KR20020010988A - Process for polyurethan foam core having open cell - Google Patents
Process for polyurethan foam core having open cell Download PDFInfo
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- KR20020010988A KR20020010988A KR1020000044358A KR20000044358A KR20020010988A KR 20020010988 A KR20020010988 A KR 20020010988A KR 1020000044358 A KR1020000044358 A KR 1020000044358A KR 20000044358 A KR20000044358 A KR 20000044358A KR 20020010988 A KR20020010988 A KR 20020010988A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/58—Moulds
- B29C44/586—Moulds with a cavity increasing in size during foaming
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/36—Feeding the material to be shaped
- B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
- B29C44/381—Spreading the foamable material in the mould by pressing the mould halves together
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/36—Feeding the material to be shaped
- B29C44/362—Regulating the feed w.r.t. the foam layer thickness
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/56—After-treatment of articles, e.g. for altering the shape
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/60—Measuring, controlling or regulating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/0005—Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
- B29K2105/0014—Catalysts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
- B29K2105/045—Condition, form or state of moulded material or of the material to be shaped cellular or porous with open cells
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0012—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
- B29K2995/0015—Insulating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/762—Household appliances
- B29L2031/7622—Refrigerators
Landscapes
- Polyurethanes Or Polyureas (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Refrigerator Housings (AREA)
Abstract
Description
본발명은 몰드압착방식에 의해 개방셀 폴리우레탄폼 코어를 제조하는 방법에 관한 것이다.The present invention relates to a method for producing an open cell polyurethane foam core by a mold pressing method.
개방셀 폴리우레탄 폼은 폴리올과 발포제, 실리콘 계면활성제, 촉매 및 기타의 첨가제들로 이루어진 원액(R액)과 이소시아네이트 원액(P액)을 혼합반응시켜 제조하는 데, 그 제조방식에 따라 크게 가열된 상하의 콘베어에 발포원액을 유출시켜 상하의 콘베어의 간격에 의해 일정한 두께로 성형하여 만드는 콘베어방식과, 발포원액을 몰드내에 주입시킨후, 폴리우레탄 섬유가 형성되는 시점인 겔타임(gel time)시점 또는 겔타임시점에서 부터 원액의 반응이 거의 종료되어 점착력이 없어지는 시점인 택프리타임(tack free time)시점의 어느 한 시점에서 상부몰드를 일정한 속도로 하강시켜 물리적인 압력에 의해 폴리우레탄의 셀을 터트려 개방셀을 형성한 다음, 몰드속에서 일정시간동안 경화시킨 후 탈형하여 네면의 모서리부와 표면층을 제거하여 코어를 만드는 몰드압착 방식으로 구분할 수 있다. 본발명과 대비한 종래의 몰드압착방식에 의한 제조방법은 다음과 같다.Open-cell polyurethane foams are prepared by mixing and reacting a stock solution (R solution) and an isocyanate stock solution (P solution) consisting of a polyol and a blowing agent, a silicone surfactant, a catalyst, and other additives. The gel method or gel which is the timing of forming polyurethane fibers after pouring the foaming stock solution into the upper and lower conveyors and molding them to a certain thickness by the gap between the upper and lower conveyors. From the time point, the reaction of the stock solution is almost finished and the adhesive force is lost. At any point of the tack free time, the upper mold is lowered at a constant speed, and the polyurethane cell is blown by physical pressure. After forming an open cell, it is cured for a predetermined time in the mold and demolded to remove the four corners and the surface layer to form a core. It may be identified as a mold pressing method. The production method according to the conventional mold pressing method in contrast with the present invention is as follows.
몰드 압착방식에 있어서는 몰드속도 및 압착시점이 중요하다. 종래의 몰드압착방법에 의한 오픈셀 폴리우레탄폼의 제조는 도 1에서 도시하고 있는데, 구체적으로 일정한 온도와 초기두께가 설정된 몰드내에서 발포원액을 주입하는 제 1공정, 목표로하는 최종두께로 압착하여 몰드내에서 경화 안정시간을 거친 후 탈형하는 제 2공정, 물성이 불균일한 표면층과 모서리부를 잘라내는 제 3공정으로 이루어진다.이러한 종래방식의 요점은 제 1공정에서 미리 일정한 초기두께로 설정된 몰드내에 원액을 주입하는 것과, 최종두께로 압착하는 제2공정에서의 압착시점을 주입된 발포원액이 반응을 시작하여 폴리우레탄 섬유가 형성되는 시점인 겔타임시점 또는 겔타임에서부터 원액의 반응이 거의 종료되어 점착력이 없어지는 시점인 택프리타임의 어느 한시점에서 실시하는 것과, 제 3공정에서 물성이 불균일한 표면층과 모서리부를 잘라내는 것이다.In mold pressing method, mold speed and pressing point are important. The production of open cell polyurethane foam by a conventional mold pressing method is shown in Figure 1, specifically, the first step of injecting the foam stock solution in a mold in which a constant temperature and initial thickness is set, the compression to the target final thickness And a second step of demolding after curing stability time in the mold, and a third step of cutting out the surface layer and the edge of the non-uniform physical properties. The reaction of the stock solution is almost finished from the gel time point or the gel time point at which the foaming stock solution injected at the time of injection of the stock solution and the second step of pressing at the final thickness starts the reaction and the polyurethane fibers are formed. The surface layer having uneven physical properties in the third step; Frost will cut the part.
이러한 종래의 몰드압착에 의한 진공단열재의 코어제조방법은 제 1공정에서 미리 일정한 초기두께로 설정된 몰드내에 원액을 주입한 후 상부몰드를 하강시켜 목표로 하는 코어의 최종두께로 압착시키기 때문에 압착시점과 압착속도에 따라 제조되는 개방셀 코어의 성능편차가 크고, 대량생산에 있어 균일한 품질의 달성을 위한 설비조건의 설정이 어렵다. 또한 성형된 판넬의 전체 두께가 균일한 성능을 갖지 못하여 네면의 모서리부와 표면층을 잘라내야하는 공정이 추가되므로 시간적인 손실 및 재료비 손실이 있어 경제적이지 못하다.The core manufacturing method of the vacuum insulation material by the conventional mold pressing method is to inject the raw liquid into the mold set to the predetermined initial thickness in the first step, and then the upper mold is lowered and pressed to the final thickness of the target core. The performance deviation of the open cell core manufactured according to the crimping speed is large, and it is difficult to set equipment conditions for achieving uniform quality in mass production. In addition, since the overall thickness of the molded panel does not have a uniform performance, the process of cutting the four corners and the surface layer is added, which is not economical because there is a time loss and a material cost loss.
본발명은 최종두께로 몰드를 조정하여 원액을 따르고, 일정속도로 상부몰드를 상승시키고, 다시 하강시켜 셀을 터트려 개방셀 폴리우레탄폼을 제조하는 방법을 제공하여, 별도의 불균일부분의 절단없이 제조된 코어의 단열성능이 판넬전체로 균일하게 함으로써 진공단열재를 냉장고에 적용할 경우에 냉장고 소비전력양의 절감효과를 크게함과 동시에, 대량생산시에 불균일부를 절단하는 공정이 없어 시간 및 비용면에서 매우 효과적인 방법이다.The present invention provides a method of manufacturing an open cell polyurethane foam by popping a cell by adjusting the mold to the final thickness, pouring the upper mold at a constant speed, and then lowering it again to pop open the cell, and without cutting any non-uniform parts. As the heat insulation performance of the core is made uniform to the whole panel, when the vacuum insulator is applied to the refrigerator, the power consumption of the refrigerator is greatly increased, and there is no process of cutting out uneven parts during mass production. It's a very effective way.
도 1은 진공단열재의 구성도이다.1 is a configuration diagram of a vacuum insulator.
도 2는 종래의 몰드압착방식에 의한 진공단열재코어 제조공정의 개략도이다.Figure 2 is a schematic diagram of a vacuum insulation material core manufacturing process by a conventional mold pressing method.
도 3은 본발명의 진공단열재 개방셀 제조공정의 구체적예이다.Figure 3 is a specific example of the vacuum insulator open cell manufacturing process of the present invention.
본발명은 폴리우레탄폼 코어를 제조하는 방법에 관한 것으로, 더욱 구체적으로는, 폼코어의 최종목표두께로 상하부몰드간격을 설정하여 발포원액을 주입하는 공정, 일정시점에서 상부몰드프레스를 위로 이동시키는 공정, 및 최종목표두께로 상부몰드를 일정속도로 하강시키는 공정으로 이루어지는 개방셀 폴리우레탄폼 코어를 제조하는 방법에 관한 것이다.The present invention relates to a method for manufacturing a polyurethane foam core, more specifically, a process for injecting the foam stock solution by setting the upper and lower mold intervals to the final target thickness of the foam core, to move the upper mold press up at a certain point A process for producing an open cell polyurethane foam core comprising a process and a step of lowering an upper mold at a constant speed to a final target thickness.
본발명은 종래의 상하프레스 몰드에 의한 압착방식에서 보다 코어의 물성, 즉 밀도, 압축강도, 개방셀의 함량이 균일하여 진공단열재 전체의 단열성능이 종래대비 약 30%가 향상된다. 또한, 몰드에 주입된 원액이 성형되어 전체가 균일한 성능을 유지하기 때문에 종래에는 성형된 코어의 테두리부분을 스크랩으로 30-50%정도 잘라내야 했지만, 본발명은 스크랩으로 테두리부분을 잘라낼 필요가 없으므로생산시간을 단축하고 비용도 절감할 수 있다. 또한, 제조공정에 있어 초기두께를 설정한 후 발포원액을 주입하고 목표로 하는 최종두께로 압착하는 종래와는 달리, 본발명에서는 먼저 상하몰드를 최종두께로 설정하여 발포원액을 주입한 후 상부몰드를 서서히 폴리우레탄폼이 형성되어 올라오는 속도에 맞춰 상승시켜줌으로써 폴리우레탄폼이 상부몰드의 적절한 누름작용에 의해 하부몰드에 균일하게 충진됨으로써 종래보다 적은양의 발포원액을 주입하더라도 코어의 단열성능, 밀도, 압축강도, 개방셀의 함량이 판넬전체로 균일등 충진성이 우수하여 재료비의 절감도 가능하다.In the present invention, the physical properties of the core, that is, the density, the compressive strength, and the content of the open cell are more uniform than those of the conventional pressing method by the upper and lower press molds, so that the thermal insulation performance of the entire vacuum insulation material is improved by about 30%. In addition, since the stock solution injected into the mold is molded to maintain uniform performance, it is necessary to cut the edge of the molded core by scrap 30-50%, but the present invention needs to cut the edge by scrap. This reduces production time and costs. In addition, unlike the conventional method of injecting a foam stock solution after setting the initial thickness in the manufacturing process and compressing it to a target final thickness, in the present invention, first, the upper and lower molds are first set to a final thickness, and then the upper mold is injected. By gradually increasing the polyurethane foam to the rising speed, the polyurethane foam is uniformly filled in the lower mold by the appropriate pressing action of the upper mold, so that even if a small amount of foam stock is injected, the core's thermal insulation performance, Its density, compressive strength, and open cell content make it possible to reduce the material cost because of excellent filling properties such as uniformity over the entire panel.
구체적으로, 본발명은 상하부 몰드 프레스에서 폴리우레탄폼 코어를 제조하는 방법에 있어서, a) 폴리우레탄폼코어의 최종 목표두께로 상하부 몰드 간격을 설정한 후에 폴리우레탄 발포원액을 주입하는 제 1공정,Specifically, the present invention is a method of manufacturing a polyurethane foam core in the upper and lower mold presses, a) a first step of injecting a polyurethane foam stock solution after setting the upper and lower mold intervals to the final target thickness of the polyurethane foam core,
b) 발포원액의 크림타임(cream time)시점에서 시작해서 원액의 겔타임(gel time)시점에 종료하는 속도로 상부몰드를 상승시키는 제 2공정,b) a second step of raising the upper mold at a rate starting from the cream time of the foamed stock solution and ending at the gel time of the stock solution;
c) 상부몰드를 코어두께인 상기 최종목표두께로 압착하는 제 3공정으로 이루어지는, 불균일 부분을 절단하는 공정이 없는 개방셀 폴리우레탄폼 코어를 제조하는 방법에 관한 것이다.c) A method for producing an open-cell polyurethane foam core without a step of cutting a non-uniform portion, comprising a third step of pressing the upper mold to the final target thickness as the core thickness.
구체적 일례에서, 본발명은 상기 제 3공정의 압축개시시점이 i) 겔타임, ii)헬스버블타임 또는 iii) 헬스버블타임부터 택프리타임까지중 어느 한시점으로 이루어지는 군에서 선택된 한시점에서 압착하는, 개방셀 폴리우레탄폼 코어를 제조하는 방법에 관한 것이다. 압축개시시점 및 몰드의 하강속도는 폴리우레탄폼중에 형성된 셀의 균일성에 큰 영향을 미치며, 특히 폴리우레탄폼 코어 제조용 원액이 경화되면셀의 개방이나 압착에 지나친 에너지가 소모되며 형성된 셀의 크기가 균일하지 않아 얻어진 진공단열재의 단열성이 불균일하다는 문제가 생길 수 있다.In a specific example, the present invention is the compression start point of the third process is pressed at one time selected from the group consisting of any one of i) gel time, ii) health bubble time or iii) health bubble time to tack free time It relates to a method for producing an open cell polyurethane foam core. The starting point of compression and the descending speed of the mold have a great influence on the uniformity of the cells formed in the polyurethane foam. Especially, when the stock solution for polyurethane foam core is cured, excessive energy is consumed in opening or pressing the cells, and the size of the formed cells is uniform. The problem may arise that the thermal insulation of the obtained vacuum insulation material is nonuniform.
또한, 구체적 일례에서 본발명은 제 3공정의 최종목표두께로 압착하는 상부몰드하강 압착속도가 0.5-1.5 mm/초인 코어의 제조방법에 관한 것이다. 하강속도가 지나치게 큰 경우에는 몰드내의 윗부분의 셀이 압력이 많이 받아 형성된 셀크기가 불균일할 수 있으며 지나치게 낮을 때에는 원액이 경화하여 균일한 크기의 셀이 형성될 수 없다.In addition, in a specific example, the present invention relates to a method for manufacturing a core having a top mold down pressing speed of 0.5-1.5 mm / sec. If the descending speed is too large, the cell in the upper part of the mold may be highly pressured and the cell size formed may be uneven. When too low, the stock solution may harden to form cells of uniform size.
본발명에 사용되는 코어재료로는 진공단열재의 폴리우레탄 코어 제조용 조성물을 일반적으로 개방셀 폴리우레탄폼 제조용 조성물도 사용가능하다. 특히 본발명은 몰드압착방법에 의해서 셀을 깨트려 개방셀을 제조하는 것이므로 종래의 CFC 등의 셀개방제가 포함되지 조성물에 특히 적합하다. 본발명에 바람직한 폴리우레탐폼 제조용 조성물은 다음과 같다.As the core material used in the present invention, a composition for producing a polyurethane core of a vacuum insulator is generally used. In particular, the present invention is to break the cell by the mold pressing method to manufacture the open cell, so the conventional CFC It is especially suitable for the composition which does not contain a cell opener. Preferred compositions for producing polyuretam foam according to the present invention are as follows.
1) 경질폴리우레탄폼 제조용 폴리올 100 중량부, 2) 셀연결제(cell interconnecting agent) 3.0-6.0 중량부, 경질 폴리우레탄폼 제조용 정포제 1.0-4.0 중량부, 물 3.0-6.0 중량부, 촉매 및 3) 경질 폴리우레탄폼 제조용 이소시아네이트 150-170 중량부로 이루어지는, 물이외의 발포제와 셀개방제를 포함하지 않는 개방셀 경질 폴리우레탄폼 제조용 조성물을 제공되며,1) 100 parts by weight of polyol for producing rigid polyurethane foam, 2) 3.0-6.0 parts by weight of cell interconnecting agent, 1.0-4.0 parts by weight of foam stabilizer for manufacturing rigid polyurethane foam, 3.0-6.0 parts by weight of water, catalyst and 3) Provided is a composition for producing an open-cell rigid polyurethane foam containing 150-170 parts by weight of isocyanate for producing rigid polyurethane foam, containing no foaming agent other than water and a cell opener.
여기서, 상기 폴리올은 방향족 아민을 개시제로 하여 유기산화물과 중합된 폴리에테르계 폴리올인 전체 폴리올 100중량에 대해 30-50중량부를 포함하며, 바람직하게는 상기 폴리올은 관능기 8가인 수크로스를 개시제로 유기산화물과 중합한폴리올, 3가 관능기 갖는 트리에탄올 아민을 개시제로 유기산화물과 중합된 폴리올(TEOA), 4가 관능기를 갖는 에틸렌디아민을 개시제로 유기산화물과 중합된 폴리올, 4가 관능기를 갖는 톨루엔 디아민을 개시제로 유기산화물과 중합된 폴리올, 2가 관응기를 갖는 에티렌글리콜을 개시제로 유기산화물과 중합한 폴리올, 6가 관능기의 솔비톨을 개시제로 유기산화물과 중합한 폴리올로 구성된 군에서 선택된 세가지 이상의 폴리올과 방향족 아민을 개시제로 하여, 에틸렌 옥사이드, 프로필렌 옥사이드 및 이들의 혼합물로 이루어진 군에서 선택된 알킬렌 옥사이드와 중합한 폴리올 30-50부로 이루어진 폴리올인 조성물이 제공된다.Herein, the polyol includes 30-50 parts by weight based on 100 parts by weight of the total polyol, which is a polyether polyol polymerized with an organic oxide and an aromatic amine as an initiator. Preferably, the polyol is organic based on sucrose having a functional group octavalent. Polyol polymerized with an oxide, Triethanol amine having a trivalent functional group as initiator, Polyol (TEOA) polymerized with an organic oxide, Ethylenediamine having a tetravalent functional group, Polyol polymerized with an organic oxide as an initiator, Toluene diamine having a tetravalent functional group At least three polyols selected from the group consisting of polyols polymerized with an organic oxide as an initiator, polyols polymerized with an ethylene glycol having a bivalent functional group, and polyols polymerized with an organic oxide with sorbitol of a hexavalent functional group as an initiator Ethylene oxide, propylene oxide and mixtures thereof, based on aromatic amines as initiator The polyol composition comprising the selected alkylene oxide and 30 to 50 parts of a polymeric polyol from the group consisting of are provided.
상기 이소시아네이트의 인덱스(NCO/OH)가 0.9 - 1.1인 것이 바람직하다. 본 조성물에서는 종래의 셀발포제나 셀개방제를 포함하지 않는 대신에 셀연결제를 사용하며 이는 칼슘 스테아레이트, 칼슘 히마스트, 및 스테아르산으로 이루어진 군에서 선택된다.It is preferable that the index (NCO / OH) of the said isocyanate is 0.9-1.1. In the present composition, a cell linking agent is used instead of a conventional cell foaming agent or a cell opener, and it is selected from the group consisting of calcium stearate, calcium hismas, and stearic acid.
여기서, 촉매는 발포 촉매(blowing catalyst)와 겔화 촉매 (gelling catalyst)로 이루어며, 발포 촉매제는 TMHDA(N, N-테트라메틸 헥산 디아민)이고, 겔화촉매는 디플로필렌 글리콜과 트리에틸렌 디아민의 혼합물이 바람직하다. 상기 발포 촉매의 함량은 0.01 - 0.1중량부이고, 겔화촉매의 함량은 0.1-1.0이 바람직하다.Here, the catalyst consists of a blowing catalyst and a gelling catalyst, the blowing catalyst is TMHDA (N, N-tetramethyl hexane diamine), and the gelling catalyst is a mixture of diflohylene glycol and triethylene diamine. This is preferred. The content of the blowing catalyst is 0.01 to 0.1 parts by weight, the content of the gelling catalyst is preferably 0.1-1.0.
상기 조성물은 래의 휘발성 발포제인 CFC 및 HCFC 화합물등을 사용하지 않기에 환경에 무해하고 저렴하며, 셀개방제를 사용하지 않기 때문에 고가의 특정 등급의 폴리올에 사용이 한정되지 않는 장점이 있으며, 이러한 조성물을 몰드프레스내에서 발포시키면서 몰드의 압착에 의해 셀을 물리적으로 개방시켜 개방셀 경질 폴리우레탄폼을 제조함으로써 본발명의 개방셀 경질 폴리우레탄폼은 압축강도, 굴곡강도 및 밀도가 높기 때문에 본발명의 개방셀 경질 폴리우레탄폼으로 제조된 진공단열판넬은 종래의 진공단열재가 가지는 장기 수축이나 변형이 없고, 내부에서 발생되는 가스가 적어 단열성능을 장기적으로 오래 유지할 수 있는 장점이 있다.The composition is harmless and inexpensive to the environment because it does not use CFC and HCFC compounds, which are conventional volatile blowing agents, and has no advantage in that it is not limited to the use of expensive polyols. Open cell rigid polyurethane foams of the present invention have a high compressive strength, flexural strength and density by physically opening the cell by pressing the mold while foaming the composition in a mold press to produce an open cell rigid polyurethane foam. The vacuum insulation panel made of an open cell rigid polyurethane foam has no long-term shrinkage or deformation with the conventional vacuum insulation material, and has less gas generated therein, so that the thermal insulation performance can be maintained for a long time.
구체적으로, 도 3에서 종래의 상하몰드압착방식에 의한 진공단열재 코어제조방법과 비교하여 본원발명의 제조방법을 설명하고자 한다.Specifically, in Figure 3 will be described the manufacturing method of the present invention as compared to the conventional method for manufacturing a vacuum insulation core by the vertical mold pressing method.
본발명은 신규의 몰드압착방식에 의한 코어제조에 관한 것으로서, 그 제조공정은 크게 몰드온도설정에서 발포원액주입까지의 공정(1), 발포원액을 주입후 상부몰드를 목표로 하는 최종두께까지 상승시키는 공정(2), 압착공정(3) 및 탈형에 의한 최종코어의 제조공정으로 이루어진다.The present invention relates to a core manufacturing by a novel mold crimping method, and the manufacturing process is largely increased from the mold temperature setting to the injection of the foam stock solution (1), and after the injection of the foam stock solution to the final thickness aimed at the upper mold. It consists of the process (2), the crimping process (3), and the manufacturing process of the final core by demolding.
먼저, 제 1공정에서와 같이 최종목표로 하는 코어두께가 되도록 상하부 몰드의 간격을 유지시킨 후 하부몰드내에 발포원액을 주입시키고, 제 2공정에서 주입된 발포원액이 반응을 개시하여 흰색에서 크림상태로 변화는 시간인 크림타임(cream time)을 기점으로 하여 상부몰드를 상승시켜 폴리우레탄 섬유가 형성되는 시점이 겔타임이 될때 상승이 종료되도록 상승속도를 맞추어 상부몰드를 상승시킨다. 여기서, 초기두께란 최종두께에 대비하여 압착비율을 경정하는 두께를 말하며, 몰드압착방식의 경우 통상 최종두께가 15mm의 코어를 제조할 경우에 초기두께는 30-90mm이다. 제 3공정인 압착공정에서는 초기두께로 된 상부몰드롤 다시 목표로 하는 최종두께로 압착시키는 공정으로서, 이로 인해 최종 코어가 형성되며, 압착성형된 코어는 최종공정에서처럼 몰드내에서 압착된 상태로 일정한 경화 안정화시간을 거친 후 몰드로부터 탈형시켜 최종의 완성된 코어를 제조한다.First, as in the first step, the gap between the upper and lower molds is maintained so as to be the core thickness as the final target, and then the foam stock solution is injected into the lower mold, and the foam stock solution injected in the second process starts the reaction and creams in white. The furnace change raises the upper mold at the time of the cream time which is the time, and raises the upper mold by adjusting the ascending speed so that the rising is completed when the polyurethane fiber is formed at the gel time. Here, the initial thickness refers to a thickness for determining the compression ratio relative to the final thickness, and in the case of the mold pressing method, the initial thickness is usually 30-90 mm when a final thickness of 15 mm is produced. In the third process, the crimping process, the upper mold roll of the initial thickness is pressed again to the target final thickness, whereby a final core is formed, and the crimped core is fixed in the mold as in the final process. After curing settling time, the mold is demolded to produce the final finished core.
이상의 공정에서 본발명의 요지는 상부몰드의 상승공정과 압착공정으로서, 첫째, 상부몰드의 상승공정에 있어서 상부몰드의 상승속도는 반드시 크림타임부터 시작에서 겔타임이 될때 초기두께가지 상부몰드의 상승이 끝나도록 조절하는 것이 바람직하다. 만약, 상승속도가 너무 커서 겔타임 훨씬전에 이미 상부몰드가 초기두께까지 상승하면 원액의 반응시간에 비해 상부몰드의 상승속도가 너무 빠르게 올라감으로써 형성되는 폴리우레탄폼이 상부몰드의 적절한 누름작용이 미치지 못하여 하부몰드에 폴리우레탄폼이 고르게 퍼지지 못하게된다. 반대로,상승속도가 너무 느리면 즉, 겔타임이후의 어느시점이 될때까지 상부몰들르 느린속도로 상승시킨다면 하부몰드에서의 폴리우레탄폼의 충진은 고리게 되지만 오버패킹(over packing)이 되어 형성된 폴리우레탄폼은 지나치게 딱딱한 상태가 되고 개방셀 형성에 장애를 받게 된다.In the above process, the gist of the present invention is the process of raising the upper mold and the pressing process. It is desirable to adjust this to end. If the upper mold rises to the initial thickness long before the gel time, because the rising speed is too high, the polyurethane foam formed by the rising speed of the upper mold rises too fast compared to the reaction time of the stock solution. This prevents the polyurethane foam from spreading evenly on the lower mold. On the contrary, if the ascending speed is too slow, that is, if the upper molds are raised at a slow speed until a certain point after the gel time, the filling of the polyurethane foam in the lower mold is looped, but the over-packing is formed. Urethane foam becomes excessively rigid and is impeded to open cell formation.
둘째, 압착공정에 있어 최종목표로 하는 코어두께까지의 압착은 앞선 제 2공정에서의 상부몰드를 상승시키는 즉시, 또는 폴리우레탄폼이 형성되면서 내부에 개방셀을 형성하는 시점으로 가스의 기포를 발생하는 시점이 헬스버블타임(health bubble time) 또는 겔타임시점이후에서 부터 폴리우레탄 반응이 종료되어 점착력이 없어지는 시점인 택프리타임시점의 어느 한 시점에서 압착하며, 이는 택프리타임으로 갈수록 점차 폴리우레탄폼이 경화되어 압착이 어려워지며 압착후의 코어성능에 악영향을 받기 때문이다. 또한 압착시의 상부몰드의 하강속도는 폴리우레탄 원액의조성에 따라 다르지만 0.5mm/초 내지 2.0mm/초 범위가 되어야하며, 바람직하게는 0.8 mm/초 내지 1.2 mm/초이다.Second, the crimping to the core thickness as the final target in the crimping process generates gas bubbles immediately after raising the upper mold in the second process or at the point of forming an open cell therein as the polyurethane foam is formed. At this point, the pressure is compressed at any point in time of the free-time, which is the time when the polyurethane reaction is terminated after the health bubble time or the gel-time, and the adhesive force is lost. This is because urethane foam hardens, making it difficult to press and adversely affecting core performance after pressing. In addition, the lowering speed of the upper mold during the pressing depends on the composition of the polyurethane stock solution, but should be in the range of 0.5 mm / sec to 2.0 mm / sec, preferably 0.8 mm / sec to 1.2 mm / sec.
다음의 표 1은 본발명의 구첵적인 실시예를 나타내는 것으로서, 상부몰드의상승공정과 압착공정에 있어 본발명에 따라 제조된 진공단열재 코어의 물성, 즉 밀도, 압축강도, 개발셀의 함량이 균일하며, 진공단열재 판넬의 단열성능이 종래 대비 20-30% 향상됨을 알 수 있으며, 종래의 코어제조방법과 달리, 불균일한 모서리부나 표면층을 30-50%를 잘라낼 필요성이 없으므로 전체 제조공정수가 줄고 원재료손실도 줄일 수 있다는 장점이 있고, 냉장고에 적용할 경우에 종래의 방식으로 제조된 폴리우레탄 폼에 비해 단열성능을 향상시킬 수 있어 소비전력감소에도 기여하게 된다. 따라서, 냉장고의 단열벽을 줄일 수 있어 상대적으로 냉장고의 내부용적을 증가시킬 수 있는 장점이 있다.The following Table 1 shows a specific embodiment of the present invention, the physical properties of the vacuum insulation core manufactured according to the present invention in the process of rising and pressing the upper mold, that is, the density, compressive strength, the content of the development cell is uniform In addition, it can be seen that the thermal insulation performance of the vacuum insulation panel is improved by 20-30% compared to the conventional one, and unlike the conventional core manufacturing method, there is no need to cut 30-50% of uneven edges or surface layers, thereby reducing the total manufacturing process number and raw materials. It also has the advantage of reducing the loss, and when applied to the refrigerator can improve the thermal insulation performance compared to the polyurethane foam manufactured in the conventional manner, thereby contributing to power consumption reduction. Therefore, it is possible to reduce the insulation wall of the refrigerator, which has the advantage of relatively increasing the internal volume of the refrigerator.
본발명에서 셀개방제를 포함하는 않는 상기 폴리우레탄폼 제조용 조성물을 본발명의 몰드압착방식으로 제조한 것과, 종래방식으로 제조된 코어의 물성을 다음의 표 1에서 나타냈으며, 각각의 스크랩손실은 본발명의 코어는 0-5%이나 종래의 방식으로 제조된 코어는 30-50%이다.In the present invention, the composition for preparing the polyurethane foam containing no cell opener was prepared by the mold pressing method of the present invention, and the physical properties of the core manufactured according to the conventional method are shown in Table 1 below. The core of the present invention is 0-5% but the core made in the conventional manner is 30-50%.
본발명은 최종두께로 몰드를 조정하여 원액을 따르고, 일정속도로 상부몰드를 상승시키고, 다시 하강시켜 셀을 터트려 개방셀 폴리우레탄폼을 제조하는 방법을 제공하여, 제조된 코어의 단열성능이 판넬전체로 균일하게 함으로써 진공단열재를 냉장고에 적용할 경우에 냉장고 소비전력양의 절감효과를 크게함과 동시에 내부용적을 크게 할 수 있으며, 대량생산시에 불균일부를 절단하는 공정이 없어 시간 및 비용을 줄일 수 있는 방법이다.The present invention provides a method for producing an open cell polyurethane foam by popping a cell by adjusting the mold to the final thickness, pouring the upper mold at a constant speed, and lowering it again to pop open the cell, so that the thermal insulation performance of the manufactured core is paneled. By making it uniform throughout, the application of vacuum insulator to the refrigerator can reduce the power consumption of the refrigerator and increase the internal volume.It also reduces the time and cost because there is no process to cut uneven parts during mass production. That's how it can be.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2014120767A1 (en) * | 2013-01-29 | 2014-08-07 | Continental Structural Plastics, Inc. | Vacuum molding of thermoset sheet articles |
| KR101588630B1 (en) * | 2014-10-17 | 2016-01-27 | (주)대한솔루션 | Headlining having heat-shield for vehicle and the method thereof |
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| JP3322852B2 (en) * | 1998-06-26 | 2002-09-09 | 日清紡績株式会社 | Open cell rigid polyurethane foam molding and method for producing the same |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2014120767A1 (en) * | 2013-01-29 | 2014-08-07 | Continental Structural Plastics, Inc. | Vacuum molding of thermoset sheet articles |
| US10471668B2 (en) | 2013-01-29 | 2019-11-12 | Continental Structural Plastics Inc. | Vacuum molding of thermoset sheet articles |
| KR101588630B1 (en) * | 2014-10-17 | 2016-01-27 | (주)대한솔루션 | Headlining having heat-shield for vehicle and the method thereof |
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