Flame-retardant substance carrier predicularly for flat products made from

Abstract

One device is a carrier by means of which a flame retardant substance (2) is effectively applied into a product (3) and which comprises a flat flexible or semi-flexible non-metallic web (1) applied with a layer of the flame retardant substance (2) having an expansion effect. The flame-retardant substance (2) is preferably a melt of ammonium polyphosphate and pentaerythritol, finally with melamine, whereby the melt is applied into the structure of the web (1) and then pressed into the mass of the product (3). The web (1) is preferably made of glass fiber bundles and glass fiber filaments, has a regular structure, has meshes with a size of up to 40 * 40 mm, preferably rectangular meshes with a size of 2 mm to 15 mm, and has a surface weight of up to 350 g / m2, preferably in the range of 100 to 140 g / m2. And the density of the flame-retardant substance on the surface of the net (1) is 250-1200 g / m < 2 >. The layer of the flame-retardant substance (2) can be applied by impregnation and / or spraying and / or gluing and / or immersion in a liquid or molten flame-retardant substance (2).

Description

TECHNICAL FIELD

[0001] The present invention relates to a carrier applied with a flame retardant substance, wherein the carrier is applied to a product, mainly to a flat product made of recycled plastic material. The carrier significantly improves the flame retardancy and also improves the mechanical characteristics, mainly the bending strength, the puncture resistance, the long-term shape stability and other mechanical characteristics in the case of flat products. The flame retardant carrier preferably comprises a non-toxic flame retardant impregnation substance applied to the carrier in liquid or powder form. BACKGROUND

[0002] It is known that building products are produced, for example, in the form of board pieces or panels pressed from granules of recyclates from various sources. Recyclates themselves are usually devoid of any flame retardancy, which can originate, for example, from food packaging where the use of hazardous substances cannot be ruled out. Considering the amount of material consumed, the production of building products preferably uses recyclates of various plastic materials, but their disadvantage is low flame retardancy.

[0003] CN106869352A discloses a panel made of waste plastic containing expanded spheres, silicon dioxide, magnesium oxide and flame retardants. The flame retardant properties of this panel are improved, but they require a high amount of flame retardants.

[0004] CN110219428A discloses a method of producing a composite panel, where one layer is responsible for achieving the desired flame retardant properties. The other layer is an industrial waste plastic whose composition can be determined.

[0005] Another approach consists in a subsequent surface treatment of the board pieces or panels with a flame retardant layer. JP2020164355A discloses a flame retardant coating material consisting of recycled semi-hydrated gypsum and finely ground powder of waste concrete material. The disadvantage is the need for additional treatment of the surface of the panel and the final adhesion problems of the applied layer.

[0006] US10731346B2 discloses a panel made of recycled plastic, which contains a coating made of glass fibers intended to protect the plastic core from the effects of fire. In order to achieve the flame retardancy of such a panel, the layer of applied glass fibers must be very thick.

[0007] SK288796 discloses impregnation of chips or shreds before pressing into board pieces and it can also be used during pressing of recycled plastic granules, but the irregularity of recyclates due to the efficiency of waste sorting can reduce the efficiency of applying the impregnated flame retardant substance into the final product.

[0008] Solutions using various hazardous substances, for example halogens such as bromine or chlorine, as flame retardants are also known. These flame retardants are dangerous to health during long-term exposure, mainly in residential areas, and they can also reduce the original physical-mechanical characteristics of the base material.

[0009] Intumescent coatings are used as surface layers on the outer surface of building products. After the fire has penetrated inside the material, the intumescent coating loses its effect. A drawback of the known intumescent coatings is also the coloring of the building product, which is often in conflict with the aesthetic and design requirements.

[0010] The present invention aims to provide a new carrier and a new method of applying a flame retardant into the material of a product, mainly a building product, which does not reduce the mechanical properties of the product. The process of injecting the carrier or the method into the product should be fast and in line with the requirements of industrial production efficiency, regardless of the material specification of the waste plastic recyclate. SUMMARY

[0011] The above-mentioned drawbacks of the prior art are significantly remedied by the carrier applied with a flame-retardant substance according to the invention, which is mainly used for flat products made of recycled material, the essence of which consists in comprising a flat flexible or semi-flexible non-metallic mesh, into which a layer of flame-retardant substance with intumescent effect is applied.

[0012] The term "mesh" herein is any grid or any planar oriented structure with openings or meshes, which can be a mesh, a sparse woven or non-woven fabric, etc. The distribution of the openings in the mesh is usually regular, but can also be random, where the gaps between the fibers of the mesh have different shapes and sizes. In a preferred arrangement, the non-metallic mesh consists of glass fiber bundles and / or glass fiber filaments, particularly preferably the non-metallic mesh is formed by commercially available meshes used in construction for reinforcing plaster and joints. In a preferred arrangement, the mesh made of glass fiber filaments has a regular structure with meshes of size up to 40x40 mm, particularly preferably of size 2 mm to 15 mm, such as for example 10x10 mm, and has a basis weight of up to 350 g / m 2 , particularly preferably between 100 and 140 g / m 2 . The mesh is a non-metallic mesh, so that both the heat transfer is reduced and better adhesion to the molten recyclate is achieved. At the same time, the material of the mesh withstands high temperatures of at least 500°C, so that the mesh does not melt or burn through quickly.

[0013] "Intumescent" herein is also a general term for final micro-intumescence. Intumescence is manifested by foaming the surface of the pellets, which is usually associated with the loss of the original mechanical properties of the pellets. Micro-intumescence is accompanied by the creation of smaller cores, whereby the space around them is foamed. Due to the thermal effect, intumescence is usually accompanied by the release of CO2 and nitrogen-containing gases around the core.

[0014] The layer of flame retardant substance is applied to the surface of the web from at least one side, preferably from both sides, especially preferably it is applied in a mass around the entire surface of the filaments of the web, which can be achieved by dipping (immersion) the web into a liquid or molten solution of the flame retardant substance. One important feature of the flame retardant carrier according to the invention is that it maintains its perforated character even after the application of the flame retardant substance. Thus, the applied layer of the flame retardant substance is less than or significantly less than about half of the size of the mesh in the web, respectively. Maintaining the openings in the flame retardant carrier is important for the purpose of effective connection with the mass of the building product, into which the web is subsequently pressed (pushed).

[0015] During the application of the flame retardant carrier, the base material of the product penetrates the free openings in the flame retardant carrier, which increases the mutual adhesion and improves the transfer of forces into the web during the mechanical stress of the product. After the application of the flame retardant substance having an expanding and / or micro-expanding effect according to the invention, the size of the free openings in the web forms at least 40% of the surface, preferably at least 60% of the surface. At the same time, the expansion occurring during the exposure does not matter to the extent that the openings in the web are completely foamed, because this would require a high amount of the flame retardant substance. When the amount of the flame retardant substance applied is in the range of 250 to 1200 g / m2, the size of the openings in the web is in the range of 0.1 to 0.5 mm, preferably in the range of 0.2 to 0.4 mm. 2 The high flame retardancy of the resulting product has been proven by measurements on the web surface, i.e. on the material corresponding to a ratio of 2:1 to 5:1 of the basic material mass of the web itself.

[0016] The high flame retardant effect is due to two basic factors having a synergistic effect and not disclosed in the prior art. The first factor is the concentration of the amount of the flame retardant substance in a relatively thin layer. Concentrating the flame retardant substance in a relatively thin layer increases the efficiency during the fire plane effect compared to diffusing the flame retardant substance into the core of the product. In the cross-section of the building product, for example in the cross-section of the building board according to the invention, the flame retardant substance is distributed non-uniformly in such a way that it is concentrated in a thin continuous layer in which the non-metallic web is placed. The second factor increasing the efficiency is the fixation of the flame retardant to the filaments of the web, thus forming a structure that mechanically holds the flame retardant substance during foaming. The material of the web is heat-resistant, and during the foaming of the flame retardant substance it forms a flat frame that holds the foamed flame retardant substance in place. At the same time, the pressure caused by the foaming within the mesh of the web pushes the base material in the size of the mesh of the web and prevents the air required for combustion from entering. It is the fixation of the flame retardant substance to the structure of the web that achieves the concentration of the flame retardant substance fixed to the filaments of the web.

[0017] In the fire-free state, the filaments of the web assume an important mechanical task, i.e. the transmission of the tension during the loading of the panel due to tension, bending or rotation. In the case of commercially available glass fibre webs (sieves), the mechanical properties have been significantly improved, mainly in the case of flat construction products containing plastic recyclates, which are mainly recyclates from sorted waste or sorted public waste, whose quality and purity are lower than that of industrially produced recyclates.

[0018] An important manifestation of the invention is the optimal use of the respective amount of flame-retardant substance, for example the use of an amount of flame-retardant substance that is economically acceptable for a given type of construction product. The placement of the flame-retardant substance in a concentrated layer, instead of spreading it throughout the layer of the core of the product, improves the flame-retardant effect. This feature of the invention does not exclude the implementation when the flame-retardant substance is generally distributed in the core of the construction product and at the same time the flame-retardant substance is concentrated in a layer together with the web.

[0019] The above-mentioned deficiencies are significantly remedied by the production method of the flame-retardant carrier according to the invention, which is designed mainly for subsequent use in flat products made of recycled plastic, the essence of which lies in the fact that a layer of flame-retardant substance with an expanding effect is applied to a flat flexible or semi-flexible non-metallic web, by dipping and / or immersing and / or gluing and / or soaking into a liquid or molten flame-retardant substance. The method is characterised preferably by the fact that the layer of flame-retardant substance is applied in the range of 250 - 1200 g / m 2 Surface application of the web. The method of applying liquid glue during and subsequently applying powder particles of flame-retardant substance, as well as the method of dipping the web in a liquid melt of flame-retardant substance, are disclosed in the examples implementing the invention.

[0020] When the web is dipped into the flame-retardant substance in molten form, it is preferable to melt the ground mixture of ammonium polyphosphate and pentaerythritol, with the final addition of melamine. Both components - ammonium polyphosphate and pentaerythritol - are in anhydrous form, present in a broad range of 5 to 95% of the mass of the resulting mixture. In the case of using three components, each of the three components can form 5 to 50% of the mass of the resulting mixture. The feed components in anhydrous form are heated to 240°C to 350°C, while producing a melt; the blended melt is kept at a temperature of 240°C to 350°C for at least 30 seconds, and subsequently the melt in liquid form is applied to the web at a temperature of at least 150°C. The application can be carried out by dipping the web into a container filled with the melt or by spraying with a jet. After the application, the web is wound on a reel and prepared for use in the production line of construction products, mainly made of plastic recyclates.

[0021] In one arrangement, the method can include, first, mixing the unheated feed components in a dry, anhydrous state, wherein the components are mixed mechanically and the resulting solid particulate mixture is heated to a molten state, whereby polymerization occurs in the melt. In another arrangement, each feed component can be heated independently and subsequently mixed into a common melt in which polymerization occurs, in liquid form. A method can also be employed in which the feed components are placed in a single vessel in which they are mixed and heated, resulting in first the mixing of a dry mixture and subsequently the mixing of the individual components into a blended melt. The blended melt has a temperature of 240°C to 350°C for at least 30 seconds, such that polymerization has a corresponding product.

[0022] The adjustment of the planar quantity required during the application of the flame-retardant substance to the web can be achieved by adjusting the properties of the jet, adjusting the movement speed of the web on the production line, or repeating the winding and applying the flame-retardant substance.

[0023] Ammonium polyphosphate [NH4 PO3] n Used as food additive, emulsifier (E545). It is also used as a halogen-free flame retardant. There are two major basic classes of ammonium polyphosphate depending on the polymerization level: crystalline phase I type APP and crystalline phase II type APP. Phase I ammonium polyphosphate has short straight chains (n < 100), it is more sensitive to water and has lower thermal stability; it starts to decompose at temperatures higher than 150°C. Phase II ammonium polyphosphate has a high polymerization level of n > 1000, its structure is branched (networked) and it has higher temperature stability; it starts to decompose at about 285°C to 300°C and it has higher solubility in water than phase I type APP.

[0024] Pentaerythritol, 2,2-bis(hydroxymethyl) 1,3-propanediol C5H 12 O4, CAS 115-77-5, is a white crystalline powder, tetravalent monohydroxy. It is used in the production of alkyd resins, emulsifiers, explosives, coating materials, synthetic lubricating oils. It is considered an environmentally friendly alternative to polychlorinated biphenyls (PCBs).

[0025] Melamine, 2,4,6-triamino-1,3,5-triazine, general formula: C3-H6-N6, CAS number 108-78-1, is mainly used in the production of plastics and nitrogen-containing fertilizers. Melamine is not toxic at low doses. Because it is undesirable for melamine to be present in food, it is described as harmful, but the toxic dose of melamine in food is comparable to table salt, exceeding 3 g per kg of individual live weight. From this perspective, the use of melamine in the additive according to the invention is harmless.

[0026] The resulting construction articles of mainly flat shape such as panels, boards, walls, partitions, including recyclates from plastic waste, are also subject of the present invention, the essence of which lies in the fact that they comprise a flexible or semi-flexible non-metallic mesh, to which a layer of flame-retardant substance with swelling effect has been applied, whereby the longitudinal orientation of the mesh essentially corresponds to the longitudinal course of the building product. It is preferred to press the mesh into the mass of the product up to a depth of 3 mm from the surface, finally into the mass of the flat product from both sides. During the expected mechanical stresses, the mesh should preferably be oriented in the direction of the tensile stress. For example, when a panel is subjected to bending loads, the mesh should be placed on the side of the force action, in the case of beams on supports, the mesh should be placed on the opposite side of the force action. If the mesh is not visible on the surface, it is preferred that its position is highlighted graphically on the building product itself.

[0027] The tests of the building products according to the examples confirmed high mechanical properties and excellent fire resistance in a wide range of recyclate components, for example (in mass percent): PE-LD / PE-HD-polyethylene: 70-75%, PET polyethylene terephthalate: 10-15%, PA-polyamide: 0,05-3%, POM-polyoxymethylene: 0,05-3%, PP-polypropylene: 0,05-3%, chemical wood pulp: 10-15%, wood fiber material: 0,05-3%; or PE-LD / PE-HD-polyethylene: 65-70%, PET polyethylene terephthalate: 5-10%, PA-polyamide: 0,05-2%, POM-polyoxymethylene: 0,05-2%, PP-polypropylene: 0,05-2%, chemical wood pulp: 25-30%, wood fiber material: 0,05-2%.

[0028] The mechanical properties compared to standard OSB are as follows: Parameters OSB Panel according to the invention Bending ultimate tensile strength 10,5 / 11 / 15 N / mm 2 ]] 13,9 - 30,99 N / mm 2 ]] Elastic modulus [1 800 / 2 050 N / mm 2 ]] 1250 - 3652,8 N / mm 2 ]] Vertical tensile strength 0,28 / 0,4 / 0,45 N / mm 2 ]]> [0,31 -0,49 N / mm 2 ]] Swelling xxx / xxx / 17% 2,91 - 5,48% Moisture content 5-13% 0,6 -2,0% Density 600 - 640 kg / m 3 ]] 850 - 1151 kg / m 3 ]] Panel thickness 12 mm 6,5-10 mm The advantage of the present invention is the efficient use of non-toxic flame-retardant substances, while improving the mechanical properties and maintaining the appearance and color of the building product. BRIEF DESCRIPTION OF DRAWINGS

[0029] By way of example Figures 1 to 6 The invention is further disclosed. The dimensions of the individual components, the ratio of the filaments of the mesh to the thickness of the layer of flame-retardant substance are only for illustration and cannot be interpreted as limiting the scope of protection sought.

[0030] Figure 1 is a cross-section of a building panel with one mesh on the top side of the board.

[0031] Figure 2 shows a mesh with flame-retardant substance applied on one side.

[0032] Figure 3A mesh with flame-retardant material applied throughout the entire volume is depicted.

[0033] Figure 4 A production line is schematically depicted that applies flame retardant by immersing it in the melt.

[0034] Figure 5 A schematic diagram depicts the application of a mesh to the bottom and top sides of a continuously pressed building panel.

[0035] Figure 6 A layer of flame-retardant material applied by a roller is depicted. Detailed Implementation Example 1

[0036] In this embodiment, a mesh with regular openings and dimensions of 10 mm × 10 mm with a surface density of 145 g / m² is used. 2 Fiber textile web 1. Web 1 is placed in a roll in an unwinding device, then passed through a guide roller assembly, and immersed in a molten melt in a flat container with electric heating. The composition of the melt is measured as follows: 50 parts by weight of ammonium polyphosphate and 50 parts by weight of pentaerythritol. The loose, anhydrous feed components are placed in a common container, where they are mixed and then heated to above 285°C, thereby producing a blended melt, which is held at a temperature above 285°C for at least 2 minutes after mixing. Subsequently, the melt is transferred to a flat container, where it is held at a temperature of at least 185°C by electric heating. When web 1 is immersed in the melt, a layer of polymer of flame retardant 2 is applied to the surface of the individual filaments of web 1. The amount of this layer on the surface of web 1 is 500 ± 100 g / m. 2 The mesh 1 then passes through guide rollers, where it is cooled to 100°C, and is subsequently wound onto a reel.

[0037] First, the reel of mesh 1 is inserted into a production line for producing building panels made from recycled plastic. The composition of the recycled material in this specific embodiment is as follows: PE-LD / PE-HD - Polyethylene: 73%, PET (Polyethylene terephthalate): 13% PA-polyamide: 1%, POM (polyacetal): 1%, PP - Polypropylene: 1%, Chemical wood pulp: 10%, Wood fiber material: 1%.

[0038] Due to variations in particle size, the local irregularity of component volume can be ±50%. Example 2

[0039] In this embodiment, the three components of the melt are weighed as follows: 40 parts by weight of ammonium polyphosphate, 40 parts by weight of pentaerythritol, and 20 parts by weight of melamine. The melt is sprayed onto one side of the mesh 1, thereby maintaining its position during the pressing of the mesh 1 into the building product 3 such that the side of the mesh 1 to which the flame retardant 2 is applied is oriented toward the outer surface of the building product 3.

[0040] The feed components of the melt are melted separately at a temperature above 250°C and then mixed into the blend melt, where polymerization takes place for at least 5 minutes. Spraying is achieved via a heated jet.

[0041] The preparation of the melt is carried out simultaneously with the production line used to produce building panels, so that the mesh 1 enters from above onto the surface of the plastic recycling after spraying and is pressed before the melt cools, which reduces the energy requirements of production and reduces the number of operation steps.

[0042] The composition of the recycled material in this specific embodiment is as follows: PE-LD / PE-HD - Polyethylene: 65%, PET (Polyethylene terephthalate): 6.5% PA-polyamide: 1%, POM (polyacetal): 1%, PP - Polypropylene: 1%, Chemical wood pulp: 25%, Wood fiber material: 0.5%.

[0043] Due to variations in particle size, the local irregularity of component volume can be ±25%. Example 3

[0044] In this embodiment, the mesh 1 is first immersed in liquid adhesive, and then the flame retardant 2 with an expanding effect is applied to it in loose (powder) form with a particle size of 50 μm. Industrial applicability

[0045] The industrial applicability is obvious. According to the invention, devices (carriers) with flame-retardant substances applied in various ways can be repeatedly produced and used industrially, whereby the carrier can be preferably used in flat products made from recycled materials, while also improving their mechanical properties.

[0046] List of reference numerals 1-Net 2-Flame retardant materials 3-Products.

Claims

1. A flame-retardant material carrier primarily used in flat products made from recycled materials, characterized in that: It includes a flexible or semi-flexible non-metallic mesh (1) with a layer of flame-retardant material (2) having an expansion effect, so that the material of the mesh (1) can withstand temperatures up to 500°C.

2. The flame-retardant carrier for flat products made from recycled materials as described in claim 1, characterized in that: The net (1) is made of glass fiber filaments and / or glass fiber yarn.

3. The flame-retardant carrier for flat products made from recycled materials, as described in claim 1 or 2, is characterized in that: The net (1) has a regular structure and has mesh sizes up to 40×40 mm, preferably rectangular mesh sizes of 2 mm to 15 mm.

4. A flame-retardant carrier for flat products made from recycled materials, as claimed in any one of claims 1 to 3, characterized in that: The net (1) has a strength of up to 350 g / m 2 Preferably, it is between 100 and 140 g / m 2 Surface weight within the range.

5. A flame-retardant carrier for flat products made from recycled materials, as claimed in any one of claims 1 to 4, characterized in that: The surface of the free opening in the mesh (1) is at least 40% of the total surface of the mesh (1), preferably at least 60%.

6. A flame-retardant carrier for flat products made from recycled materials, as claimed in any one of claims 1 to 5, characterized in that: The amount of the flame retardant layer on the surface of the mesh (1) is 250-1200 g / m. 2 .

7. A flame-retardant carrier for flat products made from recycled materials, as claimed in any one of claims 1 to 6, characterized in that: The layer of flame retardant material (2) on the mesh (1) is located on one or both sides of the mesh.

8. A flame-retardant carrier for flat products made from recycled materials, as claimed in any one of claims 1 to 7, characterized in that: The flame retardant (2) is a melt of ammonium polyphosphate and pentaerythritol.

9. A flame-retardant carrier for flat products made from recycled materials, as claimed in any one of claims 1 to 7, characterized in that: The flame retardant (2) is a melt of ammonium polyphosphate, pentaerythritol and melamine.

10. A method for producing a flame-retardant carrier designed primarily for use in flat products made from recycled plastics, characterized in that: A layer of flame retardant material (2) with an expanding effect is applied to a flat, flexible or semi-flexible non-metallic mesh (1) by impregnation and / or spraying and / or gluing and / or immersion in a liquid or molten flame retardant material (2).

11. The method for producing a flame-retardant carrier according to claim 10, characterized in that: The mesh (1) is immersed in a melt of ammonium polyphosphate and pentaerythritol, or in a melt of ammonium polyphosphate, pentaerythritol and melamine.

12. The method for producing a flame-retardant carrier according to claim 11, characterized in that: The feed component in anhydrous form is heated to a temperature in the range of 240°C to 350°C to generate the melt; the blended melt is held at a temperature in the range of 240°C to 350°C for a period of time of at least 30 seconds; and then the melt in liquid state is applied to the mesh (1) at a temperature of at least 150°C.

13. A building product, primarily comprising a flat building product derived from recycled materials from plastic waste, characterized in that: It includes a flexible or semi-flexible non-metallic mesh (1) to which a layer of flame-retardant material (2) with an expansion effect is applied, such that the longitudinal orientation of the mesh (1) substantially corresponds to the longitudinal direction of the building product (3).

14. The building product according to claim 13, primarily a flat building, characterized in that: The net (1) is pressed into the material of the product (3) at a depth not exceeding 3 mm from the surface.

15. The building product according to claim 13 or 14, primarily a flat building, characterized in that: The net (1) is pressed into the clump of the flat product (3) from both sides.

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