Flame retardant product manufacturing method and flame retardant product manufactured thereby

Abstract

The present invention relates to a method for manufacturing a flame-retardant product and a flame-retardant product manufactured thereby, and more specifically, comprises the steps of: preparing a coating agent by mixing a resin additive and an aerogel (S10); coating the coating agent onto a target object (S20); and maintaining the target object coated with the coating agent at a heat treatment temperature for a predetermined time (S30).

Description

Technology Field

[0001] The present invention relates to a method for manufacturing a flame-retardant product and a flame-retardant product manufactured thereby. Background Technology

[0003] Base paper is composed of cellulose, so it has low direct flame retardancy and burns easily; films are polymer-based, so their flame retardancy is fundamentally limited; and fibers are also made of carbon-based organic materials with a large surface area, allowing for a smooth oxygen supply and a low ignition point, making them prone to burning easily.

[0004] Therefore, products made from the aforementioned fibers, paper, films, etc. burn easily, fail to function properly, and become the cause of large fires.

[0005] Meanwhile, attempts to add additional functions by coating the aforementioned fibers, base paper, films, etc., are currently underway.

[0006] The prior art, Registered Patent No. 10-0822641 (hereinafter referred to as the prior art), relates to a method for water-based urethane fiber coating with excellent water resistance and moisture permeability. More specifically, it is intended to produce a product with excellent functionality, such as water resistance, moisture permeability, and washability, by applying a water-based urethane coating solution, prepared using a water-dispersible polyurethane resin solution and a thickener, to a pre-treated fabric, drying it with hot air, and then curing it.

[0007] However, these conventional technologies had problems such as the inability to add flame retardancy to objects such as fibers, base paper, and films. Prior art literature

[0009] Korean Registered Patent No. 10-0822641 The problem to be solved

[0010] The problem to be solved by the present invention is to have the objective of manufacturing a product with excellent flame retardancy by adding flame retardancy to a material.

[0011] In addition, the present invention has the purpose of being able to produce a product with excellent ease of manufacture and durability.

[0012] The problems of the present invention are not limited to those mentioned above, and other unmentioned technical problems will be clearly understood by those skilled in the art from the description below. means of solving the problem

[0014] The present invention for achieving the above objective comprises the steps of: preparing a coating agent by mixing a resin additive and an aerogel (S10); coating the coating agent onto a target object (S20); and maintaining the target object coated with the coating agent at a heat treatment temperature for a predetermined time (S30).

[0015] Additionally, the above step (S10) may be a step of preparing the coating agent by mixing the resin additive, the aerogel, and the curing agent.

[0016] Additionally, the above step (S10) may be a step of preparing the coating agent by mixing the resin additive, the aerogel, the curing agent, and the solvent compound.

[0017] Includes a flame-retardant product manufactured by a method for manufacturing a flame-retardant product. Effects of the invention

[0019] According to an embodiment of the present invention, flame retardancy is added to a material to produce a product with excellent flame retardancy.

[0020] In addition, the present invention has the effect of being able to produce a product with excellent ease of manufacture and durability. Brief explanation of the drawing

[0022] FIG. 1 is a schematic flowchart for explaining a method for manufacturing a flame-retardant product according to one embodiment of the present invention. FIG. 2 is a drawing for explaining additional embodiments of the present invention. Specific details for implementing the invention

[0023] The advantages and features of the present invention and the methods for achieving them will become clear by referring to the embodiments described below in detail together with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below but may be implemented in various different forms. These embodiments are provided merely to ensure that the disclosure of the present invention is complete and to fully inform those skilled in the art of the scope of the invention, and the present invention is defined only by the scope of the claims.

[0024] Throughout this specification, when a part is described as being "connected" to another part, this includes not only cases where they are "directly connected," but also cases where they are "indirectly connected" with other elements interposed between them.

[0026] FIG. 1 is a schematic flowchart for explaining a method for manufacturing a flame-retardant product according to one embodiment of the present invention.

[0027] A method for manufacturing a flame-retardant product according to one embodiment of the present invention is a coating method for adding flame retardancy to a target object such as base paper, film, or fiber (e.g., polyester, nylon, PET film, OPP film, etc.), and for convenience of explanation, it will be referred to as "the method" below.

[0028] Referring to FIG. 1, the present method may include a mixing step (S10), a coating step (S20), and a heat treatment step (S30).

[0029] The mixing step (S10) is a step of manufacturing a coating agent by mixing a resin additive and an aerogel.

[0030] The mixing step (S10) can be performed by a stirring device (1). The stirring device (1) will be described in more detail in the following description.

[0031] The above aerogel is one of the key materials for maximizing flame-retardant performance in the above object, and due to its porous structure, it has extremely low thermal conductivity, so it can perform the role of blocking heat from spreading even if it catches fire.

[0032] Aerogel is lightweight and has excellent thermal insulation properties, so it can prevent flame-retardant products manufactured by this method from becoming heavy or stiff.

[0033] The above-mentioned aerogel may be exemplarily silica aerogel, polymer aerogel, carbon aerogel, etc., but is not limited to the above-mentioned aerogel, and various aerogels may be used as long as they can add flame retardancy to the object.

[0034] The above silica aerogel is the most common form and has the effect of blocking the spread of heat and fire due to its porous structure.

[0035] The above polymer aerogel is lightweight and highly flexible, making it suitable for fabric coatings requiring flame retardancy.

[0036] Carbon aerogel is conductive, making it suitable for protecting electronic components, and it has excellent heat resistance.

[0037] The above resin additive serves to uniformly coat the coating agent generated in the mixing step (S10) onto the surface of the object and to disperse flame-retardant components (such as aerogel).

[0038] In other words, resin additives can act as a medium to enable aerogels, etc., to effectively bind to the target object.

[0039] Resin additives perform the function of enhancing flame-retardant properties while maintaining the mechanical strength of the coating agent.

[0040] For example, resin additives such as epoxy resin, polyimide, phenolic resin, and fluoropolymer may be used.

[0041] Epoxy resins have excellent heat resistance and high chemical stability, while polyimides provide high heat resistance and mechanical strength and are also used in the aviation and electronics industries. Phenolic resins have excellent flame retardancy and form a carbonized layer to prevent flame spread, and fluoropolymers have the advantage of excellent chemical resistance and strong flame retardant properties.

[0042] It goes without saying that various materials other than those described above may be used as the resin additives.

[0043] The above mixing step (S10) may be a step of preparing the coating agent by mixing the resin additive, the aerogel, and the curing agent.

[0044] The above curing agent promotes the bonding of the resin additive and the aerogel and ultimately increases durability, and examples of such agents may be used include melamine-based compounds, phenol-formaldehyde, isocyanates, and phosphasein compounds.

[0045] The above-mentioned curing agent induces a chemical reaction to firmly bond the resin additive and the flame-retardant material (aerogel) to the surface of the object, helps the coating agent adhere more stably to the object during the heat treatment process described later, increases the mechanical strength of the flame-retardant product manufactured by this method, and prevents it from being easily damaged by external impact or friction.

[0046] Melamine-based curing agents enhance flame retardancy and prevent fire spread by reacting with nitrogen to release non-combustible gas, while phenol-formaldehyde is a thermosetting resin that provides high flame retardancy and fire resistance.

[0047] In addition, isocyanates are used as curing agents for polyurethanes and other resins to increase heat resistance and mechanical strength, and phosphase compounds are used as phosphorus (P)-based flame retardants to suppress flame spread and provide stable flame retardancy.

[0048] It goes without saying that various materials other than those mentioned above can be used as curing agents.

[0049] The above mixing step (S10) may be a step of preparing the coating agent by mixing the resin additive, the aerogel, the curing agent, and the solvent compound.

[0050] Solvent compounds play a role in uniformly mixing flame-retardant additives (resins, aerogels, curing agents, etc.) to make them easy to coat onto fibers.

[0051] In addition, by controlling the viscosity during the manufacturing process, it helps enable uniform application to the surface of the target object.

[0052] In addition, it volatilizes in the subsequent coating step (S20) and does not remain in the final product, but it can play an important role in optimizing flame retardant performance and mechanical properties.

[0053] Examples of solvent compounds that may be used include N-methyl-2-pyrrolidone (NMP), dimethylformamide (DMF), acetone, and toluene.

[0054] N-Methyl-2-Pyrrolidone (NMP) is used to dissolve polymer resins and is suitable for heat-resistant coatings.

[0055] Dimethylformamide (DMF) is used to dissolve polymers and flame retardants, enabling uniform coating.

[0056] Acetone evaporates quickly, dries rapidly, and is effective for dissolving resins and flame retardants.

[0057] Toluene has strong dissolving power and can be used to stably disperse polymers and flame retardants.

[0058] The substances used as solvent compounds are not limited to the substances described above, and various other substances may be used.

[0059] Referring to FIG. 1, the coating step (S20) is a step of coating the surface of the object with the coating agent prepared in the mixing step (S10).

[0060] The coating agent produced in the mixing step (S10) can be applied to various substrates such as fibers, base paper, and films, and the coating agent can be coated onto an object using a coating method suitable for each material.

[0061] For example, the coating step (S20) can be performed by various known methods such as known dip coating, spray coating, roll coating, padding coating, etc.

[0062] The heat treatment step (S30) may be a step of maintaining the object (intermediate product) coated with the coating agent at a heat treatment temperature for a predetermined time (heat treatment temperature).

[0063] The above intermediate product can be manufactured into a flame-retardant product when the above heat treatment step (S30) is performed.

[0064] For example, the heat treatment temperature may be 120 to 380°C, and the predetermined time may be 1 to 6 hours.

[0065] The above heat treatment temperature and heat treatment time (the above predetermined time) can be determined by the components of the object (base paper, film, fiber, etc.) and the components of the coating agent.

[0066] The above heat treatment step (S30) can be performed by various known heat treatment devices, such as a conveyor-type hot air oven, a batch-type oven, an IR curing oven, a roll-to-roll heat treatment system, and a vacuum oven.

[0067] Through the above heat treatment step (S30), the strength of the coating layer can be increased and physical / chemical safety can be ensured.

[0068] In addition, by activating the flame-retardant additive (coating agent), effective flame-retardant performance can be achieved in the event of a fire. Furthermore, the aforementioned solvent chemicals can be removed to form a uniform coating layer and improve durability. Additionally, the adhesion between the object and the coating agent can be strengthened to ensure that flame-retardant performance is maintained over the long term.

[0069] Referring to FIG. 1, the present method may include an inspection step (S40) for checking the quality by inspecting the flame retardancy and mechanical properties of the flame-retardant product through a conventional inspection device.

[0071] The present invention includes a flame-retardant product manufactured by the above method.

[0072] The flame-retardant product may include an object and a coating agent coated on the surface of the object.

[0073] A flame-retardant product can be manufactured by coating the surface of an object with a coating agent prepared in the mixing step (S10) through the coating step (S20) and heat treating it through the heat treatment step (S30).

[0074] The above mixing step (S10), coating step (S20), and heat treatment step (S30) are replaced with the description above.

[0075] The flame-retardant product manufactured by the present method is coated with a coating agent on its surface, said coating agent being coated on the surface of the object (exemplarily incorporated into the structure of the fiber) and blocking the spread of flames and combustion through a chemical reaction upon combustion.

[0076] Flame-retardant products can be used in special clothing for firefighters, soldiers, etc. (clothing industry), and in vehicle interior materials and safety devices (automotive industry). Additionally, flame-retardant products can be used as internal insulation and exterior materials for electrical products (home appliances), and can also be utilized as building materials requiring fire resistance (building materials).

[0078] FIG. 2 is a drawing for explaining additional embodiments of the present invention.

[0079] Further embodiments of the present invention will be described below.

[0080] As described above, the mixing step (S10) can be performed by a stirring device (1).

[0081] Referring to FIG. 2, the stirring device (1) may include a mixing container (11) with an open upper side.

[0082] The above mixing container (11) can accommodate materials to be mixed during the mixing step.

[0083] The above stirring device (1) may include a cover portion (12) covering the upper opening of the mixing container (11), a stirring shaft (13) inserted into the mixing container (11) through the cover portion (12), a stirring blade (14) protruding from and extending from the stirring shaft (13) and having a zigzag shape, a driving unit (15) (motor) provided on the upper part of the cover portion (12) and connected to the stirring shaft (13) to rotate the stirring shaft (13), an electric resistor (16) (exemplarily a copper wire) embedded in the stirring shaft (13) and the stirring blade (14), and a power supply unit (17) provided on the upper part of the cover portion (12) and electrically connected to the electric resistor (16) to supply power to the electric resistor (16).

[0084] The stirring shaft (13) rotates by the above-mentioned drive unit (15) and the stirring blade (14) can rotate, thereby stirring each component in the mixing tank (11).

[0085] As described above, the electric resistor (16) is embedded in the stirring shaft (13) and the stirring blade (14), and as the power supply unit (17) supplies power, it generates heat (resistive heat) and supplies heat to each component.

[0086] This allows the viscosity of the coating agent components to decrease, thereby further improving mixability.

[0087] At this time, the stirring shaft (13) and the stirring blade (14) are inserted into the inner side of the mixing container (11) described above to effectively supply heat to each component of the mixing step (S10), thereby improving heat transfer efficiency and thus improving power efficiency.

[0088] In particular, the stirring blade (14) is shaped like a zigzag so that the contact area between the components and the stirring blade (14) is improved, allowing heat exchange to be performed effectively.

[0089] Meanwhile, the stirring device (1) may include a fitting groove (11h) formed from the top to the bottom of the mixing container (11).

[0090] At this time, the cover portion (12) may include a top plate (121) covering the upper opening of the mixing container (11) and a fitting protrusion (122) protruding downward from the lower circumference of the top plate (121) so as to be inserted into the fitting groove.

[0091] Through this, the cover part (12) and the mixing container (11) can be joined together.

[0092] The cover portion (12) may include an outer groove (123) that is formed by being recessed upward from the lower perimeter side of the top plate (121) and positioned further outward than the fitting protrusion (122).

[0093] Here, the inner side refers to the inner space side of the mixing container (11) when the housing including the mixing container (11) and the cover part (12) is viewed in a planar view, and the outer side refers to the outer side, and this will be applied in the following description.

[0094] That is, the insertion protrusion (122) can be positioned closer to the center side of the top plate (121) when viewed in a planar view than the outer groove (123).

[0095] The cover portion (12) may include a shielding plate (124) having a height corresponding to the side of the mixing container (11) and having its upper end inserted into the outer groove (123).

[0096] The protective plate (124) is configured to surround the side of the mixing container (11) to protect the mixing container (11) from the outside.

[0097] The cover portion (12) may include an insulating material (129) (e.g., glass wool) provided on the inner surface of the cover plate (124) and disposed between the cover plate (124) and the side portion.

[0098] More specifically, the cover portion (12) may include an installation groove (128) formed by being recessed outward from the inner surface of the cover plate (124), and the insulating material (129) may be installed by being inserted into the installation groove (128).

[0099] As the above stirring blade (14) rotates, the cover part (12) and the mixing container (11) may shake, and the insulating material (129) is placed between the cover plate (124) and the side so as to absorb and disperse the impact on the side of the cover plate (124) and the mixing container (11).

[0100] In particular, the insulating material (129) surrounds the side to prevent the heat generated by the electric resistor (126) from being transferred to the outside of the stirring device (1).

[0101] Meanwhile, as each component is rotated and mixed on the stirring blade (14) in the mixing container (11), contents may also adhere to the lower part of the top plate (121), and in order to maintain cleanliness, the top plate (121) and the mixing container (11) need to be washed after this method.

[0102] However, the above-mentioned insulation material (129) is difficult to clean with water, and its durability decreases when in contact with water. Unlike the shielding plate (124), it absorbs water, making it difficult to evaporate, and can corrode the shielding plate (129) and its side, which are formed of metal.

[0103] Therefore, the cover plate (124) and the top plate (121), on which the insulating material (129) is provided on the inner surface, need to be detachably connected.

[0104] The cover portion (12) may include a communication hole (125) formed from the circumferential surface (thickness surface) of the top plate to the outer groove (123), a nut member (126) provided on the circumferential surface of the top plate (121) and communicating with the communication hole (125), and a bolt member (127) that is screw-fastened to the nut member (126), penetrates the communication hole (125), and presses the cover plate (124) inserted into the outer groove (123).

[0105] The above communication hole (125) can be in communication with the above outer groove (123).

[0106] The above outer groove (123) may include an inner portion extending downward from the inner end of the groove bottom and an outer portion extending downward from the outer end of the groove bottom. The above communication hole (125) may be formed from the outer portion to the thickness surface.

[0107] The bolt member (127) can press the upper portion of the cover plate (124) inserted into the outer groove (123) toward the inner portion to combine the top plate (121) and the cover plate (124), and when the bolt member (127) moves outward to release the pressure on the cover plate (124), the cover plate (124) can be separated from the top plate (121).

[0108] Therefore, only the top plate (121) can be washed separately, and the batter liquid can be manufactured more cleanly in this method. At the same time, contact between the shielding plate (124) and the insulation material (129) and moisture can be prevented, thereby preventing a decrease in durability.

[0109] Referring to FIG. 2, the stirring device (1) may include an elastic pad (120) placed in the fitting groove (11h).

[0110] Additionally, the stirring device (1) may include a screw protrusion protruding upward from the upper part of the fitting protrusion (122), and a detachable coupling means formed upward from the lower part of the top plate (121) so that the screw protrusion is inserted, and including a screw groove that is screw-fastened to the screw protrusion.

[0112] Although embodiments of the present invention have been described above with reference to the attached drawings, those skilled in the art will understand that the present invention may be implemented in other specific forms without changing the technical concept or essential features thereof. Therefore, the embodiments described above should be understood as illustrative in all respects and not restrictive. Explanation of the symbols

[0114] 1: Stirring device

Claims

Claim 1 A method for manufacturing a flame-retardant product characterized by comprising: a step of preparing a coating agent by mixing a resin additive and an aerogel (S10); a step of coating the coating agent onto a target object (S20); and a heat treatment step (S30) of maintaining the target object coated with the coating agent at a heat treatment temperature for a predetermined time. Claim 2 A method for manufacturing a flame-retardant product according to claim 1, wherein the step (S10) is a step of mixing the resin additive, the aerogel, and the curing agent to produce the coating agent. Claim 3 A method for manufacturing a flame-retardant product according to claim 2, wherein the step (S10) is a step of mixing the resin additive, the aerogel, the curing agent, and the solvent compound to produce the coating agent. Claim 4 In claim 3, the step (S10) is performed by a stirring device, wherein the stirring device comprises: a mixing container; a cover portion covering an upper opening of the mixing container; a stirring shaft inserted into the mixing container by penetrating the cover portion; a stirring blade extending from the stirring shaft and having a zigzag shape; a driving unit provided on the upper part of the cover portion and connected to the stirring shaft and rotating the stirring shaft; an electric resistor embedded in the stirring shaft and the stirring blade; and a power supply unit provided on the upper part of the cover portion and connected to the electric resistor to supply power, wherein the stirring device further comprises a fitting groove formed from the upper part of the mixing container downwards, and the cover portion comprises: an upper plate covering an upper opening of the mixing container; a fitting projection provided protruding downwards from the lower perimeter of the upper plate so as to be inserted into and fitted into the fitting groove; an outer groove formed upwards from the lower perimeter of the upper plate and formed outside the fitting projection; and an upper portion inserted into the outer groove and having a height corresponding to the side of the mixing container. A method for manufacturing a flame-retardant product, comprising: a shielding plate; a communication hole formed from the periphery of the top plate to the outer groove; a nut member provided on the periphery of the top plate and communicating with the communication hole; a bolt member screw-fastened to the nut member, penetrating the communication hole and pressing the shielding plate inserted into the outer groove; an installation groove formed on the inner surface of the shielding plate and an insulating material inserted into the installation groove; wherein the stirring device further comprises an elastic pad disposed in the fitting groove; and wherein the stirring device further comprises a detachable coupling means including a screw protrusion protruding upward from the upper part of the fitting protrusion, and a screw groove formed upward from the lower part of the top plate so that the screw protrusion is inserted and screw-fastened to the screw protrusion. Claim 5 A flame-retardant product manufactured by the method for manufacturing a flame-retardant product described in claim 1.

Images