WO2013005994A2 - Panneau composite ininflammable en aluminium utilisant un corps expansé et durci en résine phénolique et son procédé de fabrication - Google Patents
Panneau composite ininflammable en aluminium utilisant un corps expansé et durci en résine phénolique et son procédé de fabrication Download PDFInfo
- Publication number
- WO2013005994A2 WO2013005994A2 PCT/KR2012/005327 KR2012005327W WO2013005994A2 WO 2013005994 A2 WO2013005994 A2 WO 2013005994A2 KR 2012005327 W KR2012005327 W KR 2012005327W WO 2013005994 A2 WO2013005994 A2 WO 2013005994A2
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- WIPO (PCT)
- Prior art keywords
- composite panel
- aluminum composite
- phenol resin
- combustible
- aluminum
- Prior art date
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Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/292—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and sheet metal
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
- B32B15/098—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
Definitions
- the present invention relates to an aluminum composite panel manufacturing technology, and more particularly, by forming a core layer between the front and rear aluminum plates with a phenol resin cured foam, high thermal insulation performance of 0.020 W / mK or less level
- the present invention relates to a technology for providing an aluminum composite panel having a non-flammability similar to that of a second flame retardant.
- Composite panels are commonly used for building exterior wall finishing.
- the composite panel is composed of a steel plate such as aluminum, magnesium, iron and the front panel.
- the core layer (core) between the front plate and the back plate is formed of a material showing an insulating effect such as glass wool, polyethylene (PE), talc (Talc).
- the core layer is formed of polyethylene (PE)
- PE polyethylene
- Korean Patent Registration No. 10-0828630 (2008.05.02) includes 15 to 25% by weight of polyethylene (PE), 5 to 15% by weight of ethylene vinyl acetate (EVA) and 60 to 80 weight of a flame retardant filler.
- PE polyethylene
- EVA ethylene vinyl acetate
- a flame retardant aluminum composite panel comprising a flame retardant synthetic resin mixed with%.
- the core layer is filled with a flame retardant or an excess of talc.
- the specific gravity is large so that the workability is difficult and the construction cost is high.
- the panel when the glass wool or rock wool is filled in the core layer, the panel has an advantage of being nonflammable, but there is a problem that thermal insulation performance is deteriorated due to high thermal conductivity.
- glass wool or rock wool has a problem that acts as a harmful element to the human body.
- the present invention is an aluminum composite panel that can solve the risk of fire, a gas generation problem and construction cost problems that are a problem in the aluminum composite panel using polyethylene (PE) or talc (talc) as a core layer and It aims at providing the manufacturing method.
- PE polyethylene
- talc talc
- the present invention is to provide an aluminum composite panel having a high thermal insulation performance of the level of 0.020 W / mK or less and non-combustible according to the flame retardant class 2 and a manufacturing method thereof.
- the non-combustible aluminum composite panel according to the present invention for achieving the above object is a core layer formed of a phenol resin cured foam; And a front plate and a rear plate formed on the front and rear surfaces of the core layer, each having an aluminum layer.
- the core layer is formed of a phenol resin cured foam, thereby ensuring heat insulation and flame retardancy. Therefore, the application of the composite panel according to the present invention to the building insulation provides a flame retardant level of flame retardancy because it provides an effect that can improve the safety in fire.
- the heat insulation composite panel according to the present invention exhibits a high thermal insulation property of less than 0.020 W / mK thermal conductivity, there is an effect that can reduce the heating cost.
- the present invention does not use a freon gas in the core material, using an environmentally friendly blowing agent such as hydrocarbon (hydrocarbon), not HCFC (hydro-chloro-fluoro-carbon) blowing agent, there is no risk factor for global warming and long-term high It provides the effect of maintaining insulation performance and condensation prevention.
- an environmentally friendly blowing agent such as hydrocarbon (hydrocarbon), not HCFC (hydro-chloro-fluoro-carbon) blowing agent
- FIG. 1 is a flow chart showing a method for producing an aluminum composite panel comprising a phenolic resin cured foam according to the invention.
- Figure 2 is a cross-sectional view showing an aluminum composite panel comprising a phenolic resin cured foam according to the present invention.
- FIG. 1 is a flow chart showing a method for producing an aluminum composite panel comprising a phenolic resin cured foam according to the invention.
- the illustrated aluminum composite panel manufacturing method includes a front plate / back plate preparing step (S100), a phenol resin cured foam forming step (S110), a high temperature compression step (S120), and a curing / aging step (S130). Include.
- the front plate and the back plate each comprise an aluminum layer.
- the aluminum layer may be formed of one sheet or two or more aluminum plates. It is preferable that the thickness of an aluminum layer is 0.5-2 mm. At this time, when the thickness of the aluminum layer is less than 0.5 mm it is difficult to secure the strength of the panel structurally. On the contrary, when the thickness exceeds 2 mm, the weight may be increased, thereby reducing the construction efficiency.
- a protective layer, a chromate layer, or the like may be further formed on the outer surface of the aluminum layer on the front plate or the back plate.
- the front plate may also be added to the coating layer for improving the appearance as the exterior wall finishing material. Only one layer of these protective layers, chromate layers, paint layers, etc. may be formed on the outer surface of the aluminum layer, and a plurality of layers having the same shape as the aluminum layer / chromate layer / paint layer / protective layer It can be formed on the surface.
- the phenol resin composition may include a foam stabilizer, a foaming agent, a curing agent, and an additive.
- the phenol resin composition may include 1 to 10% by weight foam stabilizer, 5 to 25% by weight foaming agent, 5 to 25% by weight curing agent and 0.1 to 10% by weight additive.
- Foam stabilizers act as surfactants.
- the phenolic resin and the curing agent are hydrophilic and hydrocarbon-based blowing agents have hydrophobic characteristics. Foaming agents are used to help the hydrophilization of the blowing agent for mixing with the blowing agent and other compositions.
- foam stabilizers may be silicone-based or polysiloxane-based.
- the foaming agent When the foam stabilizer is 1 to 10% by weight of the total weight of the phenol resin composition and the content of the foam stabilizer is less than 1% by weight, the foaming agent does not have a hydrophilic function, and thus it is difficult to mix the foaming agent with the phenol resin and the curing agent. On the contrary, when the content of the foam stabilizer exceeds 10% by weight, the hydrophilization property may be excessive, resulting in a problem that the phenol resin cannot be combined with the front plate or the back plate.
- the blowing agent is a physical blowing agent, which forms a phenol resin composition into bubbles due to the heat of reaction, and is characterized by low thermal conductivity and low boiling point.
- the blowing agent uses an aliphatic hydrocarbon having 1 to 8 carbon atoms.
- HCFC hydro-chloro-fluoro-carbon
- the present invention by using a hydrocarbon as a blowing agent, it is possible to solve the burden on the risk of environmental threats as compared to the conventional.
- the hydrocarbons that can be used as the blowing agent include cyclopentane, isopentane, isobutane, and the like, and are preferably selected in consideration of thermal conductivity and boiling point of the blowing agent.
- the blowing agent preferably includes at least one member selected from the group consisting of at least one of isopentane, isobutane and cyclopentane.
- the blowing agent is preferably included in 5 to 25% by weight of the total weight of the phenol resin composition.
- the content of the blowing agent is an important factor in controlling the density of the entire phenolic resin composition, and in order to prepare a phenolic resin cured foam having a density in the range of 30 to 40 kg / m 3, it is preferable to add the above content.
- the density of the phenol resin cured foam may exceed 40 kg / m 3
- the density of the phenol resin cured foam is 30 kg. It may be less than / m 3 .
- the curing agent acts as a catalyst to lower the foaming temperature and to foam at a relatively low temperature.
- a curing agent may use benzene sulfonic acid, paratoluene sulfonic acid, xylene sulfonic acid, phenol sulfonic acid and the like.
- curing agent is contained in 5 to 25 weight% of the total weight of a phenol resin composition. If the content of the curing agent is less than 5% by weight, the catalytic function may not be performed. If the content of the curing agent exceeds 25%, a large amount of unreacted curing agent is generated, resulting in acidity, thereby increasing corrosion of the metal.
- the additive is an organic amino group-containing compound for reducing outgassing by removing unreacted monomers.
- the additive is preferably included in 0.1 to 10% by weight of the total weight of the phenol resin composition. If the weight of the additive is less than 0.1% by weight, it is difficult to remove the unreacted monomer, and outgassing may occur. If the weight of the additive is more than 10% by weight, the additive acts as an impurity to improve the quality of the entire phenolic resin foam. Can be degraded.
- the additive may comprise a neutralizing agent.
- the neutralizing agent serves to increase the pH of the phenolic resin cured foam to about 3 to 9 bar bar, which can be used to compensate for corrosion problems on the metal adhesion surface due to the acidic curing agent.
- the neutralizing agent may be a hydroxide of a metal such as aluminum hydroxide, magnesium hydroxide, calcium oxide, magnesium oxide, aluminum oxide or zinc oxide, or a metal powder such as oxide or zinc, a metal carbonate such as calcium carbonate, magnesium carbonate, barium carbonate or zinc carbonate. It may include.
- the said neutralizing agent can be used individually by 1 type, or can be used in combination of 2 or more type.
- the neutralizing agent is preferably included in 0.1 to 10% by weight of the total weight of the phenolic resin composition, when the content of the neutralizing agent is less than 0.1% by weight of the cured phenolic resin foam formed will be acidic, in the case of more than 10% by weight Problems may occur in which the physical properties of the formed phenol resin cured foam are changed.
- additives may include a plasticizer.
- the plasticizer gives flexibility to the bubble wall and prevents the wall from being broken or deteriorated so that the foaming gas in the bubble escapes and is replaced with air, thereby enhancing long-term durability.
- Specific examples of the plasticizer may include triphenyl phosphate, dimethyl terephthalate, dimethyl isophthalate, polyethylene glycol, polyol, and the like.
- the said plasticizer is contained in 1 to 15 weight% of the total weight of the phenol resin composition for phenol resin cured foam formation.
- the content of the plasticizer is less than 1% by weight, the phenolic resin cured foam does not affect long-term durability, and when it exceeds 15% by weight, the performance of the phenolic resin cured foam may be impaired.
- the independent foaming rate of the cured phenol resin formed can be determined depending on the components or foaming conditions of the phenol resin composition.
- the closed cell content of the phenol resin cured foam is 80% or more.
- the independent bubble ratio defines the fraction of closed bubbles among the bubbles formed in the unit area.
- the independent bubble ratio is less than 80%, the remaining gas remains inside the phenol resin-cured foam, which results in outgassing. It may cause, and the structural strength is remarkably lowered, which may result in deterioration of the characteristics of the exterior panel.
- an aluminum composite panel is manufactured by a T-die using an extruder, and an air layer is generated and condensation occurs due to a technology of injecting a filler such as an inorganic material into the core layer between the aluminum composite panels.
- a filler such as an inorganic material
- the aluminum composite panel manufacturing method of the present invention is to prepare a front plate / back plate corresponding to the outer shell material of the aluminum composite panel (S100), while injecting the phenolic resin composition there between foaming and curing (S110) Containing, by putting a phenolic resin composition between the front plate / back plate can be immediately foamed and hardened to prevent condensation.
- the aluminum composite panel is formed by compressing the phenol resin composition introduced between the front plate and the back plate through the pressing process through the front plate and the back plate. At this time, when the size of the aluminum composite panel is determined, it can be cut to a predetermined size.
- the pressing step is characterized in that to press the phenol resin composition at a predetermined temperature.
- a conveyor belt capable of pressing the conveyor belt and the lower conveyor belt is rotated at a predetermined interval, the front plate, the phenol resin composition and the back plate may be introduced therebetween.
- the operating temperature and the operating pressure of the conveyor belt are important because they act as an influence factor that the foam can have uniform and independent bubbles.
- the pressing process may be carried out at a temperature of 65 ⁇ 100 °C, preferably 70 ⁇ 90 °C. If the running temperature in the pressing process is less than 65 °C, for example, when using the conveyor belt foam curing of the phenolic resin composition may not sufficiently occur within a limited time passing through the conveyor belt, the curing rate if the temperature exceeds 100 °C The evaporation or foaming rate of the blowing agent is more rapid, the cell (cell) becomes larger and burst, the heat insulation performance may be lowered.
- the pressing process may be performed by applying a pressure of 0.3 ⁇ 2.0kgf / cm 2 , preferably 0.5 ⁇ 1.5kgf / cm 2 .
- the pressure applied in the pressing process is less than 0.3kgf / cm 2 , the desired aluminum panel shape cannot be maintained because the foaming pressure does not have sufficient foaming pressure to form a sufficient phenolic resin foaming agent, and a pressure exceeding 2.0kgf / cm 2 is applied. In this case, a cell in which the foaming gas is trapped may be broken.
- curing is made for the purpose of post-curing and includes a aging step to remove VOC (volatile organic compounds). It is preferable to put in a convection oven for 10 to 200 minutes per cm 2 of the core layer at less than 75 °C. If the curing time is less than 10 minutes, the curing and aging is not sufficiently made, the thermal conductivity may increase and the thermal insulation properties may be reduced.
- VOC volatile organic compounds
- the improvement of the characteristics compared to the time and cost put into the curing may result in a waste of only cost.
- the composite panel which has the core layer formed from the phenol resin cured foam, and the front plate / back plate provided with an aluminum layer can be manufactured.
- FIG. 2 is a cross-sectional view showing an aluminum composite panel using a phenol resin cured foam according to the present invention.
- the illustrated aluminum composite panel includes a core layer 100, a front plate 110, and a back plate 120.
- the core layer 100 is formed of a phenol resin cured foam.
- the front plate 110 is formed on one surface of the core layer 100 (upper core layer in FIG. 2), and the back plate 120 is formed on the other surface of the core layer 100.
- front plates 110 and back plates 120 are provided with aluminum layers 110d and 120b.
- the composite panel according to the present invention can be completed only by the basic structure of the front plate 110 and the back plate 120 having the core layer 100 and the aluminum layers 110d and 120b formed of such a phenol resin cured foam. have.
- the aluminum composite panel according to the present invention may have a separate chromate layer formed on the outer surface of the aluminum layer provided on the front plate 110 or the rear plate 120 so as to be used as an external finishing material.
- 110c) the paint layer 110b, the protective layers 110a and 120a may be further formed.
- the front plate 110 is defined after the construction, the name is defined based on the portion exposed to the outside, the rear plate 120 has been described as showing the opposite side, but is not limited thereto.
- the present invention provides a high insulation non-combustible aluminum composite panel made of a phenol resin cured foam, and may exhibit non-combustibility according to thermal conductivity and flame retardant secondary level of 0.020 W / mK or less.
- a mixture containing 4% by weight of a polysiloxane foam stabilizer (polysiloxane), 3% by weight of a neutralizer (calcium carbonate), 3% by weight of a plasticizer (polyol), 10% by weight of a blowing agent (cyclopentane), and a curing agent (paratoluene).
- Sulphonic acid) 15 wt% of the phenolic resin composition by injecting and mixing in three phases was mixed between aluminum plates of 2 mm thickness using a conveyor belt carried out at an operating temperature of 80 ° C. and an operating pressure of 1.0 kgf / cm 2 .
- phenol resin mixtures were foamed and cured immediately on a conveyor belt for 10 minutes to form phenol resin cured foams having an independent foam ratio of 90%. After curing and aging for 60 minutes per 1 cm 2 at 75 °C to produce an aluminum composite panel.
- An aluminum composite panel was manufactured under the same conditions as in Example 1, but the independent bubble ratio was 80%.
- An aluminum composite panel was manufactured under the same conditions as in Example 1, but the independent bubble ratio was 60%.
- An aluminum composite panel was manufactured under the same conditions as in Example 1 except that polyethylene was used as the core layer instead of the phenol resin cured foam.
- An aluminum composite panel was manufactured under the same conditions as in Example 1, except that talc was used as the core layer instead of the phenol resin cured foam.
- the composite panel made of a phenol resin cured foam according to the present invention has excellent initial heat insulating performance and long term durability performance. Due to this high energy load reduction rate can be seen that can be used as a high-efficiency building finishing material.
- the phenolic foam of the core layer has a semi-combustibility corresponding to the flame retardant secondary.
- semi-combustible grade testing methods there are heat release rate tests (KS F ISO 5660-1) and gas hazard tests (KS F 2271).
- the heat release rate test shall use a cone calorimeter method and the total heat release rate shall not exceed 8 MJ / m 2 and the maximum heat release rate shall not exceed 200 kW / m 2 when 50 kW / m 2 radiant heat is applied for 10 minutes.
- the gas hazard test may be quasi-non-combustible if the average time of inactivity is greater than 9 minutes when observing 8 rats due to the combustion gases of the test specimen.
- phenol foam it can be seen that the use of non-freon gas is environmentally friendly, no harmful gas is generated, and the flame retardancy is excellent, so that the risk of fire is low.
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Abstract
La présente invention concerne un panneau composite ininflammable en aluminium constituant un très bon isolant thermique et formé d'un corps expansé et durci en résine phénolique, ainsi qu'un procédé de fabrication dudit panneau. Le panneau composite en aluminium de la présente invention comporte une couche centrale située entre une plaque avant et une plaque arrière comportant chacune une couche d'aluminium, un corps expansé et durci en résine phénolique étant présent dans ladite couche centrale. Ainsi, le panneau composite en aluminium peut présenter de très bons résultats en matière d'isolation thermique avec une conductivité thermique inférieure ou égale à 0,020 W/mK, ainsi qu'en matière d'ininflammabilité avec un caractère ignifuge de niveau 2. Le panneau de la présente invention peut être utilisé en tant que matériau de finition pour mur extérieur dans les constructions à haute efficacité énergétique, ledit mur pouvant présenter une constructibilité supérieure et prévenir la condensation.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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KR10-2011-0067334 | 2011-07-07 | ||
KR1020110067334A KR101382045B1 (ko) | 2011-07-07 | 2011-07-07 | 페놀 수지 경화 발포체를 이용한 불연 알루미늄 복합 판넬 및 그 제조 방법 |
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WO2013005994A2 true WO2013005994A2 (fr) | 2013-01-10 |
WO2013005994A3 WO2013005994A3 (fr) | 2013-03-14 |
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PCT/KR2012/005327 WO2013005994A2 (fr) | 2011-07-07 | 2012-07-05 | Panneau composite ininflammable en aluminium utilisant un corps expansé et durci en résine phénolique et son procédé de fabrication |
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KR (1) | KR101382045B1 (fr) |
WO (1) | WO2013005994A2 (fr) |
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CN111051406B (zh) * | 2017-09-15 | 2022-10-25 | 乐金华奥斯株式会社 | 酚醛发泡体及其制备方法 |
KR102057228B1 (ko) | 2018-05-29 | 2019-12-18 | 정도영 | 알루미늄 복합 판넬 코어재 제조용 조성물 및 이를 이용한 알루미늄 복합 판넬 코어재 제조용 마스터 배치 칩 및 알루미늄 복합 판넬의 제조방법 |
Citations (3)
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JP2003056089A (ja) * | 2001-08-20 | 2003-02-26 | Comany Inc | 断熱不燃パネル用の接合部材 |
KR20080053285A (ko) * | 2005-09-08 | 2008-06-12 | 아사히 유키자이 고교 가부시키가이샤 | 발포성 레졸형 페놀 수지 성형 재료 및 페놀 수지 발포체 |
KR20110049004A (ko) * | 2009-11-04 | 2011-05-12 | 서희교 | 다용도 조립식 판넬 및 이의 제조방법 |
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JP2002339472A (ja) * | 2001-05-15 | 2002-11-27 | Comany Inc | 断熱不燃パネル |
JP4370414B2 (ja) * | 2004-04-06 | 2009-11-25 | 鹿島建設株式会社 | 樹脂製パネル |
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2011
- 2011-07-07 KR KR1020110067334A patent/KR101382045B1/ko active IP Right Grant
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- 2012-07-05 WO PCT/KR2012/005327 patent/WO2013005994A2/fr active Application Filing
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
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JP2003056089A (ja) * | 2001-08-20 | 2003-02-26 | Comany Inc | 断熱不燃パネル用の接合部材 |
KR20080053285A (ko) * | 2005-09-08 | 2008-06-12 | 아사히 유키자이 고교 가부시키가이샤 | 발포성 레졸형 페놀 수지 성형 재료 및 페놀 수지 발포체 |
KR20110049004A (ko) * | 2009-11-04 | 2011-05-12 | 서희교 | 다용도 조립식 판넬 및 이의 제조방법 |
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KR101382045B1 (ko) | 2014-04-14 |
WO2013005994A3 (fr) | 2013-03-14 |
KR20130005747A (ko) | 2013-01-16 |
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