Flame-retardant and non-combustible composition and fire-resistant product comprising the same

Abstract

The present invention relates to a flame-retardant and non-combustible composition capable of stably providing excellent flame retardancy, non-combustibility, and thermal insulation performance by combining a phosphorus-based flame-retardant component and a graphite-based filler in a composite composition comprising an inorganic binder component and an organic binder component, and to a refractory product using the same. The composition according to the present invention can be applied by coating or impregnating the surface or interior of a substrate, fabric, or substrate, and can be utilized in various industrial fields as performance degradation is suppressed even in high-temperature and flame exposure environments.

Description

Technology Field

[0001] The present invention relates to the field of flame-retardant and non-combustible technology, and specifically to a flame-retardant and non-combustible composition capable of providing complex performance such as flame retardancy, thermal insulation, and process stability when applied to various substrates, fabrics, or substrates, and a product applying the same. Background Technology

[0002] As regulations and requirements for fire safety continue to strengthen across industries, the demand for materials with flame-retardant and non-combustible properties is rapidly increasing, particularly in the fields of construction materials, high-power / high-voltage industrial equipment and cables, electrical and electronic components, materials for preventing thermal runaway in secondary batteries, and textile materials. In particular, due to the proliferation of high-density and lightweight structures and composite materials, industrial interest is growing in technologies that can impart flame-retardant performance to existing materials while minimizing degradation of physical properties.

[0003] In line with this trend, various flame-retardant compositions centered on inorganic fillers or phosphorus-based flame retardants have been proposed in the past, and technologies applying them in the form of coatings, impregnation, or lamination have been widely used. Furthermore, recently, attempts have been made to simultaneously improve not only flame-retardant performance but also thermal insulation and structural stability by utilizing micronized carbon-based materials, layered structural materials, and nano-scale fillers.

[0004] However, these conventional technologies have often had limitations in simultaneously satisfying flame-retardant performance, process stability, and diversity of applications. For example, cases have been reported where the excessive use of specific flame-retardant components leads to reduced dispersibility or causes sedimentation and non-uniformity issues during the coating process. Furthermore, since performance variations based on particle size and content conditions have not been systematically established, there is room for improvement in terms of reproducibility and design freedom. Prior art literature

[0005] Republic of Korea Published Patent Application No. 10-2022-0041365 The problem to be solved

[0006] The present invention aims to overcome the limitations of conventional flame-retardant and non-combustible compositions, such as the trade-off between flame-retardant and thermal insulation performance, reduced compositional stability, and lack of process reproducibility, and to provide a flame-retardant and non-combustible composition that is applicable to various substrates and fabrics while comprehensively improving flame retardancy, thermal insulation, and coating stability.

[0007] However, the problems that this invention seeks to solve are not limited to those mentioned above, and other unmentioned problems will be clearly understood by a person skilled in the art from the description below. means of solving the problem

[0008] To achieve the above objectives, the present invention provides a flame-retardant and non-combustible composition comprising: a first mixture comprising an inorganic binder component, a phosphorus-based flame-retardant component, and a surface modifier; and a second mixture comprising an organic binder component, ionized water, and a thickener, wherein, based on 100 parts by weight of the flame-retardant and non-combustible composition, the composition comprises 20 to 40 parts by weight of the inorganic binder component, 10 to 20 parts by weight of the phosphorus-based flame-retardant component, 10 to 20 parts by weight of the surface modifier, 20 to 30 parts by weight of the organic binder component, 1 to 3 parts by weight of the ionized water, and 0.5 to 2 parts by weight of the thickener.

[0009] In one embodiment of the present invention, the first mixture may include a catalytic metal oxide and a foaming agent, and based on 100 parts by weight of the flame-retardant and non-combustible composition, the catalytic metal oxide may be included in an amount of 8 to 14 parts by weight and the foaming agent may be included in an amount of 0.5 to 1.5 parts by weight.

[0010] The above catalytic metal oxide may include one or more selected from the group consisting of zinc oxide (ZnO), aluminum oxide (Al2O3), iron oxide (Fe2O3 or Fe3O4), zirconium oxide (ZrO2), tin oxide (SnO2), cerium oxide (CeO2), molybdenum oxide (MoO3), magnesium oxide (MgO), copper oxide (CuO or Cu2O), antimony oxide (Sb2O3), nickel oxide (NiO), tungsten oxide (WO3), and vanadium oxide (V2O5), and specifically, titanium dioxide (TiO2).

[0011] In one embodiment of the present invention, if the inorganic binder component is included in an amount of less than 20 parts by weight, the bonding strength between the inorganic components may be reduced, which may lower the mechanical stability and durability of the coating layer; if it is included in an amount exceeding 40 parts by weight, the viscosity of the composition may increase excessively, which may lower dispersibility and coating ability, and consequently, a problem may arise in which it is difficult to secure uniform flame retardant and non-combustible performance.

[0012] In one embodiment of the present invention, if the phosphorus-based flame retardant component is included in an amount of less than 10 parts by weight, the supply of phosphorus-based components required for the flame retardant reaction is insufficient, so flame retardant performance and non-combustible performance may not be sufficiently expressed, and if it is included in an amount exceeding 20 parts by weight, the proportion of inorganic components in the composition increases excessively, resulting in reduced dispersibility and reduced uniformity and mechanical stability of the coating layer.

[0013] In one embodiment of the present invention, if the surface modifier is included in an amount of less than 10 parts by weight, the interfacial bonding force between the inorganic component and the flame retardant component and the binder is not sufficiently secured, so dispersion stability and coating uniformity may be reduced, and if it is included in an amount exceeding 20 parts by weight, the viscosity and fluidity of the composition change due to the excessive presence of the surface modifier, so coating stability and mechanical properties may be reduced.

[0014] In one embodiment of the present invention, if the organic binder component is included in an amount of less than 20 parts by weight, the inorganic component and the flame retardant component are not sufficiently bonded and fixed, which may result in a decrease in the adhesion and mechanical stability of the coating layer, and if it is included in an amount exceeding 30 parts by weight, the proportion of the organic component becomes excessive, which may lead to a decrease in flame retardant performance or a decrease in shape stability when exposed to high temperatures. Effects of the invention

[0015] The flame-retardant and non-combustible compositions according to the embodiments of the present invention can stably exhibit excellent flame retardancy and non-combustibility when applied to a substrate or fabric, and can provide excellent thermal insulation performance by effectively suppressing the rise in back surface temperature even under conditions of exposure to high-temperature flames. In addition, the composition according to the embodiments of the present invention has excellent dispersion stability, so sedimentation or layer separation is suppressed even under conditions of prolonged standing, and uniformity of coating thickness is ensured when applied in coating or impregnation processes, thereby improving process reproducibility. Furthermore, the composition according to the embodiments of the present invention exhibits excellent evaluation results in the LOI value, which is a flame retardancy certification indicator, and in the UL-94 combustion test, thereby providing the effect of significantly improved flame retardant performance compared to conventional compositions. Brief explanation of the drawing

[0016] FIG. 1 is an optical microscope image showing the shape and distribution according to particle size (S: average about 150 μm, M: average about 250 μm, L: average about 500 μm) of fine particulate graphite according to one embodiment of the present invention. FIG. 2 is a fire resistance test equipment according to one embodiment of the present invention. FIG. 3 is an image showing the state in which a fire resistance and thermal insulation test is performed according to one embodiment of the present invention. Figure 4 is a temperature graph showing the change in front temperature and back temperature according to the flame exposure time during fire resistance and thermal insulation tests for a sample applied to a standard fabric (#118, XTBS180 glass fabric fiber) for Example 3 (XTBS_EXG, EG(S) 10%) of the present invention. Figure 5 is a photograph showing the condition of a sample after fire resistance and thermal insulation tests, applied to a standard fabric (#118, XTBS180 glass fabric fiber) for Example 3 (XTBS_EXG, EG(S) 10%) of the present invention. Figure 6 is a temperature graph showing the change in front temperature and back temperature according to the flame exposure time during fire resistance and thermal insulation tests for a sample applied to XTBS-220 for Example 3 (XTBS_EXG, EG(S) 10%) of the present invention. FIG. 7 is a temperature graph showing the change in front temperature and back temperature according to the flame exposure time during fire resistance and thermal insulation tests for a sample applied to an ultra-thin, highly flexible glass fabric fiber (#7628) for Example 3 (XTBS_EXG, EG(S) 10%) of the present invention. FIG. 8 is a temperature graph showing the change in front temperature and back temperature according to flame exposure time during fire resistance and thermal insulation tests for a sample applied to an ultra-thin, highly flexible glass fabric fiber that has been post-treated (silane) for Example 3 (XTBS_EXG, EG(S) 10%) of the present invention. FIG. 9 is a temperature graph showing the change in front temperature and back temperature according to the flame exposure time during fire resistance and thermal insulation tests for a sample applied to glass fabric fiber (Beihai fabric) for Example 3 (XTBS_EXG, EG(S) 10%) of the present invention. Specific details for implementing the invention

[0017] The first aspect of the present invention provides a flame-retardant and non-combustible composition comprising: a first mixture comprising an inorganic binder component, a phosphorus-based flame-retardant component, and a surface modifier; and a second mixture comprising an organic binder component, ionized water, and a thickener, wherein, based on 100 parts by weight of the flame-retardant and non-combustible composition, the composition comprises 20 to 40 parts by weight of the inorganic binder component, 10 to 20 parts by weight of the phosphorus-based flame-retardant component, 10 to 20 parts by weight of the surface modifier, 20 to 30 parts by weight of the organic binder component, 1 to 3 parts by weight of the ionized water, and 0.5 to 2 parts by weight of the thickener.

[0018] In one embodiment of the present invention, the inorganic binder component can serve to stably bind the phosphorus-based flame retardant component and the inorganic filler and to ensure the mechanical stability of the coating layer or impregnation layer, and the phosphorus-based flame retardant component can act as a key component to exhibit flame retardant and non-combustible performance by inducing the formation of a carbonized layer and a phosphorus-based flame retardant reaction upon exposure to high temperatures. Additionally, the surface modifier can serve to improve the dispersion stability and coating uniformity of the composition by enhancing the interfacial affinity between the inorganic binder component, the phosphorus-based flame retardant component, and other inorganic components. The organic binder component can fix the inorganic component to the surface or interior of the substrate and provide adhesion and flexibility to the coating layer or impregnation layer, and the ionized water can contribute to maintaining dispersion stability during long-term storage by minimizing interference between ions within the composition. The thickener can serve to improve the uniformity of coating thickness and process reproducibility during the coating process by controlling the viscosity of the composition and simultaneously suppressing the sedimentation of the inorganic component and the flame retardant component. In addition, the catalytic metal oxide can act as an inorganic filler to assist in the heat insulation effect upon exposure to high temperatures, while simultaneously maintaining the color stability and surface quality of the coating or impregnation layer. The foaming agent can suppress bubbles generated during the mixing and stirring process, thereby improving the dispersion stability of the composition and the reproducibility of the coating process.

[0019] In one embodiment of the present invention, the inorganic binder component may be a styrene-acrylic copolymer aqueous emulsion that has excellent handling properties in terms of mixing stability with the inorganic component and forming a coating layer. In addition, the phosphorus-based flame retardant component may be a phosphate-based component capable of inducing the formation of a carbonized layer through a phosphorus-based flame retardant reaction upon exposure to high temperature, and may include one or more selected from the group consisting of melamine phosphate, melamine pyrophosphate, melamine polyphosphate, aluminum phosphate, magnesium phosphate, calcium phosphate, guanidine phosphate, triphenyl phosphate, tricresyl phosphate, resorcinol bis(diphenyl phosphate), and bisphenol A bis(diphenyl phosphate); specifically, it may be ammonium polyphosphate. As the above organic binder component, an acrylic aqueous resin solution may be used to stably fix the inorganic component and the flame retardant component to the surface or interior of the substrate and to ensure the adhesion and flexibility of the coating layer or impregnation layer.

[0020] In one embodiment of the present invention, the flame-retardant and non-combustible composition further comprises a graphite-based filler, and the graphite-based filler may be added in an amount of 5 to 20 parts by weight per 100 parts by weight of the flame-retardant and non-combustible composition.

[0021] The graphite-based filler described above provides a heat-blocking effect and a heat diffusion inhibition effect based on its layered structure upon exposure to high temperatures, and at the same time, by reinforcing the structural stability of the carbonized layer formed by the phosphorus-based flame-retardant component, it can contribute to the continuous manifestation of flame-retardant and thermal insulation performance. In addition, the graphite-based filler can effectively delay the transfer of heat from flames or high temperatures to the rear by complicating the heat transfer path through the anisotropy of the heat conduction direction and the exfoliated layered structure.

[0022] If the graphite-based filler is added in an amount of less than 5 parts by weight, the improvement effect on flame retardant and thermal insulation performance is not sufficiently manifested, and the flame retardant performance may remain at the basic level of inorganic binder and phosphorus-based flame retardant component. On the other hand, if the graphite-based filler is added in an amount exceeding 20 parts by weight, the dispersion stability and coating uniformity of the composition may be reduced, or the mechanical stability and process reproducibility of the coating layer may be reduced.

[0023] In one embodiment of the present invention, the graphite-based filler may include particulate graphite (expandable graphite, EG), graphene nanoplates, or super graphite.

[0024] In one embodiment of the present invention, the particle diameter of the fine graphite is 10 μm to 250 μm, the thickness of the graphene nanoplate is 50 nm to 100 nm, and the particle diameter of the super graphite may be 1 μm or less. If the particle diameter of the fine graphite exceeds 250 μm, dispersibility within the composition may be reduced, making it difficult to achieve uniform mixing with the inorganic binder and the phosphorus-based flame retardant component, and consequently, flame retardant and thermal insulation performance may be locally unevenly expressed within the coating layer or impregnation layer. Furthermore, if the particle size is excessively large, there is a risk that the coating stability and surface quality of the composition may be reduced, or that process reproducibility may be reduced.

[0025] Specifically, the particle diameter of the fine particulate graphite may be 10 μm to 200 μm, 10 μm to 150 μm, 30 μm to 250 μm, 30 μm to 200 μm, 30 μm to 150 μm, 50 μm to 250 μm, 50 μm to 200 μm, 50 μm to 150 μm, 100 μm to 250 μm, 100 μm to 200 μm, 100 μm to 150 μm, 120 μm to 250 μm, 120 μm to 200 μm, and 120 μm to 150 μm.

[0026] In one embodiment of the present invention, the first mixture and the second mixture may be manufactured separately, taking into account different component combinations and functional roles. Specifically, the first mixture is intended to primarily secure dispersion stability and interfacial bonding strength between the inorganic and flame-retardant components by including an inorganic binder component, a phosphorus-based flame-retardant component, a surface modifier, a catalytic metal oxide, and a foaming agent, while the second mixture is intended to precisely control the viscosity, fluidity, and applicability of the composition by including an organic binder component, ionized water, and a thickener. If these components are mixed simultaneously in a single mixing step, local aggregation of the phosphorus-based flame-retardant component or the inorganic component, abrupt changes in viscosity, or non-uniform dispersion may occur, which may lead to a decrease in the applicability and reproducibility of the flame-retardant performance of the composition. Accordingly, by preparing the first mixture and the second mixture separately and then mixing them, the dispersion stability of the inorganic component and the applicability and adhesion strength provided by the organic component can be simultaneously and stably secured.

[0027] In one embodiment of the present invention, the inorganic binder component, the phosphorus-based flame retardant component, and the graphite-based filler do not function independently of each other, but interact upon exposure to high temperatures to produce a combined flame retardant and thermal insulation effect. Specifically, the carbonized layer formed by the phosphorus-based flame retardant component is structurally reinforced by the layered structure of the graphite-based filler, and the inorganic binder component stably supports the carbonized layer and the filler structure, thereby allowing flame retardant and non-combustible performance to be maintained for a long time even under high temperature conditions.

[0028] A flame-retardant and non-combustible composition according to one embodiment of the present invention may be applied to fabrics, fibers, films, sheets, or substrates, and may be applied using gravure coating, comma coating, squeegee coating, or impregnation coating.

[0029] The above gravure coating can be performed using a direct gravure method or a micro-gravure method. The direct gravure method transfers the coating liquid through contact between a backup roll and a gravure roll, making it suitable for high-speed production. The micro-gravure method allows for more uniform and precise application of the coating liquid by miniaturizing the roll radius to minimize the contact area between the substrate and the coating roll. Additionally, comma coating allows for precise control of the coating thickness by adjusting the gap between the comma roll and the substrate, while squeegee coating allows for thin and uniform application of the coating liquid to the substrate using a squeegee, while simultaneously improving penetration into the substrate. Furthermore, impregnation coating is a method in which the substrate is immersed in the coating liquid to allow the liquid to penetrate into the pores and crevices of the substrate, thereby providing flame-retardant and non-combustible performance not only on the surface of the substrate but also inside.

[0031] A second aspect of the present invention provides a flame-retardant and non-combustible fire-resistant product comprising any one selected from a film, a sheet, a pad, or a fire-resistant composite, wherein the flame-retardant and non-combustible composition according to the first aspect of the present invention is formed by coating or impregnating the surface or interior of a substrate, fabric, or substrate.

[0032] In one embodiment of the present invention, the flame-retardant and non-combustible refractory product may be manufactured by the flame-retardant and non-combustible composition forming a coating layer on the surface of a substrate, fabric, or base, or by penetrating into the interior of the substrate to form an impregnation layer. Accordingly, the flame-retardant and non-combustible refractory product can reliably impart flame-retardant and non-combustible performance not only to the surface of the substrate but also throughout its internal structure.

[0033] In one embodiment of the present invention, the flame-retardant and non-combustible refractory product may be formed as a single-layer structure or as a laminated structure including multiple layers, and, if necessary, may have a composite structure in which a layer to which a flame-retardant and non-combustible composition is applied is laminated with another functional layer. Through such a structure, mechanical strength, heat resistance, and shape stability can be simultaneously secured.

[0034] In one embodiment of the present invention, the flame-retardant and non-combustible refractory product can maintain its flame-retardant and non-combustible performance for a long time by suppressing peeling, cracking, or performance degradation of the coating layer or impregnation layer even in environments exposed to high temperatures, flames, or heat sources. In particular, the structure formed by the interaction between the inorganic binder component and the phosphorus-based flame-retardant component included in the flame-retardant and non-combustible composition can be stably maintained even under high temperature conditions.

[0035] In one embodiment of the present invention, the flame-retardant and non-combustible refractory product can be applied to various substrates such as insulating materials, industrial fibers, glass fibers, silica-based substrates, carbon sheets, tapes, or films, and accordingly can be utilized in various industrial fields such as high-power / high-voltage industrial equipment and cables, materials for preventing thermal runaway in secondary batteries, electrical and electronic components, building interior materials, industrial protective materials, heat-resistant members, or flame-retardant structural materials.

[0037] Hereinafter, the structure of the present invention and the resulting effects are to be explained in more detail through specific embodiments and comparative examples. However, these embodiments are intended to explain the present invention more specifically, and the scope of the present invention is not limited to these embodiments.

[0039] [Example]

[0040] Example 1. Preparation of flame-retardant and non-combustible fire-retardant liquids

[0041] [Table 1]

[0042]

[0043] (1) Preparation of the first mixture

[0044] 36 g of an aqueous emulsion of a styrene-acrylic copolymer as an inorganic binder was mixed with 18 g of a phosphate-based component as a flame retardant. Subsequently, 11 g of a surface modifier (silicone-based coupling agent) was added to improve the dispersibility and interfacial bonding strength of the flame retardant and inorganic components. Then, 10 g of a catalytic metal oxide was added to reinforce flame retardant performance and provide color stability, and 1 g of a defoaming agent was added to suppress bubbles that may occur during the stirring process. After mixing the above components, a first mixture was prepared by uniformly stirring using a stirrer for at least one hour.

[0045] (2) Preparation of the second mixture

[0046] 2 g of deionized water was added to 21 g of an acrylic aqueous resin solution as an organic binder to control viscosity and stabilize the composition. Subsequently, 1 g of hydroxyethyl cellulose (HEC) was added as a thickener to control the viscosity of the composition. The above components were mixed for more than 1 hour under low-speed stirring conditions to prepare a second mixture with uniformly controlled viscosity.

[0047] (3) Mixing of the first mixture and the second mixture

[0048] A flame-retardant and non-combustible fire-retardant liquid was prepared by slowly adding a second mixture to the first mixture prepared above while continuously stirring, in which inorganic and organic components were uniformly dispersed.

[0049] Examples 2 to 9. Additional addition of fine graphite particles

[0050] [Table 2]

[0051]

[0052] Examples 2 to 9 were prepared by additionally adding fine graphite to Example 1. The fine graphite was prepared through a stripping and fine grinding process using a ball mill, and was used with S (average 150 μm) and M (average 250 μm) depending on the average particle diameter (see FIG. 1). It was prepared by additionally adding 5 g, 10 g, 15 g, and 20 g to 100 g of the composition of Example 1.

[0054] Comparative Examples 1 to 8. Change in weight of each component

[0055] [Table 3]

[0056]

[0057] Comparative Examples 1 to 8 were prepared by adding an inorganic binder, a flame retardant, a surface modifier, and an organic binder, respectively, in excess or in insufficient amounts, according to Table 3 above.

[0058] Comparative Examples 9 to 12. Addition of trace or excess amount of fine graphite

[0059] [Table 4]

[0060]

[0061] Comparative Examples 9 to 12 were prepared by additionally adding 2 g and 25 g of fine particulate graphite (S and M), respectively, to the composition of Example 1, based on 100 g of the composition of Example 1.

[0062] Comparative Examples 13 to 15. Addition of L-size (500 μm) fine graphite particles

[0063] [Table 5]

[0064]

[0065] Comparative Examples 13 to 15 were prepared by additionally adding 2 g, 5 g, and 10 g, respectively, of fine graphite (see FIG. 1) having an average particle diameter of L (500 μm) to the composition of Example 1, based on 100 g of the composition of Example 1.

[0067] Experimental Example 1. Fire Resistance and Thermal Insulation Test

[0068] (1) Experimental method

[0069] Fire resistance and thermal insulation performance were evaluated for samples prepared according to the above examples and comparative examples. The fire resistance and thermal insulation tests were performed using the XCM FRT 1.0 fire resistance test equipment, which is capable of applying a flame of approximately 900°C to 1,000°C under direct flame conditions without time limitations (see Figures 2 and 3). As a test method, after attaching the sample to a SUS plate, thermocouples were installed on the front side, which is directly exposed to the flame, and on the rear side, which is not exposed, respectively, to measure the changes in the front and rear temperatures in real time as the flame exposure time elapsed. A standard fabric (#118, XTBS180 glass fabric fiber) was used.

[0070] The above flame retardant was applied to the existing fabric using a microgravure coating method. The samples coated with the flame retardant subsequently underwent a drying process to produce test specimens, and the thickness of the test specimens was adjusted to be within the range of approximately 0.2 mm to 0.3 mm, depending on the process conditions and the type of fabric. Fire resistance and thermal insulation performance evaluations were performed based on the following criteria: average front temperature (°C), average back temperature (°C), and thermal insulation (temperature difference between the front and back temperatures, °C).

[0071] (2) Experimental results

[0072] (2-1) Examples and Comparative Examples

[0073] [Table 6]

[0074]

[0075] In Examples 1 to 9, the average front temperature was stably maintained at around 900°C, and in Examples 2 to 9, the average back temperature was further reduced, showing a tendency for significantly improved thermal insulation. In particular, the best thermal insulation characteristics were confirmed in Example 3, which applied 10% EG(S). On the other hand, in Comparative Examples 1 to 8, the average back temperature was generally high, resulting in limited thermal insulation, and in Comparative Examples 9 to 15, the improvement effect on thermal insulation performance was also limited.

[0076] (2-2) Fabric extension verification for Example 3

[0077] [Table 7]

[0078]

[0079] As a result of applying the same EG(S) 10% (Example 3), which is the best condition in the results of 2-1 above, and changing the fabric type to XTBS-220, ultra-thin high-flexibility glass fabric fiber (#7628), silane-treated ultra-thin high-flexibility glass fabric fiber, and glass fabric fiber (Beihai fabric), it was confirmed that even with different fabrics, the average front temperature was maintained at around 900℃ while the average back temperature was controlled to be low, thereby stably ensuring thermal insulation performance, and overall, a tendency was observed to maintain thermal insulation performance of 630℃ or higher.

[0081] Experimental Example 2. Dispersibility and Coating Stability Test

[0082] (1) Experimental method

[0083] The dispersibility and coating stability of the flame retardant solution prepared according to the above examples and comparative examples were evaluated. The dispersibility stability of the flame retardant solution was evaluated by observing whether sedimentation occurred after being left at room temperature (25°C) for a certain period of time, and the coating stability was evaluated by applying a micro-gravure coating method under the same process conditions. Coating was performed under the same roll speed and coating amount conditions, and specimens were prepared after a drying process following coating. A reference fabric (#118, XTBS180 glass fabric fiber) was used as the material. Sedimentation was evaluated by visually observing whether sedimentation or layer separation occurred in the composition while the flame retardant solution was standing after preparation; coating uniformity was evaluated based on thickness deviation (μm) by measuring the thickness of the coating layer formed after coating at multiple points; and surface defects were evaluated by visually checking for the occurrence of pinholes, streaks, and aggregation traces on the surface of the coating layer.

[0084] (2) Experimental results

[0085] [Table 8]

[0086]

[0087] Examples 1 to 9 all had a Dispersion Stability Index (DSI) of 3, indicating that no sedimentation was observed even under standing conditions, and the coating thickness deviation was in the range of ±3 μm to ±6 μm, thereby securing overall excellent coating stability. In particular, Example 3 (XTBS-EXG, EG(S) 10%) maintained a Dispersion Stability Index of 3 while exhibiting the smallest coating thickness deviation of ±3 μm, and the coating uniformity index was also evaluated as the highest grade, demonstrating the best characteristics in terms of process reproducibility and coating stability. On the other hand, in the comparative examples, the Dispersion Stability Index decreased to a level of 0 to 2, and the coating thickness deviation also showed a tendency to increase to ±8 μm or more.

[0089] Experimental Example 3. Evaluation of Flame Retardancy Certification Indicators (LOI and UL-94)

[0090] (1) Experimental method

[0091] Flame retardant performance was evaluated for samples prepared according to the above examples and comparative examples. The LOI (Oxygen Index) test was performed according to ASTM D2863 standards, and the UL-94 vertical combustion test was performed according to UL-94 standards. The tests were conducted using specimens of the same thickness range (approx. 0.25 mm), and the fabric used was a standard fabric (#118, XTBS180 glass fabric fiber).

[0092] Flame retardant performance evaluation was performed based on the following criteria: the LOI value (%) is a value that measures the minimum oxygen concentration required for the sample to continue burning, and a higher value indicates better flame retardancy, and the UL-94 vertical combustion rating was evaluated by classifying it into V-0, V-1, V-2, or Fail based on the burning time under specified conditions, whether self-extinguishing occurs, and whether melt drop occurs.

[0093] (2) Experimental results

[0094] [Table 9]

[0095]

[0096] Examples 1 to 9 showed a tendency for LOI values ​​to increase and UL-94 grades to improve depending on the EG conditions, and in particular, the best flame retardant performance was confirmed in Example 3, which applied 10% EG(S). On the other hand, the comparative examples showed a tendency for LOI values ​​to be relatively low and UL-94 grades to remain at an inferior level.

[0098] The various embodiments described above may be embodied in other specific forms without departing from the technical idea and essential features. Accordingly, the above detailed description should not be interpreted restrictively in all respects but should be considered exemplary. The scope of the various embodiments shall be determined by a reasonable interpretation of the appended claims, and all modifications within the equivalent scope of the various embodiments are included within the scope of the various embodiments. Furthermore, embodiments may be constructed by combining claims that do not have an explicit citation relationship in the patent claims, or they may be included as new claims through amendments made after filing.

Claims

Claim 1 A first mixture comprising an inorganic binder component, a phosphorus-based flame retardant component, and a surface modifier; A flame-retardant and non-combustible composition comprising a second mixture including an organic binder component, ionized water, and a thickener, wherein, based on 100 parts by weight of the flame-retardant and non-combustible composition, the composition comprises 20 to 40 parts by weight of the inorganic binder component, 10 to 20 parts by weight of the phosphorus-based flame-retardant component, 10 to 20 parts by weight of the surface modifier, 20 to 30 parts by weight of the organic binder component, 1 to 3 parts by weight of the ionized water, and 0.5 to 2 parts by weight of the thickener; wherein the flame-retardant and non-combustible composition further comprises a graphite-based filler, wherein the graphite-based filler is added in an amount of 5 to 20 parts by weight per 100 parts by weight of the flame-retardant and non-combustible composition, wherein the graphite-based filler comprises fine graphite, and the particle diameter of the fine graphite is 10 μm to A flame-retardant and non-combustible composition having a diameter of 250 μm, wherein the first mixture and the second mixture are each manufactured separately and then mixed. Claim 2 delete Claim 3 delete Claim 4 delete Claim 5 A flame-retardant and non-combustible fire-resistant product formed by coating or impregnating the surface or interior of a substrate, fabric, or base material with a flame-retardant and non-combustible composition according to claim 1, and comprising any one selected from a film, sheet, pad, or fire-resistant composite material.

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