Skin material of insulating material, insulating material, and method for manufacturing insulating material

Abstract

Provided are a skin material of an insulating material, an insulating material comprising the skin material, and a manufacturing method therefor, the skin material comprising a composite skin material sequentially including a first nonwoven fabric layer, a kraft paper layer, and a second nonwoven fabric layer, wherein the basis weight of the second non-woven fabric layer is 40 g / ㎡ to 60 g / ㎡ and the permeability from the second non-woven fabric layer toward the first non-woven fabric layer in the composite skin layer at 100 Pa is 2 L / min·㎠ to 8 L / min·㎠.

Description

Insulating material, insulating material and method for manufacturing the insulating material

[0001] The present invention relates to a cotton material for insulating material, an insulating material, and a method for manufacturing the insulating material.

[0002]

[0003] When manufacturing thermosetting foam insulation, face sheets are applied to the upper and lower surfaces of the thermosetting foam. The required properties of the face sheets may vary depending on the manufacturing process and intended use of the insulation. Specifically, insulation, such as ceiling or wall insulation, can be constructed using the cast-in-place concrete method. Cast-in-place concrete involves laying insulation in formwork, wiring, pouring concrete, and removing the formwork after curing. The insulation must not delaminate during this process, requiring excellent peel strength. Furthermore, ceiling insulation requires workers to repeatedly walk on the insulation while it is placed on the formwork. Therefore, unlike wall insulation, ceiling insulation requires excellent walking strength to withstand the repeated impact of workers. Furthermore, even higher peel strength is required to prevent delamination between the foam and the face sheets, even in environments where workers repeatedly walk on the insulation. In addition, these days, thicker, high-density foams are increasingly preferred, and even when including such thick foams, the peel strength of the face material to the foam is required to be significantly high so as to exhibit excellent adhesion.

[0004] In addition to the above properties, it is also required that the foam material have excellent properties such as dimensional stability and workability.

[0005]

[0006] An object of the present invention is to provide a face sheet of an insulating material including a composite face sheet that exhibits low air permeability while simultaneously exhibiting remarkably excellent peel strength.

[0007] Another object of the present invention is to provide a face material of an insulating material including a composite face material that exhibits excellent walking strength including a nonwoven layer and exhibits remarkably excellent peel strength along with low air permeability.

[0008] In addition, another object of the present invention is to provide a face material of an insulating material including a composite face material that simultaneously exhibits excellent walking strength, low air permeability, and significantly excellent peel strength, tensile strength, and tear strength.

[0009] In addition, another object of the present invention is to provide an insulating material including a first composite face material having excellent walking strength so as to protect the foam from the repetitive walking work of a worker when installing the insulating material, and a second composite face material of a different type from the first composite face material that does not require walking strength, but is characterized in that deformation such as warping does not occur in the insulating material.

[0010] In addition, another object of the present invention is to provide a method for manufacturing the insulating material including the surface material of the insulating material.

[0011] The objectives of the present invention are not limited to those mentioned above. Other objectives and advantages of the present invention not mentioned above can be understood through the following description and will be more clearly understood through the embodiments of the present invention. Furthermore, it will be readily apparent that the objectives and advantages of the present invention can be realized by the means and combinations thereof set forth in the claims.

[0012]

[0013] One embodiment of the present invention can provide a composite face material sequentially including a first nonwoven fabric layer, a kraft paper layer, and a second nonwoven fabric layer, wherein the second nonwoven fabric layer has a basis weight of 40 g / m2 to 60 g / m2, and at 100 Pa, the air permeability from the second nonwoven fabric layer of the composite face material toward the first nonwoven fabric layer is 2 L / min.㎠ to 8 L / min.㎠.

[0014] Another embodiment according to the present invention may provide an insulating material comprising: a thermosetting foam; a first composite face material attached to one surface of the thermosetting foam; and a second composite face material attached to the other surface of the thermosetting foam, the second composite face material sequentially including a third nonwoven layer, a kraft paper layer, and a metal layer.

[0015] Another embodiment according to the present invention can provide a method for manufacturing an insulating material, comprising the step of discharging a thermosetting resin foam composition between a first composite face material and a second composite face material to foam and cure to form a thermosetting foam, wherein the first composite face material comprises a composite face material sequentially including a first nonwoven fabric layer, a kraft paper layer, and a second nonwoven fabric layer from the outside, wherein the second nonwoven fabric layer has a basis weight of 40 g / m2 to 60 g / m2, and at 100 Pa, the air permeability from the second nonwoven fabric layer of the first composite face material toward the first nonwoven fabric layer is 2 L / min.㎠ to 8 L / min.㎠.

[0016]

[0017] The surface material of the insulating material according to the present invention can exhibit low air permeability while simultaneously exhibiting remarkably excellent peel strength.

[0018] In addition, the surface of the insulating material according to the present invention can exhibit excellent walking strength by including a non-woven layer, and can simultaneously exhibit remarkably excellent peel strength along with low air permeability.

[0019] In addition, the surface material of the insulating material according to the present invention can simultaneously exhibit excellent properties such as tensile strength and tear strength along with the above effects.

[0020] In addition, the insulation material according to the present invention can include a first composite face material having excellent walking strength so as to protect the foam from the repetitive walking work of a worker when installing the insulation material, and a second composite face material of a different type from the first composite face material that does not require walking strength, while preventing deformation such as warping from occurring in the insulation material.

[0021] In addition, the insulation material according to the present invention may include a foam having excellent physical properties such as thermal conductivity by using an eco-friendly foaming agent and using the surface material of the insulation material.

[0022] In addition to the effects described above, specific effects of the present invention are described below while explaining specific details for carrying out the invention.

[0023]

[0024] Figure 1 is a schematic cross-sectional view of a surface of an insulating material according to one embodiment of the present invention.

[0025] Figure 2 is a schematic cross-sectional view of an insulating material according to one embodiment of the present invention.

[0026] Figure 3 (A) shows the surface shape after perforating the kraft layer of the present invention, and (B) shows the surface shape after perforating a PET film using the same method.

[0027] Figure 4 schematically illustrates the punching process of the present invention.

[0028] Figure 5 illustrates a method for measuring walking intensity according to the present invention.

[0029] Figure 6 is a graph measuring the walking strength on the surface of the insulation material.

[0030] Figure 7 is a schematic diagram briefly showing a method for measuring the dimensional stability of the insulating material of the present invention.

[0031] Figure 8 is a schematic diagram briefly showing a specimen for measuring the peel strength of the present invention.

[0032] Figure 9 is a photograph measuring the peel strength of the present invention.

[0033]

[0034] The aforementioned objects, features, and advantages are described in detail below with reference to the accompanying drawings, so that those skilled in the art can easily implement the technical concepts of the present invention. In describing the present invention, detailed descriptions of known technologies related to the present invention will be omitted if they are deemed to unnecessarily obscure the gist of the present invention. Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0035] In this specification, air permeability refers to a value measured under a certain pressure using an air permeability measuring device (IDM Instruments, foam porosity tester) on a specimen cut to 10 cm (W, width) X 10 cm (L, length).

[0036] To clearly illustrate various layers and regions in the drawings, the thicknesses are enlarged. Furthermore, for convenience of explanation, the thicknesses of some layers and regions are exaggerated in the drawings. Throughout the specification, the same reference numerals designate the same components.

[0037] Hereinafter, the phrase "any configuration is placed on (or below)" a component or "on (or below)" a component may mean that any configuration is placed in contact with the upper surface (or lower surface) of said component, and that other configurations may be interposed between said component and any configuration placed on (or below) said component.

[0038] Below, the surface of the insulating material according to some embodiments of the present invention will be described.

[0039]

[0040] In general, insulation materials may have different properties required for the facing depending on the manufacturing process and intended use. Specifically, insulation materials, such as ceiling or wall insulation, can be constructed using the poured concrete method. In the poured concrete method, concrete materials are poured into a formwork, and the formwork may be removed after curing. The insulation material must not peel off during this process, so excellent peel strength is required. Furthermore, ceiling insulation materials are subject to repeated walking by workers while the insulation material is placed on the formwork. Therefore, unlike wall insulation materials, ceiling insulation materials must also have excellent walking strength to withstand the repeated walking of workers. Furthermore, even in environments where the impact of repeated walking by workers is applied, the insulation material must not peel off between the foam and the facing material, so a higher peel strength is required.

[0041] In addition, the insulation material can be manufactured by dispensing a foam composition between the upper and lower face sheets, foaming and curing therebetween, and producing a foam. During the foaming and curing process, heat and gases such as moisture are generated. If the heat and moisture gases thus formed are not properly discharged through the face sheets, the foam cells are likely to be destroyed, the physical properties of the foam, such as thermal conductivity, are reduced, the foam is easily damaged, and the foam is prone to warping. In addition, air pockets may be generated, reducing the peel strength.

[0042] Furthermore, demand for thicker, high-thickness foams is increasing. However, high-thickness foams generate greater internal heat due to the curing reaction at the center of the thickness, and this heat is difficult to dissipate sufficiently to the outside, resulting in excessively high internal temperatures within the foam composition. Consequently, the foam's physical properties deteriorate due to foam bubble rupture, making the foam more susceptible to damage and warping. Furthermore, warping can lead to reduced peel strength, a higher risk of appearance and construction defects, and long-term product shrinkage. Furthermore, if gases such as water vapor generated during the foaming and curing processes are not properly discharged, air pockets can form, further reducing peel strength. Even with thick foams, a significantly high peel strength is required to ensure excellent adhesion. This issue is particularly problematic when manufacturing phenolic foams.

[0043] Accordingly, in order to prevent the above-mentioned problem, the air permeability of the insulation material's surface is increased to allow for the discharge of high-temperature heat and gases generated during the foam formation process.

[0044] However, if the air permeability of the cotton material is increased, the cotton material's surface appearance may become rough, which may lower the marketability, leading to the product being perceived as defective. In addition, if the air permeability is too high, the composition may be excessively impregnated and flow out between the cotton material, contaminating the equipment and soiling the cotton material surface, which may lead to the product being perceived as defective. Furthermore, if the composition is cured while the cotton material has a large impregnated area, the flexibility of the cotton material may be reduced, which may lower the dimensional stability. Furthermore, if the flexibility and dimensional stability of the cotton material are reduced, the cotton material's ability to absorb or compensate for dimensional changes in the foam due to temperature, etc. may be reduced, which may form gaps, thereby lowering the properties of the insulation.

[0045] Accordingly, there is a demand to reduce the air permeability of the cotton sheet to address the above issues. However, reducing the air permeability of the cotton sheet can easily lead to a decrease in peel strength. Furthermore, when manufacturing insulation using cotton sheets with such low air permeability, the foam cells can easily be destroyed, and other foam properties, such as the independent cell ratio, thermal conductivity, compressive strength, and flexural failure load, can easily deteriorate.

[0046]

[0047] According to one embodiment of the present invention, a face sheet of an insulating material includes a composite face sheet sequentially comprising a first nonwoven fabric layer, a kraft paper layer, and a second nonwoven fabric layer, wherein the second nonwoven fabric layer has a basis weight of 40 g / m2 to 60 g / m2, and at 100 Pa, air permeability from the second nonwoven fabric layer of the composite face sheet toward the first nonwoven fabric layer is 2 L / min.㎠ to 8 L / min.㎠. The face sheet of the insulating material can control the degree of impregnation of the foam composition, and thus can exhibit the desired effect. Specifically, it can exhibit low air permeability to improve the appearance quality, while simultaneously exhibiting remarkably excellent peel strength. In addition, it can simultaneously exhibit excellent physical properties such as excellent walking strength, tensile strength, tear strength, and dimensional stability. The face sheet of the insulating material can be used for an insulating material constructed using a pouring concrete method.

[0048] FIG. 1 is a schematic cross-sectional view of a face sheet of an insulating material according to one embodiment of the present invention, showing a composite face sheet (100) sequentially including a first nonwoven fabric layer (11), a kraft paper layer (12), and a second nonwoven fabric layer (13) from the outside. Hereinafter, each component constituting the face sheet of the insulating material will be described as follows.

[0049]

[0050] Specifically, the second non-woven fabric layer of the insulating face material can be attached to a thermosetting foam, and the basis weight of the second non-woven fabric layer can be 40 g / m2 to 60 g / m2. By having a basis weight within the above range, the second non-woven fabric layer can appropriately dissipate high-temperature heat or gas generated during the foam formation process, while appropriately controlling the degree to which the face material is impregnated with the foam composition. In particular, in the case of a high-thickness foam, a relatively long time is required for foaming and curing during the manufacturing process, and the degree of impregnation of the face material with the foam composition can be increased during this process. The face material of the insulating material can solve the above problem by including the second non-woven fabric layer. Thus, the physical properties of the face material, such as tensile strength and tear strength, can be maintained or improved to a certain level or higher, and the air permeability of the face material can be lowered while exhibiting significantly improved peel strength. For example, when the basis weight of the second nonwoven fabric layer is less than the above range, it is easy to dissipate high-temperature heat or gas generated during the foam formation process, but the nonwoven fabric layer is excessively impregnated with the foam composition, so that the adhesive strength is lowered, the tensile strength is not sufficiently improved, and the dimensional stability is not sufficiently improved, which may make it difficult to exhibit the intended performance. In addition, when the basis weight of the second nonwoven fabric layer exceeds the above range, it is difficult to dissipate high-temperature heat or gas such as water vapor generated during the foam formation process, the degree of impregnation of the composition into the nonwoven fabric layer is too low, so that the adhesive strength is lowered, and the dimensional stability is not sufficiently improved, which may make it difficult to exhibit the intended performance.

[0051]

[0052] The second nonwoven fabric layer may be a polypropylene spunbond nonwoven fabric, which is different from a nonwoven fabric containing glass fibers typically included in cotton. The spunbond nonwoven fabric refers to a nonwoven fabric manufactured by a spunbond method, and the spunbond method refers to a method of manufacturing a nonwoven fabric by spinning a raw material and self-adhering it with heat. There is no particular limitation on the type of fiber forming the nonwoven fabric, and fibers of an appropriate material that can secure the desired effect may be applied. For example, the fiber forming the nonwoven fabric may be a synthetic resin fiber. Synthetic resin fibers may include, but are not limited to, polyolefin fibers such as polyethylene fibers or polypropylene fibers, polyester fibers, polyimide fibers, polyamide fibers, and / or polyvinyl chloride fibers. While a nonwoven fabric containing glass fibers typically included in a cotton material exhibits a tear strength of 10 gf to 30 gf, the second nonwoven fabric layer may exhibit a tear strength of 800 gf to 1200 gf. The tear strength may be measured by the method described below.

[0053] The above second nonwoven layer can exhibit a breathability of 60 L / min.㎠ to 150 L / min.㎠ under 50 Pa conditions.

[0054] The thickness of the second nonwoven layer may be 230 ㎛ to 350 ㎛. For example, it may be 230 ㎛ or more, or 290 ㎛ or more, or 340 ㎛ or less, or 350 ㎛ or less.

[0055]

[0056] Nonwoven fabrics are generally susceptible to dimensional changes due to shrinkage and expansion caused by factors such as humidity and heat. Meanwhile, cotton fabrics are subject to moisture from high-temperature and high-humidity foam compositions, and the foam can experience dimensional changes due to heat. Insulating materials must withstand both the high temperatures of summer and the cold temperatures of winter, requiring cotton fabrics to exhibit excellent dimensional stability.

[0057] The face of the above ceiling-mounted insulation material includes a kraft paper layer on top of the second non-woven fabric layer to improve dimensional stability. In general, when the face of the insulation material includes mesh or PET film, it can exhibit better dimensional stability. In addition, mesh or PET film can exhibit better walking strength than kraft paper in terms of securing the walking strength required for the face of the ceiling-mounted insulation material. On the other hand, when the face of the insulation material includes mesh, the air permeability tends to increase, making it difficult to lower the air permeability. In addition, unlike kraft paper, PET film is a polymer material and is vulnerable to heat and can be easily deformed. For example, the thermal conductivity of PET film is 0.15 to 0.24 W / m·k, which is much higher than the thermal conductivity of kraft paper (0.05 W / m·k). Moreover, when perforating the face of the material, unlike kraft paper, it is relatively difficult to perforate PET film. Accordingly, since a certain amount of force is required during the punching process, which may necessitate a change in the process conditions, which may be uneconomical. In addition, Fig. 3 (B) shows a case where a PET film is punched, and the PET film may have a clearly protruding punched hole in the direction of the punching process, and the punched hole may be formed large. On the other hand, the kraft paper layer of the present invention can be easily punched without applying a great deal of force. In addition, as shown in Fig. 3 (A), the shape deformed by the punching in the kraft paper layer can be stably and easily flattened after the punching, thereby reducing the size of the punched hole. In addition, unlike the PET film, the kraft paper layer is a material that allows relatively air to pass through, so that the degree to which high-temperature heat and gas are concentrated in the punched hole can be controlled and dispersed. Thus, the dimensional stability of the kraft paper can be maintained, the air permeability can be lowered, the heat or gas emission rate generated during the foam formation process can be well controlled, and the degree of impregnation by the foam composition can be adjusted to exhibit excellent physical properties such as excellent adhesive strength, thereby achieving the desired effect.

[0058] The basis weight of the above kraft paper layer may be 70 g / m2 to 120 g / m2. For example, it may be 70 g / m2 to 100 g / m2 or 80 g / m2 to 100 g / m2. Accordingly, while reducing the air permeability of the face material, it is possible to easily control the peel strength, tear strength, tensile strength, walking strength, dimensional stability, and workability to all be at excellent levels.

[0059] The kraft paper layer may exhibit hydrophobicity, thereby further reducing moisture absorption and improving peel strength. In addition, by reducing moisture absorption, deformation, peeling, and condensation of the foam may be suppressed, thereby providing excellent long-term durability and excellent insulation. For example, the kraft paper layer may exhibit hydrophobicity by adding a sizing agent selected from alkyl ketene dimer (AKD), alkenyl succinic anhydride (ASA), or a mixture thereof. Accordingly, the moisture absorption rate or the degree of impregnation of the composition may be controlled. The sizing agent may be added by coating the kraft paper layer, but is not limited thereto. The sizing agent-treated kraft paper layer may have a contact angle of 85° to 100°, or a contact angle of 90° to 92° with respect to distilled water, but is not limited thereto. The above contact angle can be obtained by measuring the angle formed between the surface of the specimen and the critical points on the left and right ends by magnifying the angle with a microscope equipped with a contact angle measuring device (DSA100, KRUSS, Germany) at room temperature.

[0060] The above kraft paper can have a breathability of 0 L / min.㎠ to 2 L / min.㎠ under 50Pa conditions.

[0061] The thickness of the above kraft paper layer may be 100 μm to 165 μm. For example, it may be 100 μm or more, 125 μm or more, or 155 μm or less, or 165 μm or less.

[0062]

[0063] Conventional cotton contains aluminum in the outermost layer, but the aluminum layer is easily torn when subjected to impact from a worker's walking, which poses a problem in that it does not provide sufficient walking strength.

[0064] The face of the above-mentioned insulation material can exhibit excellent walking strength by including a non-woven fabric layer on the outermost layer attached toward the exterior of the building. More specifically, the first non-woven fabric layer can be included on the other side (other side) of the kraft paper layer where the second non-woven fabric layer is not laminated, thereby forming a composite face material having a sandwich structure together with the second non-woven fabric layer. Accordingly, the insulation material can exhibit excellent walking strength in locations where it is directly subjected to continuous and repeated impacts due to the worker's repetitive walking tasks during installation.

[0065]

[0066] The basis weight of the first nonwoven fabric layer may be 20 g / m2 to 60 g / m2, for example, 20 g / m2 to 40 g / m2 or 40 g / m2 to 60 g / m2. In one embodiment, the first nonwoven fabric layer may have a basis weight of 40 g / m2 to 60 g / m2, and for example, the first nonwoven fabric layer may have the same basis weight as the second nonwoven fabric layer. Accordingly, when installing the face material on the insulation, construction can be performed without distinguishing between the upper and lower parts of the face material, so that the insulation material can be manufactured more efficiently.

[0067] In another embodiment, the basis weight of the first nonwoven fabric layer may be 20 g / m2 to 40 g / m2, which may be lower than the basis weight of the second nonwoven fabric layer. In addition, the face material of the insulating material may include the first nonwoven fabric layer having a lower basis weight than the second nonwoven fabric layer, while exhibiting excellent bonding strength by easily dissipating high-temperature heat and gas generated during the foam formation process along with low air permeability. When the basis weight of the first nonwoven fabric layer exceeds 60 g / m2, the walking strength may be good, but the air permeability may be affected, which may worsen the bonding strength and may cause the face material to lift. The nonwoven fabric having a basis weight of 20 to 40 g / ㎡ can exhibit a permeability of 150 L / min.㎠ to 202 L / min.㎠ under 50 Pa conditions, and when the basis weight is 40 to 60 g / ㎡, the nonwoven fabric can exhibit a permeability of 60 L / min.㎠ to 150 L / min.㎠ under 50 Pa conditions.

[0068] The first nonwoven fabric layer may be a polypropylene spunbond nonwoven fabric, such as the second nonwoven fabric layer. The first nonwoven fabric layer may exhibit a tear strength of 600 gf to 800 gf when the basis weight is 20 to 40 g / ㎡, and may exhibit a tear strength of 800 gf to 1200 gf when the basis weight is 40 to 60 g / ㎡.

[0069] The thickness of the first nonwoven layer may be 120 µm to 350 µm, 120 µm to 340 µm, 120 µm to 245 µm, 120 µm to 230 µm, 230 µm to 350 µm, or 230 µm to 340 µm.

[0070]

[0071] The surface of the above insulating material includes a composite surface material sequentially including the first nonwoven fabric layer, the kraft paper layer, and the second nonwoven fabric layer so as to simultaneously exhibit the desired function, and the composite surface material can exhibit a permeability of 2 L / min.㎠ to 8 L / min.㎠ at 100 Pa.

[0072] The face of the above-mentioned insulating material has an air permeability within the above range, and can provide excellent walking strength, control the degree of impregnation of the face with the foam composition, and prevent the composition from leaking through the face. In addition, it can prevent moisture from being absorbed into the face. In addition, it can appropriately discharge high-temperature heat and gases generated during the foam formation process. Accordingly, the desired effect can be achieved without deterioration of the physical properties of the foam. In particular, in an insulating material including a high-thickness foam, the face may be placed in a high-pressure environment due to the high-temperature heat and gases generated during foaming and curing. Therefore, air permeability at a high pressure of 100 Pa is important, and the face may have an air permeability of 2 L / min.㎠ to 8 L / min.㎠ from the second nonwoven fabric layer toward the first nonwoven fabric layer at 100 Pa. Preferably, it may have a permeability of 2 L / min.㎠ to 6 L / min.㎠, 2 L / min.㎠ to 4 L / min.㎠, or 2.4 L / min.㎠ to 3.5 L / min.㎠. The permeability can be measured using a permeability measuring device (IDM Instruments, foam porosity tester) as described in Experimental Example 1.

[0073] For example, if the air permeability of the face material is below the above range, high-temperature heat and gases may not be discharged, resulting in air pockets and deformation of the insulation, which may lower the marketability due to poor appearance. In addition, the peel strength may be reduced, and the dimensional stability may not be sufficiently improved, and thus the desired effect may not be achieved. In addition, the physical properties of the foam may be deteriorated. In addition, if the air permeability of the face material exceeds the above range, the foam composition may seep into the face material, lowering the peel strength. In addition, if the foam composition flows between the face materials and contaminates the surface of the face material, the product may be recognized as a defective product, which may lower the marketability. In addition, there may be a problem in that the physical properties such as dimensional stability may not be sufficiently improved. The air permeability of the face material of the insulating material can be formed by controlling the structure of the face material of the insulating material, the material (substance) of each layer, the thickness, the perforations, etc., and thereby the desired effect can be achieved.

[0074] The thickness of the above composite surface material (first composite surface material) may be 470 µm to 850 µm. For example, it may be 470 µm or more, 475 µm or more, 585 µm or more, or 850 µm or less, 805 µm or less.

[0075] The above composite surface material has the above structure and thickness, so it can function effectively as a surface material for high-thickness insulation, for example, as a surface material for ceiling insulation.

[0076] The face of the above-mentioned insulating material can be perforated so that the composite face material has the air permeability within the above range. The perforation process can utilize various perforation methods known in the art and is not particularly limited. In addition, the degree of perforation of the face material can be appropriately adjusted depending on the material, thickness, etc. of the face material within the range that allows the air permeability within the above-mentioned range. For example, the size of the perforation hole can generally be determined based on the size of the pin for perforation. However, if the perforation pin is too thin, the degree of perforation may vary depending on the thickness of the face material, and thus the air permeability may vary.

[0077] The above composite material can be perforated by a perforation roller. The composite material can be perforated by passing a perforation roller equipped with pins while moving between the unwinder and the rewinder. The perforation roller can have a certain size (diameter) and include pins arranged at a certain interval. The diameter and interval of the perforation can be adjusted by the pins included in the perforation roller. In addition, the number of perforations can be determined according to the number of times the perforation roller passes over the composite material. At this time, depending on the number of perforations, the number of perforation holes per unit area increases or the size of the perforation holes increases due to partial overlapping, thereby increasing breathability. In this case, high-temperature heat and gas discharge can be facilitated, but the degree of impregnation of the composition can also increase, which can cause problems such as a decrease in peel strength and a decrease in walking strength. Fig. 4 schematically illustrates the perforation process of the present invention. As shown in Fig. 4, it may have four sections from the unwinder (101) to the rewinder (105). Specifically, it may include a first section (a) from the unwinder (101) to the first roll (102), a second section (b) from the first roll (102) to the second roll (103), a third section (c) from the second roll (103) to the third roll (104), and a fourth section (d) from the third roll (104) to the rewinder (105). In addition, a perforated roller (106) having a pin embedded therein may be included in the second section (b). Here, the perforated roller (106) may be located in the third section (c) of the second section (b) or close to the second roll (103).

[0078] The above composite material can be perforated once by a perforation roller while moving from the unwinder to the rewinder after being placed between the unwinder and the rewinder, so as to have the air permeability within the above range. For example, in the case of a single perforation, the perforation holes included in the composite material can be formed by the shape of the perforation roller.

[0079] The surface of the above insulation material may have 4 to 6 perforations per unit area of ​​6 mm X 6 mm. For example, it may have 4 to 5 perforations per unit area of ​​6 mm X 6 mm or 4 perforations per unit area of ​​6 mm X 6 mm.

[0080] For example, if the number of perforations exceeds the above range, the air permeability increases, and accordingly, high-temperature heat and gas discharge may be facilitated, but the degree of impregnation of the composition may also increase, which may cause problems such as a decrease in peel strength and a decrease in walking strength. In addition, if the number of perforations is less than the above range, the air permeability may decrease, but high-temperature heat and gas discharge may be difficult, which may easily cause air pockets to occur, and thus, there may be problems such as a decrease in peel strength and a decrease in physical properties, and the appearance quality of the insulation may deteriorate. However, it is not limited thereto.

[0081] The face of the above insulating material may include perforated holes having a diameter of 500 μm to 800 μm. For example, the perforated holes included in the face of the above insulating material may have a diameter of 500 μm or more, 550 μm or more, 600 μm or more, 650 μm or more, 700 μm or more, 800 μm or less, or 750 μm or less. The diameter of the perforated holes may be measured from another surface of the first nonwoven fabric layer to which the kraft paper is not attached.

[0082] If the diameter of the perforated holes formed in the face of the above-mentioned insulating material exceeds the above range, the air permeability increases, and accordingly, high-temperature heat and gas can be easily discharged, but the degree of impregnation of the composition also increases, which may cause problems such as a decrease in peel strength and a decrease in walking strength. In addition, if the number of perforated holes is less than the above range, the air permeability may decrease, but high-temperature heat and gas can be difficult to discharge, so air pockets are likely to occur, and thus, there is a problem of a decrease in physical properties such as a decrease in peel strength, and the appearance quality of the insulating material may be deteriorated, but is not limited thereto.

[0083] The surface of the above insulating material includes 4 to 6 perforated holes having a diameter of the above range per unit area of ​​6 mm X 6 mm, thereby lowering the air permeability while exhibiting excellent peel strength, and at the same time, it is possible to more easily control the desired effects such as excellent tensile strength, tear strength, walking strength, and dimensional stability.

[0084]

[0085] The peel strength of the thermosetting foam of the above composite face material (first composite face material) may be 400 gf / 50 mm to 900 gf / 50 mm. The peel strength may be measured according to the method described in the examples described below. The peel strength may be 400 gf / 50 mm or more, 500 gf / 50 mm or more, 600 gf / 50 mm or more, 650 gf / 50 mm or more, 700 gf / 50 mm or more, 750 gf / 50 mm or more, or 760 gf / 50 mm or more in other examples, and may also be 900 gf / 50 mm or less, 880 gf / 50 mm or less, or 871 gf / 50 mm or less.

[0086]

[0087] FIG. 2 is a schematic cross-sectional view of an insulation material (1000) according to another embodiment of the present invention, which comprises: a thermosetting foam (300); a first composite face material (100) attached to one surface of the thermosetting foam; and a second composite face material (200) sequentially including a third nonwoven layer (21), a kraft paper layer (22), and a metal layer (23) attached to the other surface of the thermosetting foam.

[0088] The above insulation can be constructed using a pouring concrete method. And, the insulation can be used for pouring a ceiling or a wall. For example, it can be used for pouring a ceiling. The insulation used for pouring a ceiling requires excellent walking strength due to the repeated walking work of a worker when installing the insulation on one side, for example, the upper side, of a thermosetting foam. The insulation is located on the outside and includes a first composite face material on the side requiring walking strength. The first composite face material may be the composite face material (upper composite face material) sequentially including the first non-woven fabric layer, the kraft paper layer, and the second non-woven fabric layer described above. In this case, the second non-woven fabric layer may be impregnated and attached to one side of the thermosetting foam.

[0089] The above-mentioned insulating material can exhibit low air permeability, including the above-mentioned composite face material (first composite face material), but can also exhibit excellent walking strength, significantly improved peel strength, and excellent tensile strength, tear strength, and dimensional stability. The above-mentioned first composite face material is as described above.

[0090]

[0091] And, the insulation material includes a second composite face material (lower face material) sequentially including a third nonwoven fabric layer, a kraft paper layer, and a metal layer, attached to a side, for example, a lower face, to which the first composite face material is not attached in the thermosetting foam.

[0092] At this time, the second composite face material does not require walking strength, and includes a composite face material different from the first composite face material, and the second composite face material can provide the insulating material with excellent flame retardancy and significantly improved peel strength, and also provide excellent tensile strength, tear strength, and dimensional stability.

[0093]

[0094] Specifically, the second composite face material may include a third nonwoven fabric layer, which is attached to the other side of the foam to which the first composite face material is not attached. The third nonwoven fabric layer may have the same properties as the second nonwoven fabric layer of the first composite face material. For example, the basis weight of the third nonwoven fabric layer may be 40 g / m2 to 60 g / m2.

[0095] In addition, the second composite face material can be provided with a kraft layer on top of the third nonwoven fabric layer to provide dimensional stability. The kraft layer of the second composite face material can be used to exhibit the same characteristics as the kraft layer of the first composite face material.

[0096] In addition, the second composite face material may include a metal layer on top of the kraft paper layer to provide flame retardancy or non-combustibility to the face material and improve dimensional stability, corrosion resistance, and constructability. The metal layer is not particularly limited, but may include, for example, one selected from the group consisting of iron, stainless steel (SUS), aluminum, magnesium, copper, and combinations thereof.

[0097] The thickness of the metal layer can be controlled within an appropriate range depending on the purpose, and for example, can be adjusted within a range of about 1 μm to 80 μm. In other examples, the thickness of the metal layer may be 5 μm or more, 10 μm or more, or 15 μm or more, or 70 μm or less, 60 μm or less, 50 μm or less, 40 μm or less, 30 μm or less, or 20 μm or less.

[0098] The thickness of the second composite face material sequentially including the third nonwoven fabric layer, the kraft paper layer, and the metal layer may be 350 μm to 500 μm. For example, it may be 350 μm or more, 373 μm or more, or 500 μm or less, or 483 μm or less.

[0099] The peel strength of the thermosetting foam of the second composite face material may be from 400 gf / 50 mm to 1900 gf / 50 mm. The peel strength may be measured according to the method described in the examples described below. The above peel strength may be, in other examples, 400 gf / 50 mm or more, 500 gf / 50 mm or more, 600 gf / 50 mm or more, 700 gf / 50 mm or more, 900 gf / 50 mm or more, 1100 gf / 50 mm or more, 1200 gf / 50 mm or more, 1300 gf / 50 mm or more, or 1400 gf / 50 mm or more, or 1900 gf / 50 mm or less, 1800 gf / 50 mm or less, 1700 gf / 50 mm or less, 1600 gf / 50 mm or less, 1500 gf / 50 mm or less, 1400 gf / 50 mm or less, or 1300 gf / 50 mm or less.

[0100] The above insulation material may have a dimensional change rate of 1% or less according to the following Equation 1 according to the following experimental example. For example, it may be 0.8% or less, or 0.75% or less. The lower the dimensional change rate, the better, and the dimensional change rate of the above insulation material may be 0% or more.

[0101] [Formula 1]

[0102] Dimensional change rate (%) = (|initial length (a) - final length (a') |) / initial length (a) X 100

[0103] In the above equation 1, the initial length (a) is the length of each line at n points that are equal in the length (L) and width (W) directions of the insulation, and the later length (a') means the later length (a') of each line at each point after the insulation is left in a 70°C oven for 48 hours. (n is 2 to 5)

[0104]

[0105] Considering that the required physical properties of the above insulation material differ depending on the installation location, the insulation material may include different types of facings on both surfaces. Specifically, the insulation material may include a first composite facing material having excellent walking strength to protect the foam from the worker's repetitive walking tasks during installation, and a second composite facing material having a metal layer considering flame retardancy and having a non-sandwich structure. Meanwhile, if the types of facings on both surfaces are different, deformation such as warping of the insulation material may easily occur during the curing process and / or use of the insulation material. For example, when the surface of the insulation material is placed so that it touches the floor, the four corners (vertices) of the surface of the insulation material facing the floor may be significantly bent away from the floor by a certain height, or the central surface of the insulation may be significantly bent convexly toward the ceiling.

[0106] As described above, the above insulation material includes a first composite face material and a second composite face material attached to both surfaces of the foam body in different types, while making the air permeability of the first composite face material and the second composite face material almost the same so as to prevent deformation such as warping from occurring. Specifically, the second composite face material, like the first composite face material, may have an air permeability of 2 L / min.㎠ to 8 L / min.㎠ at 100 Pa. The air permeability refers to a value measured in the direction of the metal layer from the third nonwoven fabric layer using an air permeability measuring device (IDM Instruments, foam porosity tester) according to Experimental Example 1. The second composite face material may preferably have a breathability of 2 L / min.㎠ to 6 L / min.㎠, or 2 L / min.㎠ to 4 L / min.㎠, or 3 L / min.㎠ to 4 L / min.㎠, or 3.3 L / min.㎠ to 4 L / min.㎠. For example, the difference between the breathability of the second composite face material and the breathability of the first composite face material (=|breathability of the first composite face material - breathability of the second composite face material|) may be 0 to 1.1 L / min.㎠, for example, 0.5 to 1.1 L / min.㎠.

[0107] Accordingly, the above-mentioned insulation material can reduce the degree of warpage as described above. For example, when the insulation material is placed on the floor and the height of the center surface part of the insulation material from the floor surface (initial height, H1) is measured. Then, when the height of the center surface part of the insulation material from the floor surface (H2) is measured after leaving it at room temperature for 4 days, the H2 may be 3 mm or less.

[0108]

[0109] The respective layers of the first composite face material and the second composite face material can be laminated and attached to each other using various attachment methods known in the industry, and, if necessary, can be bonded by applying an adhesive to one or more layers. For example, by using a urethane adhesive, the adhesion between the metal layer and the kraft paper layer can be enhanced. In particular, the urethane adhesive has excellent adhesive properties, and can stably discharge high-temperature heat and gases generated during foam manufacturing.

[0110]

[0111] The thermosetting foam may be a high-thickness foam included in the ceiling-casting insulation. For example, the thermosetting foam may have a thickness of 100 mm or more or 120 mm or more. For example, it may have a thickness of 130 mm or more, 140 mm or more, 150 mm or more, 160 mm or more, 170 mm or more, or 180 mm or more, and 220 mm or less, 210 mm or less, 200 mm or less, 190 mm or less, or 180 mm or less.

[0112] The above insulation material, while containing a thick thermosetting foam as described above, can effectively discharge high-temperature heat and gases during the manufacturing process and, by controlling the degree of impregnation of the composition, simultaneously exhibit significantly improved peel strength and excellent physical properties as described above even at low air permeability.

[0113] The thermosetting foam may be, for example, a polyurethane foam, a polyisocyanurate foam, or a phenol foam, and may be specifically a phenol foam. The ceiling insulation material may be brittle and contain a phenol foam with a high foaming temperature, while exhibiting excellent physical properties such as walking strength and peel strength.

[0114] The above phenol foam may be a foamed cured product of a foam composition including a phenol resin, a curing agent, a foaming agent (hydrocarbon foaming agent), and a surfactant.

[0115] Specifically, the phenolic resin can be obtained by reacting phenol and formaldehyde. The foam composition can contain the phenolic resin in an amount of about 30 wt% to about 90 wt%. In addition, the phenolic resin can have a viscosity of about 1,000 cps to about 50,000 cps under a temperature condition of about 40°C. The viscosity can be measured using a Brookfield viscometer.

[0116] The curing agent may include one acid curing agent selected from the group consisting of toluene sulfonic acid, xylene sulfonic acid, benzene sulfonic acid, phenol sulfonic acid, ethylbenzene sulfonic acid, styrene sulfonic acid, naphthalene sulfonic acid, and combinations thereof. The foam composition may include the curing agent in an amount of about 3 parts by weight to about 15 parts by weight based on 100 parts by weight of the phenolic resin. The phenolic foam may exhibit appropriate crosslinking, curing, and foaming properties by including the curing agent.

[0117] The above phenolic foam may contain a blowing agent. Using conventional freon-based blowing agents can facilitate control of the foam's physical properties. However, the use of freon-based blowing agents is restricted due to environmental concerns, such as ozone layer depletion. Therefore, there is a growing demand for insulation materials containing more environmentally friendly foams.

[0118] The phenol foam of the present invention can exhibit excellent physical properties by using the surface material while including a more environmentally friendly blowing agent. For example, the present invention can include one blowing agent selected from the group consisting of hydrofluoroolefin (HFO) compounds, hydrocarbon compounds, and combinations thereof. Specifically, the hydrofluoroolefin compound can include at least one selected from the group consisting of monochlorotrifluoropropene, trifluoropropene, tetrafluoropropene, pentafluoropropene, hexafluorobutene, and combinations thereof. In addition, the hydrocarbon compound can include an aliphatic hydrocarbon having 1 to 8 carbon atoms. For example, the hydrocarbon compound can be a chlorine-substituted or unsubstituted aliphatic hydrocarbon. For example, it may include at least one selected from the group consisting of dichloroethane, propyl chloride, isopropyl chloride, butyl chloride, isobutyl chloride, pentyl chloride, isopentyl chloride, n-butane, isobutane, n-pentane, isopentane, cyclopentane, hexane, heptane, cyclopentane, and combinations thereof. The phenol foam may include an aliphatic hydrocarbon having 1 to 8 carbon atoms, and thus may exhibit excellent insulation properties along with environmental friendliness. The foaming agent may be included so that the total content of the foaming agent is about 5 to about 15 parts by weight based on about 100 parts by weight of the phenolic resin.

[0119] In addition, the phenol foam may include one surfactant selected from the group consisting of amphoteric, cationic, anionic, nonionic surfactants, and combinations thereof. For example, the phenol foam may include an ethoxylated castor oil surfactant, i.e., a nonionic surfactant.

[0120] The above phenol foam may further contain additives such as urea and flame retardants.

[0121] The above phenol foam may have a thermal conductivity of 0.016 W / m·K to 0.029 W / m·K measured at an average temperature of 20°C according to KS L 9016. The above thermal conductivity is an initial thermal conductivity, and may be, for example, 0.025 W / m·K or less, 0.023 W / m·K or less, 0.022 W / m·K or less, 0.021 W / m·K or 0.020 W / m·K or less, but is not limited thereto.

[0122] And, the phenol foam may have a thermal conductivity of 0.017 W / m·K to 0.029 W / m·K measured at an average temperature of 20°C after drying at 70°C for 7 days and then drying at 110°C for 14 days according to EN13166. The thermal conductivity is a long-term thermal conductivity, and may be, for example, 0.025 W / m·K or less, 0.023 W / m·K or less, 0.022 W / m·K or less, or 0.021 W / m·K or less, but is not limited thereto.

[0123] In addition, the independent cell ratio of the phenol foam may be 75% to 98%, and the compressive strength according to KS M ISO 844 may be 80 kPa to 300 kPa.

[0124] And, according to KS M ISO 4898, the flexural failure load (N), which is the maximum load (N) until the specimen is broken at a load concentration speed of 50 mm / min and a support spacing of 200 mm on a specimen of 250 mm (L) X 100 mm (W) X 20 mm (T) in size, can be 15 N to 50 N.

[0125]

[0126] Another embodiment of the present invention provides a method for manufacturing a ceiling insulation material, comprising the step of discharging a thermosetting resin foam composition between a first composite face material and a second composite face material to foam and cure to form a thermosetting foam, wherein the first composite face material comprises a composite face material sequentially including a first nonwoven fabric layer, a kraft paper layer, and a second nonwoven fabric layer from the outside, wherein the second nonwoven fabric layer has a basis weight of 40 g / m2 to 60 g / m2, and at 100 Pa, air permeability from the second nonwoven fabric layer of the first composite face material toward the first nonwoven fabric layer is 2 L / min.㎠ to 8 L / min.㎠.

[0127] In general, a foam composition can be injected between face sheets to manufacture an insulating material with face sheets attached to both sides of the foam. At this time, the composition can increase the peel strength as it is impregnated into the face sheets. Meanwhile, the insulating material is a pourable insulating material and may include a high-thickness foam. Accordingly, as the degree of impregnation of the face sheets with the foam composition increases, there is a problem that the peel strength of the face sheets with respect to the foam is likely to decrease. In addition, the composition can easily flow out between the face sheets, contaminating the equipment and soiling the surface of the face sheets. In addition, if the composition hardens while the face sheets are largely impregnated with the composition, the flexibility of the face sheets can be reduced, which can lower the dimensional stability. Furthermore, if the high-temperature heat and gases generated during the manufacturing process of the high-thickness foam are not properly discharged, air pockets can form, which can lower the marketability due to poor appearance, lower the peel strength, and easily cause warping during curing or use.

[0128] Meanwhile, the method for manufacturing the ceiling insulation material can achieve the desired effect by including the first composite face material and the second composite face material. The first composite face material and the second composite face material are as described above.

[0129] In another embodiment according to the present invention, when two types of foams are bonded to manufacture a single insulating material, the upper and lower face sheets of the insulating material exposed to the outside may be the first composite face sheet and the second composite face sheet of the present invention, respectively. For example, a thermosetting resin foam composition is discharged between the first composite face sheet and the second composite face sheet or other face sheets, and foamed and cured to prepare a first product. A thermosetting resin foam composition is discharged between the second composite face sheet and the first composite face sheet or other face sheets, and foamed and cured to prepare a second product. In addition, the first product and the second product may be bonded using an adhesive to provide an insulating material. In this case, the upper and lower face sheets of the insulating material exposed to the outside may be the first composite face sheet and the second composite face sheet of the present invention, respectively.

[0130]

[0131] (Example)

[0132] Example 1

[0133] Cotton manufacturing

[0134] A first nonwoven fabric layer having a basis weight of 40 g / ㎡ and a thickness of 230 ㎛, a kraft paper layer having a basis weight of 80 g / ㎡ and a thickness of 125 ㎛, and a second nonwoven fabric layer having a basis weight of 40 g / ㎡ and a thickness of 230 ㎛ were sequentially laminated, and a urethane adhesive was attached between each layer during lamination to manufacture a first composite face material (upper face material).

[0135] Then, a third nonwoven layer having a basis weight of 40 g / ㎡ and a thickness of 230 ㎛, a kraft paper layer having a basis weight of 80 g / ㎡ and a thickness of 125 ㎛, and an aluminum layer (aluminum foil) having a thickness of 18 ㎛ were sequentially laminated and attached with a urethane adhesive to manufacture a second composite face material (lower face material).

[0136] At this time, the first, second and third nonwoven layers were manufactured using a spun bond method and manufactured using a nonwoven fabric made of polypropylene (PP) fibers.

[0137] And, while performing a roll-to-roll process on each of the first composite face material and the second composite face material as shown in Fig. 4, a perforation roller (106) was positioned in the second section (b), and the perforation roller (106) was passed through once to perforate the face materials. At this time, it was confirmed that each of the face materials had 4 perforation holes per unit area of ​​6 mm X 6 mm, and the perforation holes had a diameter of 715 μm. And, according to the following air permeability measurement method, the air permeability of the first composite face material was 3 L / min.㎠, and the second composite face material exhibited an air permeability of 4 L / min.㎠.

[0138]

[0139] Insulation manufacturing

[0140] An insulating material including a phenol foam was manufactured using the first and second composite face materials described above. The phenol foam was manufactured by mixing and stirring 100 parts by weight of a resole resin having a viscosity of 20,000 cps at 20°C, 15 parts by weight of a mixture of 80% by weight of toluene sulfonic acid, 15% by weight of ethylene glycol, and 5% by weight of water with respect to 100 parts by weight of the resole resin, 6 parts by weight of isopentane, 1.5 parts by weight of an ethoxylated castor oil surfactant, and 3 parts by weight of powdered urea, to manufacture a foam composition.

[0141] And, the second nonwoven fabric layer of the first composite face material and the third nonwoven fabric layer of the second composite face material were arranged to face each other. And, the foam composition was injected between the first composite face material and the second composite face material arranged at an interval of about 130 mm, and then foamed / cured at 55°C to manufacture an insulating material in which face materials were attached to both surfaces of a 130 mm thick phenolic foam. And, the insulating material was cured in an oven at 75°C for 20 hours.

[0142]

[0143] Examples 2 to 7

[0144] In the above Example 1, the first composite cotton material, the second composite cotton material and the insulating material including the same of Examples 2 to 7 were manufactured in the same manner as in Example 1, except that each layer of the cotton material was changed as shown in Tables 1 and 2 below.

[0145]

[0146] Comparative Example 1

[0147] A first composite face material was manufactured by spray coating a hot melt adhesive composition onto one side of a nonwoven fabric layer having a basis weight of 40 g / ㎡ and a thickness of 230 μm. At this time, the hot melt adhesive composition was impregnated to a thickness of up to 60% of the nonwoven fabric layer. Then, a face material identical to the first composite face material was manufactured as a second composite face material.

[0148] Except for the above, the first composite cotton material, the second composite cotton material, and the insulating material including them were manufactured in the same manner as in Example 1.

[0149]

[0150] Comparative Example 2

[0151] In the above Example 1, a first nonwoven fabric layer having a basis weight of 30 g / m2 and a thickness of 180 μm, a kraft paper layer having a basis weight of 80 g / m2 and a thickness of 125 μm, and a second nonwoven fabric layer having a basis weight of 30 g / m2 and a thickness of 180 μm were sequentially laminated, and a urethane adhesive was attached between each layer during lamination to manufacture a first composite face material. Then, the same face material as the first composite face material was used as the second composite face material. Except for the above-described, the first composite face material, the second composite face material, and the insulating material comprising the same were manufactured in the same manner as in Example 1.

[0152]

[0153] Comparative Example 3

[0154] In the above Example 1, a first nonwoven fabric layer having a basis weight of 30 g / m2 and a thickness of 180 ㎛, a kraft paper layer having a basis weight of 80 g / m2 and a thickness of 125 ㎛, and a second nonwoven fabric layer having a basis weight of 70 g / m2 and a thickness of 410 ㎛ were sequentially laminated, and a urethane adhesive was attached between each layer during lamination to manufacture a first composite face material. Then, the same face material as the first composite face material was used as the second composite face material. Except for the above-described, the first composite face material, the second composite face material, and the insulating material including the same were manufactured in the same manner as in Example 1.

[0155]

[0156] Comparative Example 4

[0157] In the above Example 1, a first nonwoven fabric layer having a basis weight of 20 g / m2 and a thickness of 120 μm, a kraft paper layer having a basis weight of 80 g / m2 and a thickness of 125 μm, and a second nonwoven fabric layer having a basis weight of 40 g / m2 and a thickness of 230 μm were sequentially laminated, and a urethane adhesive was attached between each layer during lamination to manufacture a first composite face material. Then, a face material identical to the first composite face material was used as a second composite face material.

[0158] Then, the first composite face material, the second composite face material, and the insulating material including them were manufactured in the same manner as in Example 1, except that each of the first composite face material and the second composite face material was passed through the perforation roller twice.

[0159]

[0160] Comparative Example 5

[0161] In the above Example 1, a first nonwoven fabric layer having a basis weight of 20 g / m2 and a thickness of 120 μm, a kraft paper layer having a basis weight of 80 g / m2 and a thickness of 125 μm, and a second nonwoven fabric layer having a basis weight of 40 g / m2 and a thickness of 230 μm were sequentially laminated, and a urethane adhesive was attached between each layer during lamination to manufacture a first composite face material. Then, a face material identical to the first composite face material was used as a second composite face material.

[0162] Then, the first composite face material, the second composite face material, and the insulating material including them were manufactured in the same manner as in Example 1, except that each of the first composite face material and the second composite face material was passed once through a perforated roller (106) having a pin of thin thickness (small diameter).

[0163] At this time, it was confirmed that each of the above-mentioned surfaces had four perforated holes per unit area of ​​6 mm X 6 mm, and that the perforated holes had a diameter of 150 μm.

[0164]

[0165]

[0166]

[0167]

[0168]

[0169] evaluation

[0170] Experimental Example 1: Air permeability (100 Pa pressure condition, L / min.㎠)

[0171] The first composite cotton material and the second composite cotton material of the above examples and comparative examples were cut into 10 cm (W, width) X 10 cm (L, length) to prepare specimens. For the specimens, the degree of air permeability was measured according to the degree of air flow per unit area in the direction from the second nonwoven fabric layer to the first nonwoven fabric layer and in the direction from the third nonwoven fabric layer to the metal layer under a constant pressure of 100 Pa using an air permeability measuring device (IDM Instruments, foam porosity tester). The results are shown in Tables 4 and 5.

[0172]

[0173] Ventilation Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 First composite surface material 32.62.433.53 Second composite surface material 43.73.33.943.7

[0174] Ventilation Example 7 Comparative Example 1 Comparative Example 2 Comparative Example 3 Comparative Example 4 Comparative Example 5 Composite surface material 1 2.6 4.5 3.5 2.29 1 Composite surface material 2 3.3 4.5 3.5 2.29 1

[0175]

[0176] Experimental Example 2: Peel strength for foam (gf / 50mm)

[0177] The insulating material including the cotton sheet according to the above examples and comparative examples was prepared as a 200 mm (W, width) X 300 mm (L, length) specimen, and the peel strength was measured using a peel strength tester, UTM (UTM, SHIMADZU). Specifically, two cuts (CL) were made in a vertical direction from the surface of the first composite cotton sheet and the surface of the second composite cotton sheet. The distance between the cuts (CL) was set to 50 mm. More specifically, as shown in Fig. 8, two cuts (CL) were made parallel to the longitudinal direction on the inside of both ends in the width direction of the specimen. At this time, the cut depth was set to be 10 mm or less but not less than a depth corresponding to the thickness of the cotton sheet from the surface of the cotton sheet so that the cotton sheet could be peeled. And, the end of the part formed by the sheath (width 50 mm) was fixed to the tensile jig of the tester, and the peeling was measured at a peeling speed of 300 mm / min and a peeling angle of 90° from the foam (see Fig. 9). In the case of the comparative example, since the first composite face material and the second composite face material were the same, the peeling strength was measured for the first composite face material. And, the results are shown in Table 6.

[0178]

[0179] Experimental Example 3: Measurement of walking intensity (mm)

[0180] The insulating material including the cotton material according to the above examples and comparative examples was cut into a 200 mm (W, width) X 300 mm (L, length) specimen. Then, the walking strength of the first composite cotton material portion was measured using a compressive strength device (UTM, SHIMADZU). Specifically, Fig. 5 shows a method for measuring the walking strength of the present invention, (B) is a slightly enlarged version of (A), and (C) shows a hexagonal nut used in measuring the walking strength.

[0181] As illustrated in Fig. 5, the specimen was positioned at the center of the stage so that the first non-woven layer of the first composite face material was exposed to the outside, and then a hexagonal nut (M20) (height (H): 16 mm, diameter (D): 30 mm) was placed at the center of the specimen to simulate the walking and working impact of a worker. Then, the compression speed was set to 1 to 10 mm / min, and the displacement was fixed at 10 mm. Then, the depth (mm) was measured based on the yield depth (the point where there is no slope recovery where elastic recovery is impossible) during compression. If the depth exceeded 8 mm, the walking strength was judged to be excellent.

[0182] For reference, as shown in the red graph in Fig. 6, when the conventional cotton material is compressed to a depth of about 4 mm, it loses its elastic recovery force, and the slope stops rising and instead changes to a negative slope. In other words, the conventional cotton material has weak walking strength, and when compressed to a depth of 4 mm or more, it cannot withstand the force and the foam is destroyed.

[0183] On the other hand, Example 1 shows the blue graph pattern in Fig. 6. Specifically, Example 1 showed an almost constant slope even when the cotton material was compressed to a depth of 10 mm, indicating excellent walking strength by withstanding continuous compression.

[0184]

[0185] Experimental Example 4: Measurement of tear strength (gf / sheet)

[0186] The tear strength of the first composite cotton sheets of the above Examples and Comparative Examples was measured using an Elmendorf Tear Strength measuring device (Manufacturer: Thwing-Albert Instrument Company, Device Name: Pro Tear Elmendorf Tear Tester). Specifically, the first composite cotton sheets of the above Examples and Comparative Examples were prepared as specimens measuring 76 mm (W) X 63 mm (L) and fixed to a clamp. Then, the central portion of the surface of the first non-woven fabric layer of the specimen was partially cut to a length of about 1 cm using a cutter installed in the measuring device, and then a 1600 g pendulum was allowed to fall freely to determine whether the cotton sheets were torn. Then, the force generated when the cotton sheets were torn was measured, and the results are shown in Table 6 below. If the cotton sheets were not torn, it means that the tear strength was excellent.

[0187]

[0188] Experimental Example 5: Tensile strength measurement (kgf / 5cm)

[0189] The tensile strength of the first composite face material of the above examples and comparative examples was measured using UTM (manufacturer: Instron) equipment. Specifically, the first composite face material of the above examples and comparative examples was prepared as a specimen measuring 50 mm (W) X 280 mm (L) and fixed to upper and lower clamps. Then, the test speed was set to 300 mm / min, the test was started, and the tensile strength was measured. If the face material was not torn, it means that the tensile strength was excellent.

[0190]

[0191] Experimental Example 6: Dimensional Stability (%)

[0192] The insulating material including the cotton material according to the above examples and comparative examples was prepared by cutting it into a 100 mm (W) X 100 mm (L) specimen. Then, the dimensional stability was measured according to KS M ISO 4898, specifically according to the dimensional stability measurement of KS M ISO 2796. (At this time, thickness change was excluded.) More specifically, as shown in Fig. 7, lines were drawn at n (n=3) equal points in the length (L) and width (W) directions of the specimen, and the initial length (a) of each line was measured at 25°C.

[0193] After the above specimen was maintained at 70℃ for 48 hours, the length (L) and width (W) were measured again for the length (a'), and the dimensional change rate compared to the initial length was confirmed according to Equation 1 below to evaluate the dimensional stability. The smaller the dimensional change rate, the higher the dimensional stability.

[0194]

[0195]

[0196] [Formula 1]

[0197] Dimensional change rate (%) = (|initial length (a) - final length (a') |) / initial length (a) X 100

[0198]

[0199] Experimental Example 7: Initial thermal conductivity (W / m K)

[0200] The phenol foams of the examples and comparative examples were cut into 300 mm x 300 mm sizes to prepare specimens, and the specimens were pretreated by drying at 70°C for 12 hours. Then, the thermal conductivity of the specimens was measured at an average temperature of 20°C using a thermal conductivity device HC-074-300 (EKO) according to the measurement conditions of KS L 9016 (plate heat flow meter measurement method), and the results are shown in Table 6 below.

[0201]

[0202] Experimental Example 8: Long-term thermal conductivity (W / m K)

[0203] The phenol resin foam of the examples and comparative examples was cut into a size of 300 mm x 300 mm to prepare a specimen, and the specimen was dried at 70°C for 7 days and then at 110°C for 14 days in accordance with EN13166. Then, the thermal conductivity was measured using a thermal conductivity device HC-074-300 (EKO) at an average temperature of 20°C, and the results are shown in Table 6 below.

[0204]

[0205]

[0206]

[0207] As can be seen in the above table, Comparative Example 1 does not have the structure of the present invention, and although it has low air permeability, it can be seen that the bonding strength is significantly lower, and the effects in terms of tear strength, tensile strength, walking strength, and dimensional stability are all significantly lower. In addition, Comparative Examples 2 and 3 deviate from the basis weight of the present invention, and although it has low air permeability, it cannot exhibit sufficient bonding strength. In particular, Comparative Example 2 also has low tensile strength and insufficient dimensional stability. In addition, Comparative Examples 4 and 5 deviate from the air permeability of the present invention, and it can be seen that the bonding strength is low. In addition, it can be seen that Comparative Example 5 has too low air permeability, which increases the thermal conductivity of the foam, and thus deteriorates the physical properties of the foam. On the other hand, it can be seen that the above examples exhibit significantly high bonding strength, and it can be seen that they have excellent effects in terms of tear strength, tensile strength, walking strength, and dimensional stability. In addition, it can be seen that the physical properties of the foam are not deteriorated.

[0208]

[0209] Although the present invention has been described with reference to the drawings exemplified above, it is to be understood that the present invention is not limited to the embodiments and drawings disclosed herein, and that various modifications may be made by those skilled in the art within the scope of the technical idea of ​​the present invention. Furthermore, even if the operational effects according to the configuration of the present invention have not been explicitly described while describing the embodiments of the present invention, it is natural that the effects predictable by the corresponding configuration should also be acknowledged.

[0210]

[0211] [Explanation of symbols]

[0212] 11: First nonwoven layer

[0213] 12: Kraft Formation

[0214] 13: Second nonwoven layer

[0215] 21: Third nonwoven layer

[0216] 22: Kraft Formation

[0217] 23: Metal layer

[0218] 100: Insulating face material (composite face material, first composite face material)

[0219] 200: Second composite surface

[0220] 300: Thermosetting foam

[0221] 101: Unwinder

[0222] 102: First roll

[0223] 103: Second Roll

[0224] 104: Third Roll

[0225] 105: Rewinder

[0226] 106: Perforation roller

[0227] 1000: Insulation

Claims

1. Comprising a composite cotton material sequentially including a first nonwoven layer, a kraft layer, and a second nonwoven layer, The weight of the second non-woven layer is 40 g / ㎡ to 60 g / ㎡, At 100Pa, the air permeability in the second nonwoven layer of the composite material toward the first nonwoven layer is 2 L / min.㎠ to 8 L / min.㎠. Cotton material for insulation.

2. In paragraph 1, The second non-woven layer is attached to a thermosetting foam. Cotton material for insulation.

3. In paragraph 1, The weight of the first nonwoven layer is 20 g / ㎡ to 60 g / ㎡. Cotton material for insulation.

4. In paragraph 1, The first nonwoven fabric layer and the second nonwoven fabric layer are polypropylene spunbond nonwoven fabric. Cotton material for insulation.

5. In paragraph 1, The weight of the above kraft layer is 70 g / ㎡ to 120 g / ㎡. Cotton material for insulation.

6. In paragraph 1, The above kraft layer is hydrophobic by adding a sizing agent selected from alkyl ketene dimer (AKD), alkenyl succinic anhydride (ASA), or a combination thereof. Cotton material for insulation.

7. In paragraph 6, The above kraft layer has a contact angle with water of 85° to 100°. Cotton material for insulation.

8. Thermosetting foam; The first composite face material of claim 1 attached to one side of the thermosetting foam; and A second composite face material sequentially including a third nonwoven layer, a kraft paper layer, and a metal layer attached to the other surface of the thermosetting foam; Insulation.

9. In paragraph 8, The third nonwoven layer is attached to the thermosetting foam, and the basis weight of the third nonwoven layer is 40 g / ㎡ to 60 g / ㎡. Insulation.

10. In paragraph 8, At 100Pa, the air permeability in the third nonwoven layer of the second composite surface toward the metal layer is 2 L / min.㎠ to 8 L / min.㎠. Insulation.

11. In paragraph 8, The thickness of the above first composite surface material is 470 ㎛ to 850 ㎛, The thickness of the above second composite surface material is 350 ㎛ to 500 ㎛. Insulation.

12. In paragraph 8, The peel strength of the thermosetting foam of the first composite surface material is 400 gf / 50 mm to 900 gf / 50 mm. Insulation.

13. In paragraph 8, The peel strength of the thermosetting foam of the second composite surface material is 400 gf / 50㎜ to 1900 gf / 50㎜. Insulation.

14. A step of forming a thermosetting foam by discharging a thermosetting resin foam composition between the first composite face material and the second composite face material and foaming and curing the composition, The above first composite face material comprises a composite face material including a first nonwoven fabric layer, a kraft paper layer and a second nonwoven fabric layer sequentially from the outside, The weight of the second non-woven layer is 40 g / ㎡ to 60 g / ㎡, At 100 Pa, the air permeability in the second nonwoven layer of the first composite surface material toward the first nonwoven layer is 2 L / min.㎠ to 8 L / min.㎠. Method for manufacturing insulation material.

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