insulation can be expected.

In the general formula 1, X may be 20 to 300 N / cm ² , and Y may be 20 to 80 kg / m ³ . That is, the compressive strength of the resin foam according to the present invention may be specifically 20 to 300 N / cm ² , 25 to 200 N / cm ² , 30 to 100 or 35 to 80 N / cm ² , kg / m ³ , 25 to 75 kg / m ³ or 30 to 70 kg / m ³ . When the compression strength and density of the resin foam according to the present invention satisfy the above range, the strength of the sandwich panel produced using the resin foam effectively improves.

As one example, the adhesive resin according to the present invention may be in the form of a film capable of being thermally adhered, and may be dispersed in a composition state between the first plate, the second plate and the resin foam.

As one example, the resin foam according to the present invention may be a foam of a polyester resin.

The resin may be a polyester. The polyester resin is not particularly limited as long as it has biodegradability and can retain the physical properties of the polyester and is excellent in softness characteristics and foam forming workability.

The polyester resin mainly used so far is a high molecular weight aromatic polyester resin produced by the condensation polymerization reaction of 1,4-butanediol with terephthalic acid. Here, the high molecular weight polyester may mean a polymer having an intrinsic viscosity [?] Of 0.8 (dL / g) or more. However, the aromatic polyester resin is excellent in physical properties such as high molecular weight, thermal stability and tensile strength, but is not decomposed in a natural ecosystem after disposal, causing serious environmental pollution problems for a long time.

On the other hand, it is already known that aliphatic polyester has biodegradability. However, conventional aliphatic polyesters have a low melting point due to the flexible structure of the main chain and low crystallinity, are low in thermal stability upon melting, are likely to be thermally decomposed, have a high melt flow index, There is a problem that the use thereof is limited due to poor physical properties such as tear strength. The aliphatic polyester may include, for example, polyglycolide, polycaprolactone, polylactide, and polybutylene succinate.

Specific examples of the polyester include polyethylene terephthalate (PET), polystyrene (PS), polybutylene terephthalate (PBT), polylactic acid (PLA), poly Polyglycolic acid (PGA), polypropylene (PP), polyethylene (PE), polyethylene adipate (PEA), polyhydroxyalkanoate (PHA), polytrimethylene terephthalate And may be at least one selected from the group consisting of Polytrimethylene Terephthalate (PTT) and Polyethylene naphthalate (PEN). Specifically, polyethylene terephthalate (PET) may be used in the present invention.

As one example, the resin foam according to the present invention may have a total heat release amount of 8 MJ / m ² or less based on KS F 5660-1, specifically 0.01 to 7.5 MJ / m ² , 0.05 to 7 MJ / m 2 ² , 0.1 to 5 MJ / m ^2, or 0.15 to 3 MJ / m ² .

As an example, the resin foam according to the present invention may have a flame retardancy of more than grade 2 based on KS F 4724. When the flame retardancy grade of the resin foam is the above-mentioned grade, it may exhibit semi-fireproof performance. Therefore, the sandwich panel comprising the resin foam according to the present invention can maintain a stable shape even at a high temperature by having a total emission heat quantity and a flame retardancy grade in the above range.

As an example, the resin foam according to the present invention may be a closed cell (DIN ISO4590) where at least 90% of the cells are closed cells. This may mean that the measured value of the resin foam layer in accordance with DIN ISO 4590 is that at least 90% of the cells are closed cells. For example, the closed cell of the resin foam layer may be 90 to 100% or 95 to 100%. The foamed molded article according to the present invention includes a resin foamed layer having a closed cell within the above range, so that excellent heat insulating properties can be realized. As a result, the foamed molded article can be widely used in the construction industry for insulation of a part of a building, for example, a foundation, a wall, a floor and a roof. For example, the number of cells of the foamed molded article may include 1 to 30 cells, 3 to 25 cells, or 3 to 20 cells per mm.

As one example, the resin foam may be an extrusion foam molded article.

Specifically, there are types of foaming methods largely bead foaming or extrusion foaming. In general, the bead foaming is a method of heating a resin bead to form a primary foam, aging the resin bead for a suitable time, filling the resin bead in a plate-shaped or cylindrical mold, heating the same again, and fusing and forming the product by secondary foaming.

On the other hand, the extrusion foaming can simplify the process steps by heating and melting the resin and continuously extruding and foaming the resin melt, and it is possible to mass-produce, and the cracks, Development and the like can be prevented, and more excellent bending strength and compressive strength can be realized.

As one example, in one embodiment, the resin foam according to the present invention may have a hydrophilizing function, a waterproof function, a flame retarding function or an ultraviolet shielding function, and may be a surfactant, an ultraviolet screening agent, a hydrophilizing agent, , At least one functional additive selected from the group consisting of waterproofing agents, cell size extenders, infrared attenuating agents, plasticizers, fire retardants, pigments, elastic polymers, extrusion aids, antioxidants, fillers, . Specifically, the resin foam of the present invention may include a chain extending additive, a filler, a heat stabilizer, and a foaming agent.

As one example, in one embodiment, the resin foam according to the present invention may have a hydrophilizing function, a waterproof function, a flame retarding function or an ultraviolet shielding function, and may be a surfactant, an ultraviolet screening agent, a hydrophilizing agent, , At least one functional additive selected from the group consisting of waterproofing agents, cell size extenders, infrared attenuating agents, plasticizers, fire retardants, pigments, elastic polymers, extrusion aids, antioxidants, fillers, . Specifically, the resin foam of the present invention may include a chain extending additive, a filler, a heat stabilizer, and a foaming agent.

Examples of the blowing agent include a physical blowing agent such as N ₂ , CO ₂ and Freon and a physical blowing agent such as butane, pentane, neopentane, hexane, isohexane, heptane, isoheptane, methyl chloride, etc. or azodicarbonamide , P, P'-oxybis (benzene sulfonyl hydrazide) [P, P'-oxy bis (benzene sulfonyl hydrazide)] compounds, N, N'- dinitrosopentamethylenetetramine -dinitroso pentamethylene tetramine) compound. Specifically, CO ₂ can be used in the present invention.

The flame retardant in the present invention is not particularly limited and may include, for example, a bromine compound, phosphorus or phosphorus compound, antimony compound, metal hydroxide and the like. The bromine compound includes, for example, tetrabromobisphenol A and decabromodiphenyl ether, and the phosphorus or phosphorus compound includes an aromatic phosphoric acid ester, an aromatic condensed phosphoric acid ester, a halogenated phosphoric acid ester, and the like, and the antimony compound Antimony trioxide, antimony pentoxide, and the like. Examples of the metal element in the metal hydroxide include aluminum (Al), magnesium (Mg), calcium (Ca), nickel (Ni), cobalt (Co), tin (Sn), zinc (Zn) ), Iron (Fe), titanium (Ti), boron (B), and the like. Of these, aluminum and magnesium are preferable. The metal hydroxide may be composed of one kind of metal element or two or more kinds of metal elements. For example, metal hydroxides composed of one kind of metal element may include aluminum hydroxide, magnesium hydroxide, and the like.

The surfactant is not particularly limited, and examples thereof include anionic surfactants (e.g., fatty acid salts, alkylsulfuric acid ester salts, alkylbenzenesulfonic acid salts, alkylnaphthalenesulfonic acid salts, alkylsulfosuccinic acid salts and polyoxyethylene alkylsulfuric acid ester salts) , Nonionic surfactants (for example, polyoxyalkylene alkyl ethers such as polyoxyethylene alkyl ethers, polyoxyethylene derivatives, sorbitan fatty acid esters, polyoxyethylene sorbitan fatty acid esters, polyoxyethylene sorbitol fatty acid esters, (E.g., alkylamine salts, quaternary ammonium salts, alkylbetaines, amine oxides, etc.), and water-soluble polymers such as polyoxyethylene alkylamines and alkylalkanolamides), cationic and amphoteric surfactants Or protective colloids (e.g., gelatin, methylcellulose, hydroxyethylcellulose, Polyoxyethylene-polyoxypropylene block copolymer, polyacrylamide, polyacrylic acid, polyacrylic acid salt, sodium alginate, polyvinyl alcohol partial saponification, etc.), and the like have.

The waterproofing agent is not particularly limited and includes, for example, silicone, epoxy, cyanoacrylate, polyvinyl acrylate, ethylene vinyl acetate, acrylate, polychloroprene, polyurethane and polyester resins , A mixture of polyol and polyurethane resin, a mixture of acrylic polymer and polyurethane resin, a polyimide, and a mixture of cyanoacrylate and urethane.

The ultraviolet screening agent is not particularly limited and may be, for example, an organic or inorganic ultraviolet screening agent. Examples of the organic ultraviolet screening agent include p-aminobenzoic acid derivatives, benzylidene camphor derivatives, cinnamic acid derivatives, Benzotriazole derivatives, and mixtures thereof. Examples of the inorganic ultraviolet screening agent may include titanium dioxide, zinc oxide, manganese oxide, zirconium dioxide, cerium dioxide, and mixtures thereof.

As one example, the first and second plates according to the present invention may each independently include at least one of metal, synthetic resin, cement, ceramic and gypsum board. Specifically, in the present invention, the first plate and the second plate may be metal, and the metal may include a clad steel plate.

As an example, the thickness of the sandwich panel according to the present invention may be from 3 to 50 cm, from 5 to 45 cm, from 7 to 40 cm, from 10 to 35 cm, or from 10 to 30 cm. Further, the thickness of the resin foam according to the present invention may be 2 to 30 cm, 4 to 25 cm or 10 to 20 cm. The thickness of the first plate and the second plate according to the present invention may be 0.5 to 20 cm, 1 to 15 cm, or 1.5 to 10 cm. As a result, it can be seen that the sandwich panel according to the present invention can realize properties such as excellent compressive strength, heat insulation and flame retardancy even with a relatively thin thickness. Therefore, it is possible to reduce the weight of the foamed molded article, and the production cost can be reduced.

Hereinafter, a method for manufacturing a sandwich panel according to the present invention will be described in detail.

A method of manufacturing a sandwich panel according to the present invention comprises:

Applying an adhesive resin to the surface of the polyester resin foam;

Bonding the panel to the surface to which the adhesive resin is applied using a pressure roller; And

And cutting the continuous product in which the resin foam and the panel are integrated into a unit size,

The resin foam had a water absorption of 0.8 g / 100 cm < ² > on the basis of KS M IOS 7214 Or less, and the following general formula (1) can be satisfied.

[Formula 1]

X / Y ≥ 1.5

X represents the compressive strength (N / cm ² ) of the resin foam layer according to KS M ISO 844, and Y represents the density (kg / m ³ ) of the resin foam layer according to KS M ISO 845.

In the step of applying the adhesive resin, the adhesive resin may be an adhesive resin. Further, the adhesive resin may be in various forms of an injection-molded product, a film molded product, and may be in the form of a web. The adhesive resin according to the present invention has a low melting point characteristic and may be provided in the form of a film or a nonwoven fabric of a web structure by being pressed in multiple layers.

Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples. However, the scope of the present invention is not limited by the following description.

Example  One

To prepare the resin foam, first, 100 phr of polyethylene terephthalate (PET), 1 phr of pyromellitic dianhydride (PMDA), 1 phr of talc (Tarc) and 0.1 phr of heat stabilizer were polymerized in a polymerization tank, and melt the composition at 200 ℃ put into the extruder, using an extruder, the side feeder was added 5 parts by weight of a CO ₂ as a blowing agent in the molten resin by PET 100 parts by weight of extruded foam, 35 kg / m the density ³ To prepare a resin foam. At this time, the density was measured under KS M IOS 845 conditions.

Then, an adhesive resin was applied to both sides of the resin foam, and then a clad steel sheet was bonded to produce a sandwich panel according to the present invention.

Example  2

Was prepared in the same manner as in Example 1 except that the density was controlled at 34 kg / m < ^{3 &} gt ;.

Example  3

Was prepared in the same manner as in Example 1, except that the density was controlled to 25 kg / m < ^{3 &} gt ;.

Example  4

Was prepared in the same manner as in Example 1, except that the density was controlled at 20 kg / m < ^{3 &} gt ;.

Comparative Example  One

PET was prepared in the same manner as in Example 1, except that expanded polystyrene (EPS) was used and the density was controlled at 30 kg / m ³ .

Comparative Example  2

The procedure of Example 1 was repeated except that aluminum-coated urethane (PIR) was used instead of PET and the density was controlled at 30 kg / m ³ .

Comparative Example  3

Except that high-density expanded polystyrene (XPS) was used instead of PET, and density was controlled to 30 kg / m ³ , the same procedure as in Example 1 was conducted.

Experimental Example

The sandwich panels prepared by measuring the compressive strength and the absorption amount of the resin foams prepared in Examples 1 to 4 and Comparative Examples 1 to 3 and adhering the clad steel sheet after applying the adhesive resin to the resin foams were measured for total release The calories were measured. The measurement method is described below, and the results are shown in Table 1 below.

1) Total calorific value measurement (sandwich panel)

The flame retardancy was measured under the condition of KS F 5660-1.

2) Compressive strength measurement (resin foam)

The compressive strength was measured under KS M ISO 844 conditions.

3) Absorption amount Specific (resin foam)

The absorption was measured under KS M IOS 7214 conditions.

Example 1 Example 2 Example 3 Example 4 Comparative Example 1 Comparative Example 2 Comparative Example 3 Total calorific value
(MJ / m ² ) 6 6.5 6.8 7 - 7.5 - Compressive strength
(N / cm ² ) 60 52 41 36 16 30 18 Absorption
(g / 100 cm < ² >) 0.4 0.4 0.4 0.4 One 3 0.4 1
(Compressive strength / density) 1.71 1.52 1.64 1.8 0.53 One 0.6

As shown in Table 1, in the case of Examples 1 to 4, the total heat release amount was measured to be less than 8 MJ / m ² , and thus flame retardancy was found to be second grade (semi-flammable). However, in the case of Comparative Examples 1 and 3, it was difficult to measure the total calorific value, and in Comparative Example 2, using aluminum-coated urethane (PIR) for flame retardancy, the total calorific value was good.

Compressive strengths of Examples 1 to 4 were as high as 60 N / cm ² , 52 N / cm ² , 41 N / cm ² and 36 N / cm ² , ² , 30 N / cm ² and 18 N / cm ² , respectively.

The absorption amounts of all of Examples 1 to 4 were as low as about 0.4 g / 100 cm ² . However, in Comparative Examples 1 and 2, the absorption amount was as high as 1 g / 100 cm ² or more. Particularly, in Comparative Example 2, the total heat release amount was low using PIR for flame retardancy, 100 cm < ² > so that the problem of not being easily stored outside can occur.

Therefore, by using polyethylene terephthalate (PET), the sandwich panel according to the present invention has an advantage that flame retardancy and thermal stability are improved due to a low total heat release amount, and at the same time, it has high strength and low water absorption,

Claims (8)

Resin foams;
A first plate formed on one surface of the resin foam;
A second plate formed at a position opposite to the first plate with respect to the resin foam; And
And an adhesive dispersed between the first plate, the second plate, and the resin foam,
The resin foam has a water absorption of 1 g / 100 cm < ² > as measured in accordance with KS M IOS 7214 Sandwich panel satisfying the following general formula 1:
[Formula 1]
X / Y ≥ 1.5
X represents the compressive strength (N / cm ² ) of the resin foam layer according to KS M ISO 844, and Y represents the density (kg / m ³ ) of the resin foam layer according to KS M ISO 845.
The method according to claim 1,
Wherein the adhesive is a polyester-based adhesive resin.
The method according to claim 1,
The resin foam is a sandwich panel which is a foam of a polyester resin.
The method according to claim 1,
The sandwich panel having a compressive strength (KS M ISO 844) of the resin foam of 20 to 300 N / cm ² .
The method according to claim 1,
The resin foam is a sandwich panel with a total calorific value of less than 8 MJ / m ² based on KS F 5660-1.
The method according to claim 1,
The resin foam is a sandwich panel in which at least 90% of the cells are closed cells (DIN ISO4590).
The method according to claim 1,
Wherein the first plate and the second plate each independently comprise at least one of a metal, a synthetic resin, a cement, a ceramic, and a gypsum board.
Applying an adhesive resin to the surface of the polyester resin foam;
Bonding the panel to the surface to which the adhesive resin is applied using a pressure roller; And
And cutting the continuous product in which the resin foam and the panel are integrated into a unit size,
The resin foam had a water absorption of 0.8 g / 100 cm < ² > on the basis of KS M IOS 7214 Or less, A sandwich panel manufacturing method comprising:
[Formula 1]
X / Y ≥ 1.5
X represents the compressive strength (N / cm ² ) of the resin foam layer according to KS M ISO 844, and Y represents the density (kg / m ³ ) of the resin foam layer according to KS M ISO 845.