Fire door and method for manufacturing fire door

Abstract

The present invention relates to a fire door and a method for manufacturing same, the fire door ensuring both heat insulation and fire resistance due to the core material filled in the fire door, and not including additional components other than the core material and thus preventing problems caused by foaming gas, adhesive, and the like.

Description

Fire doors and methods for manufacturing fire doors

[0001] [Cross-citation with related applications]

[0002] This invention claims the benefit of priority to Korean Patent Application No. 10-2024-0004866, filed January 11, 2024, and Korean Patent Application No. 10-2024-0180288, filed December 6, 2024, the entire contents of which are incorporated herein by reference.

[0003] [Technical Field]

[0004] The present invention relates to a fire door and a method for manufacturing the same.

[0005] Fire doors are essential facilities installed at entrances and exits of buildings to prevent flames and smoke from spreading to evacuation areas in the event of a fire. To meet their intended purpose, fire doors must be sufficiently resistant to combustion, melting, cracking, thermal decomposition, explosion, and / or deterioration when exposed to fire. They must also be durable enough to withstand high-temperature flames. To ensure these properties, fire doors are constructed with insulation or other materials inside.

[0006] These insulation materials have mainly used mineral wool or urethane foam. Mineral wool has excellent fire resistance as the core material of fire doors, but has a problem with low insulation due to its high thermal conductivity of 0.035 W / mK to 0.045 W / mK, and urethane foam has a problem with low fire resistance due to its low thermal conductivity of 0.020 W / mK to 0.025 W / mK, so it has high insulation but low fire resistance.

[0007] Conventionally, as illustrated in Figure 4 (CE-S1), insulation has been filled into the interior of a fire door by cutting and processing pre-formed insulation materials such as urethane board (UB) and then filling the interior of the fire door with the cut insulation. When manufacturing fire doors in this manner, an additional step is added: filling the gap between the insulation and the interior of the fire door with adhesive (BD) or foam to secure the insulation tightly within the door.

[0008] However, as with conventional fire door manufacturing methods, the process becomes more complex when processing insulation materials with cutting tools such as cutter blades, and even when cut to specifications, lifting or gaps between insulation materials are inevitable, which can reduce the insulation performance of the fire door itself. Furthermore, when foam insulation materials such as urethane foam are processed with cutting tools such as cutter blades, the foaming gas volatilizes, accelerating the lifespan of the insulation material, which can reduce the insulation properties of the insulation material. Furthermore, the volatilization of the foaming gas can cause deformation of the insulation material, which can also affect the appearance of the fire door.

[0009] Furthermore, using adhesives to secure cut insulation to the fire door increases manufacturing costs. Furthermore, the organic solvents contained in the adhesive can evaporate, potentially posing health risks and contributing to environmental pollution. Furthermore, absorption of the adhesive by the insulation can degrade its insulating properties and cause deformation.

[0010] To solve these problems, as illustrated in Fig. 5 (CE-S2), a method of forming a foam by injecting a foaming solution to form an insulation material inside a fire door can be considered. However, when the foaming solution is injected into the inside of the fire door through a single injection port (IH), there are problems such as uneven flowability and spreadability when the foaming solution is discharged, and eddies are formed, causing variations in the density of the foam, which in turn causes variations in the skin layer, resulting in reduced adhesion to the fire door. In addition, this density variation reduces the mechanical strength and flame retardancy of the core material, and increases voids at the top and bottom.

[0011] Furthermore, when a foam solution is injected into a fire door through a single inlet, partial shrinkage of the core material occurs due to uneven foam formation, which increases the possibility of changes over time such as product banding, air pockets, and wave phenomena. Furthermore, eddies can cause a skin layer to form along the thickness, and internal holes can form, reducing insulation performance. Furthermore, since the inlet for injecting the foam solution into the fire door must be machined, unnecessary perforations can easily allow flame penetration, making it difficult to achieve fire resistance.

[0012] The problem to be solved by the present invention is to introduce a thermosetting foam having excellent flame retardancy as a core material of a fire door, thereby satisfying both insulation and fire resistance, and to simplify the fire door manufacturing process by forming a core material using foam inside the fire door, and to ensure sufficient adhesive strength without a separate adhesive by filling the core material to fit the shape of the inside of the fire door.

[0013] That is, the purpose of the present invention is to provide a fire door that simultaneously secures thermal insulation and fire resistance from a core material filled inside the fire door, while preventing problems caused by adhesives, etc., by not including additional components other than the core material.

[0014] In addition, the present invention aims to provide a method for manufacturing the fire door.

[0015] To solve the above problem, the present invention provides a fire door and a method for manufacturing a fire door.

[0016] (1) The present invention comprises a front panel member; a rear panel member; a side cover member; and a core member, wherein the core member is present in a filled state in a space formed by the front panel member, the rear panel member, and the side cover member, has a filling rate of more than 95 volume%, an average cell size of 275 ㎛ or less, and a total heat release rate of 8 MJ / m after 10 minutes of combustion measured by the test method of ISO 5660-1. 2 Provides a fire door as follows:

[0017] (2) The present invention provides a fire door having an NCO index of 120 or more and 400 or less in the above (1).

[0018] (3) The present invention provides a fire door in which, in the above (1) or (2), the side cover member is integrated with the front panel member or the rear panel member.

[0019] (4) The present invention provides a fire door in which the core material is foam in any one of the above (1) to (3).

[0020] (5) The present invention provides a fire door in which the core material has no cut surface in any one of the above (1) to (4).

[0021] (6) The present invention provides a fire door in any one of the above (1) to (5), wherein the fire door does not contain a separate adhesive component other than the core material at the interface between the front panel member and the core material, between the rear panel member and the core material, and between the side cover member and the core material.

[0022] (7) The present invention provides a fire door in which, in any one of the above (1) to (6), when the front panel member or the rear panel member is separated from the fire door by pressure alone without a cutting surface, a part of the core material is attached to the surface of the inner surface of the fire door of the separated front panel member or the separated rear panel member.

[0023] (8) The present invention provides a fire door in which, in any one of the above (1) to (7), the front panel member, the rear panel member, and the side cover member do not have a solution injection port or a sealing portion of the solution injection port.

[0024] (9) The present invention comprises a step (S10) of discharging and filling a core reactant into a space formed by one side of a front panel member or a rear panel member and a side cover member; And in the step (S10), one side of the rear panel member or the front panel member is covered on the core reactant filled in the step, so as to correspond to one side of the front panel member or the rear panel member, and the other side of the front panel member or the rear panel member and the other side of the rear panel member or the front panel member are pressed using a vertically driven compression press to adhere them to the thickness of the fire door, thereby curing the core reactant, wherein the core reactant comprises a polyol mixture and an isocyanate compound in a weight ratio of 1:0.95 or more and 2.75 or less, and the polyol mixture comprises 65 wt% or more and 100 wt% or less of an ester polyol, and 0 wt% or more and 35 wt% or less of an ether polyol, and in the step (S10), the discharge pressure of the core reactant is 100 bar or more and 200 bar or less, and in the step (S20), the temperature of the vertically driven compression press is 35°C or more, A method for manufacturing a fire door is provided, wherein the temperature is 85°C or lower and the curing time is 8 minutes or longer.

[0025] (10) The present invention provides a method for manufacturing a fire door, wherein, in the step (S10), the polyol mixture and the isocyanate compound are mixed during discharge.

[0026] (11) The present invention provides a method for manufacturing a fire door, wherein, in step (S10), the core reactant is foamed when discharged in the above (9) or (10).

[0027] (12) The present invention provides a method for manufacturing a fire door, wherein in any one of the above (9) to (11), in the step (S10), the discharge is performed while the discharge port, which is arranged in a direction perpendicular to one side of the front panel member or the rear panel member, moves continuously in an upward or downward direction from the lower or upper side of one side of the front panel member or the rear panel member.

[0028] (13) The present invention provides a method for manufacturing a fire door, wherein the core reactant has a gelling time of 100 seconds or more and 240 seconds or less in any one of the above (9) to (12).

[0029] (14) The present invention provides a method for manufacturing a fire door, wherein the core reactant has an isocyanate conversion rate of 80% or more in any one of the above (9) to (13).

[0030] (15) The present invention provides a method for manufacturing a fire door, wherein the ester polyol comprises a first ester polyol and a second ester polyol in any one of the above (9) to (14).

[0031] (16) The present invention provides a method for manufacturing a fire door, wherein, in the above (15), the first ester polyol has a viscosity of 13,000 cP or more and 19,000 cP or less at 25°C.

[0032] (17) The present invention provides a method for manufacturing a fire door, wherein in the above (15) or (16), the second ester polyol has a viscosity of 7,500 cP or more and 16,000 cP or less at 25°C.

[0033] (18) The present invention provides a method for manufacturing a fire door, wherein the ether polyol has a viscosity of 13,500 cP or more and 17,000 cP or less at 25°C in any one of (9) to (17).

[0034] (19) The present invention provides a method for manufacturing a fire door, wherein the core reactant comprises at least one selected from the group consisting of a catalyst, a flame retardant, a foaming agent, and a foaming agent, in any one of the above (9) to (18).

[0035] (20) The present invention provides a method for manufacturing a fire door, wherein the foam formed by curing in step (S20) in any one of the above (9) to (19) has a shrinkage rate of less than 4% calculated by the following equation 1.

[0036] [Formula 1]

[0037] Contraction ratio = {(V1 - V2) / V1} X 100

[0038] In the above equation 1,

[0039] V1 is the volume of the foam immediately after it has been hardened and formed, and V2 is the volume of the foam after 24 hours.

[0040] The fire door of the present invention simultaneously secures thermal insulation and fire resistance from the core material filled inside, and does not contain additional components other than the core material, thereby preventing problems caused by foaming gas, adhesive, etc.

[0041] Figure 1 is a graph showing the FT-IR peak of isocyanate for measuring the isocyanate conversion rate according to an experimental example of the present invention.

[0042] Figure 2 is an exploded schematic diagram of a fire door according to the first embodiment and the second embodiment of the present invention.

[0043] Figure 3 is a schematic diagram showing a core forming step of a fire door manufacturing method according to the first and second embodiments of the present invention.

[0044] Figure 4 is a schematic diagram showing the core attachment step of a fire door manufacturing method according to the prior art.

[0045] Figure 5 is a schematic diagram showing the core forming step of a fire door manufacturing method according to the prior art.

[0046] Figure 6 is a perspective view of a core material according to a second embodiment of the present invention.

[0047] Figures 7 to 13 are plan views each showing an example of a core material according to a second embodiment of the present invention.

[0048] Hereinafter, the present invention will be described in more detail to help understand the present invention.

[0049] The terms or words used in the description and claims of the present invention should not be interpreted as limited to their usual or dictionary meanings, but should be interpreted as meanings and concepts that conform to the technical idea of ​​the present invention, based on the principle that the inventor can appropriately define the concept of the term to explain his or her own invention in the best way.

[0050]

[0051] First embodiment

[0052] The present invention provides a fire door.

[0053] According to a first embodiment of the present invention, the fire door (100) comprises a front panel member (10, 30); a rear panel member (30, 10); a side cover member (20); and a core member (IM), wherein the core member (IM) is present in a filled state in a space formed by the front panel member (10, 30), the rear panel member (30, 10), and the side cover member (20), has a filling rate of more than 95 volume%, an average cell size of 275 ㎛ or less, and has a total heat release rate of 8 MJ / m after 10 minutes of combustion measured by the test method of ISO 5660-1. 2 It could be as follows:

[0054] According to the first embodiment of the present invention, the front panel member and the rear panel member are panels installed on the front and rear of the fire door, respectively, and may be panels formed of metal or the like, and the front and rear are only for distinguishing the front and rear.

[0055] According to the first embodiment of the present invention, the side cover member is a structure installed on the side of a fire door, and may be a frame or panel formed of metal or the like, and may be formed as a separate structure from the front panel member or the rear panel member, or may be integrated with the front panel member or the rear panel member. When the side cover member is integrated with the front panel member or the rear panel member, the side cover member may be formed by bending an end of the front panel member or the rear panel member, or may be formed by joining the side cover member to an end of the front panel member or the rear panel member by welding or the like.

[0056] According to the first embodiment of the present invention, the core material may be present in a filled state in the space formed by the front panel member, the rear panel member, and the side cover member. Here, the space formed by the front panel member, the rear panel member, and the side cover member may refer to an empty space inside when the outer frame of the fire door is formed by the front panel member, the rear panel member, and the side cover member. In addition, the presence of the core material in a filled state may mean that the core material is not simply present in a laminated state in the space, but is filled so as to seal the space.

[0057] According to the first embodiment of the present invention, the core material may have a filling ratio of more than 95% by volume, 95.5% by volume or more, 96% by volume or more, 96.5% by volume or more, 97% by volume or more, 97.5% by volume or more, 98% by volume or more, 98.5% by volume or more, 99% by volume or more, or 99.5% by volume or more, with respect to the space formed by the front panel member, the rear panel member, and the side cover member, and the upper limit may be 100% by volume, but considering that some pores are generated during the process, the filling ratio may be 100% by volume or less, 99.9% by volume or less, 99.8% by volume or less, 99.7% by volume or less, 99.6% by volume or less, or 99.5% by volume or less, and within this range, the inside of the fire door exists in a sufficiently sealed state, so that the reduction in insulation due to the empty space can be further prevented.

[0058] According to the first embodiment of the present invention, the core material (IM) may be a foam (50). As a specific example, the core material may be a polyurethane foam formed by the reaction of a polyol and an isocyanate compound.

[0059] According to the first embodiment of the present invention, the core material may have an NCO index of 120 or more and 400 or less. The NCO index refers to an equivalence ratio (-NCO eq / -OH eq) between an isocyanate group (-NCO) of an isocyanate compound and a hydroxyl group (-OH) of a polyol, and for specific examples, it may be 120 or more, 130 or more, 140 or more, 150 or more, 160 or more, 170 or more, 180 or more, 190 or more, or 200 or more, and further, it may be 400 or less, 390 or less, 380 or less, 370 or less, 360 or less, 350 or less, 340 or less, 330 or less, 320 or less, 310 or less, or 300 or less. When the NCO index is within the above range, flame retardancy and mechanical properties can be further improved.

[0060] According to the first embodiment of the present invention, the core material may have an average cell size of 275 μm or less. Here, the cells may refer to cells of foam, specifically polyurethane foam, and the average cell size may refer to the average size of cells of the foam. As a specific example, the core material may have a cell average size of 275 ㎛ or less, 274 ㎛ or less, 273 ㎛ or less, 272 ㎛ or less, 271 ㎛ or less, 270 ㎛ or less, 269 ㎛ or less, 268 ㎛ or less, 267 ㎛ or less, 266 ㎛ or less, 265 ㎛ or less, 264 ㎛ or less, 263 ㎛ or less, or 262 ㎛ or less, and the lower limit is not particularly limited, but in the sense of specifying the cell average size, 120 ㎛ or more, 130 ㎛ or more, 140 ㎛ or more, 150 ㎛ or more, 160 ㎛ or more, 170 ㎛ or more, 180 ㎛ or more, 190 ㎛ or more, 200 ㎛ or more, 210 ㎛ or more, 220 ㎛ or more, 230 ㎛ or more, It may be 240 ㎛ or more, or 250 ㎛ or more. When the average cell size is within the above range, fine and dense cells are formed, which can further reduce the thermal conductivity due to a decrease in the gas convection and conduction effects within the cell.

[0061] According to the first embodiment of the present invention, the core material has a total heat release rate of 8 MJ / m after 10 minutes of combustion as measured by the test method of ISO 5660-1. 2 It may be as follows. The test method of the above ISO 5660-1 is a fire reaction test, and the lower the total heat release rate after 10 minutes of combustion, the better the flame retardancy, and the total heat release rate is 8 MJ / m 2 When the following is true, it can be considered that the insulation and fire resistance performance of the fire door aimed at in the present invention are satisfied. As a specific example, the core material has a total heat release rate of 8 MJ / m after 10 minutes of combustion measured by the test method of ISO 5660-1. 2 Below, 7.9 MJ / m 2 Below, 7.8 MJ / m 2Below, 7.7 MJ / m 2 Below, 7.6 MJ / m 2 Below, 7.5 MJ / m 2 Below, 7.4 MJ / m 2 Below, 7.3 MJ / m 2 Below, 7.2 MJ / m 2 Below, 7.1 MJ / m 2 Below, 7 MJ / m 2 Below, 6.9 MJ / m 2 Below, 6.8 MJ / m 2 Below, 6.7 MJ / m 2 Below, 6.5 MJ / m 2 Below, 6.4 MJ / m 2 Below, 6.3 MJ / m 2 Below, 6.2 MJ / m 2 Below, 6.1 MJ / m 2 Below, 6 MJ / m 2 Below, 5.9 MJ / m 2 Below, 5.8 MJ / m 2 Below, 5.7 MJ / m 2 Below, 5.6 MJ / m 2 Below, 5.5 MJ / m 2 Below, 5.4 MJ / m 2 Below, 5.3 MJ / m 2 Below, 5.2 MJ / m 2 Below, 5.1 MJ / m 2 or less, or 5 MJ / m 2 It could be as follows:

[0062] According to the first embodiment of the present invention, the core material may be a foam formed by foaming inside a fire door as described above, and may not be cut from a pre-manufactured insulating material, so that a separate cut surface may not exist. Here, the cut surface refers to a cut surface artificially created by cutting the insulating material.

[0063] According to the first embodiment of the present invention, the core material may be a foam formed by foaming inside the fire door as described above, and since it is not a product of cutting and processing a pre-manufactured insulating material, there is no need to use a separate adhesive to bond the front panel member, the rear panel member, and the side cover member to the insulating material. Accordingly, the fire door may not include a separate adhesive (BD) component other than the core material at the interface between the front panel member and the core material, between the rear panel member and the core material, and between the side cover member and the core material. Here, the separate adhesive (BD) component other than the core material may mean all components other than the components derived from the core material reactant for forming the core material.

[0064] According to the first embodiment of the present invention, when the front panel member or the rear panel member is separated from the fire door using only pressure without a cut surface, the separated front panel member or the separated rear panel member may be separated together with a part of the core material attached to the surface of the inner surface of the fire door. Here, separating the front panel member or the rear panel member from the fire door using only pressure without a cut surface means separating the front panel member or the rear panel member from the fire door by applying a pressure greater than the ductility of the core material without using a separate cutting device. As described above, the core material may exist in a state filled in the space formed by the front panel member, the rear panel member, and the side cover member, and since the core material is formed in a state in which it is attached by itself without being adhered to the front panel member, the rear panel member, and the side cover member by an adhesive, the interfacial adhesive strength between the front panel member, the rear panel member, the side cover member, and the core material may be very excellent. Accordingly, when the front panel member or the rear panel member is separated from the fire door by pressure alone without a cut surface, the core material is torn off together with the front panel member or the rear panel member while still adhered to the front panel member or the rear panel member, and a part of the core material can be separated together with the separated front panel member or the separated rear panel member while still attached to the surface facing the inner side of the fire door.

[0065] According to the first embodiment of the present invention, the front panel member, the rear panel member, and the side cover member may not have a solution injection port (IH) or a sealing portion of the solution injection port (IH). In order to form the core material, when a foaming solution for forming an insulation material is injected into the inside of a fire door as described above to form a foam, there is a problem that the foaming solution exhibits uneven flowability and spreadability when discharged, and eddies are formed, causing a deviation in the density of the foaming solution, and accordingly, the skin layer becomes uneven, causing a problem that the adhesion to the fire door is reduced. In addition, such a density deviation lowers the mechanical strength and flame retardant performance of the core material, and becomes a factor that increases voids at the top and bottom. In addition, when the foaming solution is injected into the inside of the fire door through a single injection port (IH), uneven foam formation causes partial shrinkage of the core material, which increases the possibility of changes over time such as product banding, air pocket formation, and wave phenomenon. Additionally, eddies can cause a skin layer to form in the thickness direction, creating internal holes that degrade insulation performance. Furthermore, because an inlet hole (IH) must be machined to inject foaming solution into the fire door, unnecessary perforations can easily allow flame penetration, making it difficult to achieve fire resistance.However, the fire door according to the first embodiment of the present invention, like the fire door manufacturing method described below, discharges a core material reactant into a space formed by one side of a front panel member or a rear panel member and a side cover member to perform filling, and as a more specific example, since the discharge port (O) arranged in a direction perpendicular to one side of the front panel member or the rear panel member discharges (FD) the core material reactant while continuously moving (OD) in an upward or downward direction from the lower or upper side of one side of the front panel member or the rear panel member, the core material is uniformly filled, and there is no need to artificially form a solution injection port (IH) in the front panel member, the rear panel member, and / or the side cover member. Accordingly, according to the first embodiment of the present invention, the fire door does not have a solution injection port in the front panel member, the rear panel member, and the side cover member, or a sealing portion for sealing the solution injection port (IH) after manufacturing the fire door, and can prevent all problems caused by the solution injection port (IH).

[0066]

[0067] The present invention provides a method for manufacturing a fire door.

[0068] According to the first embodiment of the present invention, the method for manufacturing a fire door may be a method for manufacturing a fire door as described above. As a specific example, the method for manufacturing a fire door may include a step (S10) of discharging and filling a core material reactant into a space formed by one side of a front panel member or a rear panel member and a side cover member; And in the step (S10), one side of the rear panel member or the front panel member is covered on the core reactant filled in the step, so as to correspond to one side of the front panel member or the rear panel member, and the other side of the front panel member or the rear panel member and the other side of the rear panel member or the front panel member are pressed using a vertically driven compression press to adhere them to the thickness of the fire door, thereby curing the core reactant, wherein the core reactant comprises a polyol mixture and an isocyanate compound in a weight ratio of 1:0.95 or more and 2.75 or less, and the polyol mixture comprises 65 wt% or more and 100 wt% or less of an ester polyol, and 0 wt% or more and 35 wt% or less of an ether polyol, and in the step (S10), the discharge pressure of the core reactant is 100 bar or more and 200 bar or less, and in the step (S20), the temperature of the vertically driven compression press is 35°C or more, The temperature may be 85°C or lower, and the curing time may be 8 minutes or longer.

[0069] According to the first embodiment of the present invention, the step (S10) may be a step of discharging and filling a core material reactant into a space formed by one side of the front panel member or the rear panel member and the side cover member to form a core material. The discharged core material reactant gradually swells through a chemical reaction and begins to fill one side of the front panel member or the rear panel member of the fire door and the space formed by the side cover member.

[0070] According to the first embodiment of the present invention, in the step (S10), the discharge can be performed while the discharge port arranged in a direction perpendicular to either one side of the front panel member or the rear panel member continuously moves upward or downward from the lower part or upper part of either one side of the front panel member or the rear panel member. That is, as illustrated in FIG. 3 (E-S1), the discharge is performed while the discharge port (O) is fixed so that the core material reactant does not accumulate and spread at any point in the space formed by either one side of the front panel member or the rear panel member and the side cover member, but continuously moves (OD) upward or downward from the lower part or upper part of either one side of the front panel member or the rear panel member, so that the core material reactant can be poured more uniformly into the space formed by the side cover member and the side panel member.

[0071] According to the first embodiment of the present invention, in step (S10), the polyol mixture and the isocyanate compound may be mixed during discharge. As a specific example, in step (S10), the discharge may be performed using a high-pressure foamer, and thus, the core reactant may be foamed during discharge.

[0072] According to the first embodiment of the present invention, in the step (S10), the discharge pressure of the core reactant may be 100 bar or more and 200 bar or less. If the discharge pressure is less than 100 bar, the stirring efficiency is insufficient, which causes a problem of a decrease in the conversion rate of isocyanate. If the discharge pressure exceeds 200 bar, the discharge passage of the core reactant may be blocked, causing the discharge to be difficult, making it impossible to produce a uniform foam.

[0073] According to the first embodiment of the present invention, the step (S20) may be a step for forming a core material from the core material reactant inside the fire door by covering the core material reactant filled in the step (S10) so that one side of the rear panel member or the front panel member corresponds to one side of the front panel member or the rear panel member, and using a vertically driven compression press, pressing the other side of the front panel member or the rear panel member and the other side of the rear panel member or the front panel member to make them adhere to the thickness of the fire door and hardening the core material reactant. Through such a step, a core material formed of foam can be formed.

[0074] According to the first embodiment of the present invention, in the step (S20), the temperature of the vertical drive compression press may be 35°C or higher and 85°C or lower. The temperature of the vertical drive compression press may be a processing temperature of the vertical drive compression press. As a specific example, the temperature of the vertical drive compression press may be 35°C or higher, 36°C or higher, 37°C or higher, 38°C or higher, 39°C or higher, or 40°C or higher, and may also be 85°C or lower, 84°C or lower, 83°C or lower, 82°C or lower, 81°C or lower, or 80°C or lower. When using the above-mentioned vertical driving compression press, if the temperature is below the lower limit, sufficient thermal curing does not occur, which causes a problem in that the conversion rate of isocyanate decreases, and if the temperature exceeds the upper limit, the core reactant may swell within the fire door during the above-mentioned (S20) step, and thermal curing may be completed before it is completely filled, resulting in an unfilled area.

[0075] According to the first embodiment of the present invention, in the step (S20), when the other surface of the front panel member or the rear panel member and the other surface of the rear panel member or the front panel member are pressed and pressed to the thickness of the fire door using a vertical driving compression press to harden the core reactant, the hardening time may be 8 minutes or more. As a specific example, the hardening time may be 8 minutes or more, 9 minutes or more, or 10 minutes or more, and may also be 60 minutes or less, 55 minutes or less, 50 minutes or less, 45 minutes or less, 40 minutes or less, 35 minutes or less, or 30 minutes or less. If the hardening time is less than 8 minutes, the curing of the foam in which the reaction has occurred may not be completed, which may cause problems such as shrinkage of the foam and product banding inside the fire door. In addition, if the hardening time is controlled within the upper limit range, productivity can be further improved.

[0076] According to the first embodiment of the present invention, the core reactant may include a polyol mixture and an isocyanate compound. That is, the core reactant may be a reactant for forming polyurethane.

[0077] According to the first embodiment of the present invention, the reaction of the core reactant may have a gelling time of 100 seconds or more and 240 seconds or less. First, depending on the reaction time of the foam that becomes the core, it can be divided into cream time, rising time, and gelling time. The time from the time when the polyol mixture and the isocyanate compound are mixed at a certain ratio at a temperature of 20℃ to the time when the core reactant begins to swell is called the cream time. In addition, the time until the core reactant swells and reaches the maximum height is called the rising time. In addition, the time when the foam solidifies while having elasticity after the rising time is called the gelling time. Here, it may be preferable that the core reactant have a gelling time of 100 seconds or more and 240 seconds or less. When the gelling time is adjusted within the above range, in the step (S20), the back panel member or one side of the front panel member is covered so as to correspond to one side of the front panel member or the back panel member on the core material reactant, and before putting it into the up-and-down compression press, the core material reactant can be prevented from swelling, thereby inducing the core material to be sufficiently positioned, and the reaction and curing times can be prevented from becoming too long, thereby further reducing costs along with improving productivity.

[0078] According to the first embodiment of the present invention, the core reactant may have an isocyanate conversion rate of 80% or more. For example, the core reactant may have an isocyanate conversion rate of 80% or more, 81% or more, 82% or more, 83% or more, 84% or more, or 85% or more, and may also have an isocyanate conversion rate of 100% or less, 95% or less, or 90% or less. When the isocyanate conversion rate is controlled within the above range, the chemical reaction can be prevented from continuing even after the core is formed due to residual isocyanate, and thus shrinkage and deformation of the core can be prevented in the long term, thereby preventing deformation of the fire door. The isocyanate conversion rate can be confirmed through FT-IR measurement. The peak of FT-IR indicating isocyanate is 2275 cm -1 It appears in , and the lower the peak height, the more consumed it can be judged. The peak area of ​​pure isocyanate that has not reacted at all is set as the conversion rate of 0%, and the peak area of ​​the isocyanate of the foam that has completed the reaction is set as 100% as the standard, and then by sampling the foam that has completed the chemical reaction through the actual process and measuring FT-IR, the conversion rate of the isocyanate can be derived.

[0079] According to the first embodiment of the present invention, the core reactant may include a polyol mixture and an isocyanate-based compound in a weight ratio of 1:0.95 or more and 2.75 or less. As a specific example, the core reactant may include a polyol mixture and an isocyanate-based compound in a weight ratio of 1:0.95 or more, 0.96 or more, 0.97 or more, 0.98 or more, 0.99 or more, 1 or more, 1.1 or more, 1.2 or more, or 1.3 or more, and further 2.75 or less, 2.7 or less, 2.65 or less, 2.6 or less, 2.55 or less, 2.5 or less, 2.45 or less, 2.4 or less, 2.35 or less, 2.3 or less, 2.25 or less, 2.2 or less, 2.15 or less, 2.1 or less, 2.05 or less, or 2 or less. In the above weight ratio, if the weight ratio of the isocyanate compound to the polyol mixture exceeds the lower limit, there is a problem of reduced flame retardancy, and if it exceeds the upper limit, there is a problem of reduced conversion rate of isocyanate due to an excess of isocyanate.

[0080] According to the first embodiment of the present invention, the polyol mixture may include an ester polyol and an ether polyol. As a specific example, the polyol mixture may include the ester polyol in an amount of 65 wt% or more, 66 wt% or more, 67 wt% or more, 68 wt% or more, 69 wt% or more, or 70 wt% or more, and further may include the ester polyol in an amount of 100 wt% or less, 99 wt% or less, 98 wt% or less, 97 wt% or less, 96 wt% or less, 95 wt% or less, 94 wt% or less, 93 wt% or less, 92 wt% or less, 91 wt% or less, or 90 wt% or less. Accordingly, the polyol mixture may contain the ether polyol as a remainder of 0 wt% or more, 1 wt% or more, 2 wt% or more, 3 wt% or more, 4 wt% or more, 5 wt% or more, 6 wt% or more, 7 wt% or more, 8 wt% or more, 9 wt% or more, or 10 wt% or more, and may also contain 35 wt% or less, 34 wt% or less, 33 wt% or less, 32 wt% or less, 31 wt% or less, or 30 wt% or less. If the ester polyol is contained in a content less than the above range in the components of the polyol mixture, the problem of reduced flame retardancy may occur, and in particular, as the content of the ether polyol increases, the shrinkage phenomenon of the foam inside the fire door increases, which may generate an unfilled area and cause deformation of the fire door.

[0081] According to the first embodiment of the present invention, the ester-based polyol may include a first ester-based polyol and a second ester-based polyol. Here, the first ester-based polyol and the second ester-based polyol may be of a series of ester-based polyols, but may be of different types, or may be of the same type but have different viscosities. As a specific example, the first ester-based polyol may have a viscosity of 13,000 cP (centipoise) or more and 19,000 cP (centipoise) or less at 25°C, and the second ester-based polyol may have a viscosity of 7,500 cP (centipoise) or more and 16,000 cP (centipoise) or less at 25°C. When the viscosity of the ester polyol is adjusted within the above range, the occurrence of bubbles within the core reactant can be minimized, thereby preventing the occurrence of holes or voids within the core reactant after a chemical reaction, and the occurrence of unfilled areas can be further prevented by sufficiently securing the rate at which the foam rises after the core reactant is discharged.

[0082] According to the first embodiment of the present invention, the ester polyol may be polymerized using phthalic anhydride, isophthalic acid, terephthalic acid, PET, benzoic acid or adipic acid, and ethylene oxide, propylene oxide or a mixture thereof as raw materials.

[0083] According to the first embodiment of the present invention, the ether polyol may be polymerized using at least one selected from the group consisting of ethylene glycol, 1,2-propane glycol, 1,3-propylene glycol, butylene glycol, 1,6-hexanediol, 1,8-octanediol, neopentyl glycol, 2-methyl-1,3-propanediol, glycerol, trimethylolpropane, 1,2,3-hexanetriol, 1,2,4-butanetriol, trimethylolmethane, pentaerythritol, diethylene glycol, triethylene glycol, polyethylene glycol, tripropylene glycol, polypropylene glycol, dibutylene glycol, polybutylene glycol, sorbitol, sucrose, hydroquinone, resorcinol, catechol, and bisphenol, and ethylene oxide, propylene oxide, or a mixture thereof as a raw material.

[0084] According to the first embodiment of the present invention, the ether polyol may have a viscosity of 13,500 cP (centipoise) or more and 17,000 cP (centipoise) or less at 25°C. When the viscosity of the ether polyol is adjusted within the above range, the generation of bubbles within the core reactant can be minimized, thereby preventing the generation of holes or voids within the core reactant after the chemical reaction, and the rate at which the foam rises after the core reactant is discharged can be sufficiently secured, thereby further preventing the generation of unfilled areas.

[0085] According to the first embodiment of the present invention, the isocyanate compound may be m-MDI (monomeric-methylene diisocyanate), p-MDI (polymericmethylene diisocyanate), TDI (toluene diisocyanate), derivatives thereof, or mixtures thereof.

[0086] According to the first embodiment of the present invention, the core reactant may include at least one selected from the group consisting of a catalyst, a flame retardant, a foaming agent, and a blowing agent. Here, when the core reactant includes at least one selected from the group consisting of a catalyst, a flame retardant, a foaming agent, and a blowing agent, the at least one selected from the group consisting of the catalyst, the flame retardant, the foaming agent, and the blowing agent may be mixed with an isocyanate compound when discharged in a mixed state in a polyol mixture.

[0087] According to a first embodiment of the present invention, the catalyst may include a trimerization catalyst. As a specific example, the trimerization catalyst may include a tertiary amine, a triazine, and a metal salt trimerization catalyst, and the metal salt trimerization catalyst may be an alkali metal salt of an organic carboxylic acid. The organic carboxylic acid may be acetic acid or 2-ethylhexanoic acid, and the alkali metal may be potassium or sodium.

[0088] According to the first embodiment of the present invention, when the core reactant includes the catalyst, the catalyst may be included in an amount of 0.1 part by weight or more, 0.2 part by weight or more, 0.3 part by weight or more, 0.5 part by weight or more, 0.6 part by weight or more, 0.7 part by weight or more, 0.8 part by weight or more, 0.9 part by weight or more, or 1 part by weight or more, based on 100 parts by weight of the polyol mixture, and may also be included in an amount of 5 parts by weight or less, 4.5 parts by weight or less, 4 parts by weight or less, 3.5 parts by weight or less, or 3 parts by weight or less.

[0089] According to the first embodiment of the present invention, the flame retardant may be at least one selected from the group consisting of a phosphorus-based flame retardant, a metal hydrate or metal ion-based flame retardant, a halogen-based flame retardant, an inorganic flame retardant, nanoclay, carbon nanotubes, or a mixture thereof.

[0090] According to the first embodiment of the present invention, when the core reactant includes the flame retardant, the flame retardant may be included in an amount of 5 parts by weight or more, 10 parts by weight or more, 15 parts by weight or more, 20 parts by weight or more, or 25 parts by weight or more, based on 100 parts by weight of the polyol mixture, and may also be included in an amount of 50 parts by weight or less, 45 parts by weight or less, 40 parts by weight or less, 35 parts by weight or less, or 30 parts by weight or less.

[0091] According to the first embodiment of the present invention, the foam stabilizer may be a silicone-based foam stabilizer and / or a non-silicone-based foam stabilizer. As a specific example, the silicone-based foam stabilizer may be any one including or in combination with a silicon-based copolymer, and the non-silicone-based foam stabilizer may be any one including or in combination with dinonylphenol, methyl glucoside, methyl propanediol, vinyl ether maleic acid, vegetable oil, and the like.

[0092] According to the first embodiment of the present invention, when the core reactant includes the foaming agent, the foaming agent may be included in an amount of 0.1 part by weight or more, 0.2 parts by weight or more, 0.3 parts by weight or more, 0.5 parts by weight or more, 0.6 parts by weight or more, 0.7 parts by weight or more, 0.8 parts by weight or more, 0.9 parts by weight or more, or 1 part by weight or more, based on 100 parts by weight of the polyol mixture, and may also be included in an amount of 5 parts by weight or less, 4.5 parts by weight or less, 4 parts by weight or less, 3.5 parts by weight or less, or 3 parts by weight or less.

[0093] According to the first embodiment of the present invention, the blowing agent may be at least one selected from the group consisting of cyclopentane, chlorofluorocarbon, isopentane, normal pentane, hydrochlorofluorocarbon, hydrofluorocarbon, and water.

[0094] According to the first embodiment of the present invention, when the core reactant includes the blowing agent, the blowing agent may be included in an amount of 5 parts by weight or more, 10 parts by weight or more, 15 parts by weight or more, or 20 parts by weight or more, based on 100 parts by weight of the polyol mixture, and may also be included in an amount of 50 parts by weight or less, 45 parts by weight or less, 40 parts by weight or less, 35 parts by weight or less, 30 parts by weight or less, or 25 parts by weight or less.

[0095] According to the first embodiment of the present invention, the foam formed by curing in the step (S20) may have a shrinkage rate calculated by Equation 1 below of less than 4%. As a specific example, the foam formed by curing in the step (S20) may have a shrinkage rate calculated by Equation 1 below of less than 4%, 3.5% or less, 3% or less, 2.5% or less, or 2% or less. This is an indicator of shrinkage of the core material over time, and when the shrinkage rate calculated by Equation 1 below is within the above range, it can be seen that the deterioration of the insulation over time is prevented, and the deformation of the fire door is minimized.

[0096] [Formula 1]

[0097] Contraction ratio = {(V1 - V2) / V1} X 100

[0098] In the above equation 1, V1 is the volume of the foam immediately after being formed by hardening, and V2 is the volume of the foam after 24 hours.

[0099]

[0100] Second embodiment

[0101] In the event of a fire, the most vulnerable part of a fire door's core is the area where the side cover members are located. This area has a large surface area in contact with air and is in contact with the door frame. This creates a gap in the door frame during a fire, increasing airflow and increasing the risk of combustion. To address this issue, the present invention provides a second embodiment of a fire door in addition to the first embodiment.

[0102] According to a second embodiment of the present invention, the fire door (100) includes a front panel member (10, 30); a rear panel member (30, 10); a side cover member (20); and a core material (IM), and the core material (IM) includes an insulating material (40) and a foam (50), as shown in FIG. 6, and the insulating material (40) may be included in the core material (IM) at 50% by volume or less.

[0103] According to the second embodiment of the present invention, the front panel member and the rear panel member are panels installed on the front and rear of the fire door, respectively, and may be panels formed of metal or the like, and the front and rear are only for distinguishing the front and rear.

[0104] According to a second embodiment of the present invention, the side cover member is a structure installed on the side of a fire door, and may be a frame or panel formed of metal or the like, and may be formed as a separate structure from the front panel member or the rear panel member, or may be integrated with the front panel member or the rear panel member. When the side cover member is integrated with the front panel member or the rear panel member, the side cover member may be formed by bending an end of the front panel member or the rear panel member, or may be formed by joining the side cover member to an end of the front panel member or the rear panel member by welding or the like.

[0105] According to the second embodiment of the present invention, the insulating material may be any commercially available insulating material without limitation, and as a specific example, may be at least one selected from the group consisting of composite insulating materials, organic insulating materials, and inorganic insulating materials.

[0106] According to a second embodiment of the present invention, the composite insulation material may be a PP board, a GCS board, a laminated board, etc., the organic insulation material may be a PF board, a urethane board, an isopink, a styrofoam, a heat-reflecting insulation material, etc., and the inorganic insulation material may be glass wool, insulation, mineral wool, ceramic wool, or a vacuum insulation material, etc. According to the purpose of the present invention, the insulation material preferably uses a material that does not burn in order to protect the interior from external heat in case of fire, and from this point of view, it may be at least one selected from the group consisting of glass wool, mineral wool, and ceramic wool.

[0107] According to a second embodiment of the present invention, the insulating material is in contact with an area corresponding to the inner surface of the front panel member, and the foam may be present in a filled state in the space formed by the insulating material, the rear panel member, and the side cover member. In this case, the insulating material not only increases the fire resistance of the front panel member, but also increases the fire resistance of the side cover member by the thickness of the insulating material, thereby minimizing the transfer of heat from external heat to the interior of the core material in the event of a fire, thereby preventing the spread of fire.

[0108] According to a second embodiment of the present invention, the insulating material may be in contact with an area corresponding to the inner surface of the rear panel member, and the foam may be present in a filled state in the space formed by the front panel member, the insulating material, and the side cover member. In this case, the insulating material not only increases the fire resistance of the rear panel member, but also increases the fire resistance of the side cover member by the thickness of the insulating material, thereby minimizing the transfer of heat from external heat to the interior of the core material in the event of a fire, thereby preventing the spread of fire.

[0109] According to a second embodiment of the present invention, the insulating materials (IM-1 to IM-4) are in contact with at least one surface of the inner surface of the upper surface, the lower surface, the first side surface, and the second side surface of the fire door formed by the side cover member, as illustrated in FIGS. 7 to 10, in an area (41, 42, 43, 44), and the foam (50) may be present in a filled state in a space formed by the front panel member, the rear panel member, the side cover member, and at least one of the insulating materials. In this case, the insulating material can enhance the fire resistance of the core material at the side cover member position, which is most vulnerable in the event of a fire.

[0110] According to a second embodiment of the present invention, the insulating material (IM-5) is in contact with the inner surfaces of the upper surface, the lower surface, the first side surface, and the second side surface of the fire door formed by the side cover member in an area (40) corresponding to each other, as illustrated in FIG. 11, and the foam may be present in a state of being filled in the space formed by the front panel member, the rear panel member, and the insulating material. In this case, the fire resistance of the core material by the insulating material can be further enhanced in a large fire that covers the fire door.

[0111] According to a second embodiment of the present invention, the insulating material (IM-6) is in contact with the inner surfaces of the upper surface, the lower surface, the first side, and the second side of the fire door formed by the side cover member in an area (40) corresponding to the inner surfaces thereof, as illustrated in FIG. 12, and protrudes from the inner surface of the first side or the second side so as to surround a door handle forming portion (DH) formed adjacent to the first side or the second side, and the foam may be present in a state filled in the space formed by the front panel member, the rear panel member, and the insulating material; and the space of the door handle forming portion formed by the insulating material. Since the door handle forming portion includes a door handle that is separately fastened to the fire door, in the event of a fire, the core material located in the door handle forming portion is vulnerable, just like the portion where the side cover member is located. Therefore, when the insulating material is arranged to surround the door handle forming portion as described above, the insulating material can further enhance the fire resistance of the core material of the door handle forming portion in addition to the side cover member in the event of a fire.

[0112] According to a second embodiment of the present invention, the insulating material (IM-7) is in contact with an area corresponding to the inner surface of the upper surface, the lower surface, and the first side of the fire door formed by the side cover member, as illustrated in FIG. 13, and is in contact with the inner surface of the second side of the fire door formed by the side cover member, but protrudes from the inner surface of the second side so as to surround a door handle forming portion (DH) formed adjacent to the second side, and the foam may be present in a state of being filled in the space formed by the front panel member, the rear panel member, and the insulating material.

[0113] According to a second embodiment of the present invention, the insulating material may be included in the core material at 50% by volume or less. As a specific example, the insulation may be included in the core material at 50% by volume or less, 49% by volume or less, 48% by volume or less, 47% by volume or less, 46% by volume or less, 45% by volume or less, 44% by volume or less, 43% by volume or less, 42% by volume or less, 41% by volume or less, 40% by volume or less, 39% by volume or less, 38% by volume or less, 37% by volume or less, 36% by volume or less, 35% by volume or less, 34% by volume or less, 33% by volume or less, 32% by volume or less, 31% by volume or less, 30% by volume or less, 29% by volume or less, 28% by volume or less, 27% by volume or less, or 26% by volume or less, and further, at 0.1% by volume or more, 0.2% by volume or more, 0.3% by volume or more, 0.4% by volume or more, 0.5% by volume or more, 0.6% by volume or more, It may be included in an amount of 0.7 vol% or more, 0.8 vol% or more, 0.9 vol% or more, 1 vol% or more, 2 vol% or more, 3 vol% or more, 4 vol% or more, 5 vol% or more, 6 vol% or more, 7 vol% or more, 8 vol% or more, 9 vol% or more, 10 vol% or more, 11 vol% or more, 12 vol% or more, 13 vol% or more, 14 vol% or more, 15 vol% or more, 16 vol% or more, 17 vol% or more, 18 vol% or more, 19 vol% or more, or 20 vol% or more, and within this range, the fire resistance and insulation performance of the core material of the fire door can be maximized. If the insulation material is included in the core material exceeding 50 vol%, the area occupied by the foam in the core material may not be sufficient, resulting in a decrease in insulation performance.

[0114] According to a second embodiment of the present invention, the core material may contain a greater volume ratio of the foam than the insulating material. In this case, even if the core material further includes components for enhancing additional insulation and fire resistance in addition to the insulating material and foam, the insulation area provided by the foam can be sufficiently secured, thereby minimizing any deterioration in insulation performance.

[0115] According to a second embodiment of the present invention, the thickness of the insulation may be 90% or more and 110% or less of the thickness of the side panel member. As a specific example, the thickness of the insulation may be 90% or more, 91% or more, 92% or more, 93% or more, 94% or more, 95% or more, 96% or more, 97% or more, 98% or more, or 99% or more of the thickness of the side panel member, and may also be 110% or less, 109% or less, 108% or less, 107% or less, 106% or less, 105% or less, 104% or less, 103% or less, 102% or less, or 101% or less, and within this range, the leakage of the foam reactant during foam formation can be prevented, thereby maximizing the fire resistance performance of the insulation.

[0116] According to the second embodiment of the present invention, the foam may be the same as the foam of the core material of the first embodiment. The foam may be present in a filled state in a space formed by the front panel member, the rear panel member, the side cover member, and / or the insulation, depending on the position of the insulation described above. Here, the space formed by the front panel member, the rear panel member, the side cover member, and / or the insulation may refer to a space excluding a space in which the insulation is positioned among the empty spaces inside when the outer frame of the fire door is formed by the front panel member, the rear panel member, and the side cover member. In addition, the presence of the foam in a filled state may mean that the foam is not simply present in a laminated state in the space, but is filled so as to seal the space.

[0117] According to a second embodiment of the present invention, the foam may have a filling ratio of more than 95% by volume, 95.5% by volume or more, 96% by volume or more, 96.5% by volume or more, 97% by volume or more, 97.5% by volume or more, 98% by volume or more, 98.5% by volume or more, 99% by volume or more, or 99.5% by volume or more, with respect to the space formed by the front panel member, the rear panel member, the side cover member, and / or the insulating material, and the upper limit may be 100% by volume, but considering that some pores are generated during the process, the filling ratio may be 100% by volume or less, 99.9% by volume or less, 99.8% by volume or less, 99.7% by volume or less, 99.6% by volume or less, or 99.5% by volume or less, and within this range, the inside of the fire door exists in a sufficiently sealed state, so that the insulation performance can be further prevented from being deteriorated due to the empty space.

[0118] According to a second embodiment of the present invention, the foam may be at least one selected from the group consisting of polyurethane foam, phenol foam, polystyrene foam, melamine foam, ethylene vinyl acetate foam, and methyl methacrylate foam, and from the viewpoint of maximizing insulation by lowering thermal conductivity from the foam, polyurethane foam formed by the reaction of a polyol and an isocyanate compound may be preferable.

[0119] According to a second embodiment of the present invention, the foam may have an NCO index of 120 or more and 400 or less. The NCO index refers to an equivalence ratio (-NCO eq / -OH eq) between an isocyanate group (-NCO) of an isocyanate compound and a hydroxyl group (-OH) of a polyol, and for specific examples, it may be 120 or more, 130 or more, 140 or more, 150 or more, 160 or more, 170 or more, 180 or more, 190 or more, or 200 or more, and further, 400 or less, 390 or less, 380 or less, 370 or less, 360 or less, 350 or less, 340 or less, 330 or less, 320 or less, 310 or less, or 300 or less. When the NCO index is within the above range, flame retardancy and mechanical properties can be further improved.

[0120] According to a second embodiment of the present invention, the foam may have an average cell size of 275 μm or less. Here, the cell may refer to a cell of the foam, specifically, a polyurethane foam, and the average cell size may refer to an average size of the cells of the foam. As a specific example, the core material may have a cell average size of 275 ㎛ or less, 274 ㎛ or less, 273 ㎛ or less, 272 ㎛ or less, 271 ㎛ or less, 270 ㎛ or less, 269 ㎛ or less, 268 ㎛ or less, 267 ㎛ or less, 266 ㎛ or less, 265 ㎛ or less, 264 ㎛ or less, 263 ㎛ or less, or 262 ㎛ or less, and the lower limit is not particularly limited, but in the sense of specifying the cell average size, 120 ㎛ or more, 130 ㎛ or more, 140 ㎛ or more, 150 ㎛ or more, 160 ㎛ or more, 170 ㎛ or more, 180 ㎛ or more, 190 ㎛ or more, 200 ㎛ or more, 210 ㎛ or more, 220 ㎛ or more, 230 ㎛ or more, It may be 240 ㎛ or more, or 250 ㎛ or more. When the average cell size is within the above range, fine and dense cells are formed, which can further reduce the thermal conductivity due to a decrease in the gas convection and conduction effects within the cell.

[0121] According to the second embodiment of the present invention, the foam has a total heat release rate of 8 MJ / m after 5 or 10 minutes of combustion as measured by the test method of ISO 5660-1. 2 It may be as follows. The test method of the above ISO 5660-1 is a fire reaction test, and the lower the total heat release rate after 5 or 10 minutes of combustion, the better the flame retardancy, and the total heat release rate is 8 MJ / m 2 When the following is true, it can be considered that the insulation and fire resistance performance of the fire door aimed at in the present invention are satisfied. As a specific example, the core material has a total heat release rate of 8 MJ / m after 5 or 10 minutes of combustion measured by the test method of ISO 5660-1. 2 Below, 7.9 MJ / m 2Below, 7.8 MJ / m 2 Below, 7.7 MJ / m 2 Below, 7.6 MJ / m 2 Below, 7.5 MJ / m 2 Below, 7.4 MJ / m 2 Below, 7.3 MJ / m 2 Below, 7.2 MJ / m 2 Below, 7.1 MJ / m 2 Below, 7 MJ / m 2 Below, 6.9 MJ / m 2 Below, 6.8 MJ / m 2 Below, 6.7 MJ / m 2 Below, 6.5 MJ / m 2 Below, 6.4 MJ / m 2 Below, 6.3 MJ / m 2 Below, 6.2 MJ / m 2 Below, 6.1 MJ / m 2 Below, 6 MJ / m 2 Below, 5.9 MJ / m 2 Below, 5.8 MJ / m 2 Below, 5.7 MJ / m 2 Below, 5.6 MJ / m 2 Below, 5.5 MJ / m 2 Below, 5.4 MJ / m 2 Below, 5.3 MJ / m 2 Below, 5.2 MJ / m 2 Below, 5.1 MJ / m 2 or less, or 5 MJ / m 2 It could be as follows:

[0122] According to a second embodiment of the present invention, the foam may be a foam formed by foaming inside a fire door as described above, and may not be cut from a pre-manufactured insulating material, and thus may not have a separate cut surface. Here, the cut surface refers to a cut surface artificially created by cutting the insulating material.

[0123] According to the second embodiment of the present invention, the foam may be a foam formed by foaming inside a fire door as described above, and since the insulating material is first positioned before foaming the foam reactant to form the foam, and then the foam is formed, if pores exist in the insulating material, the foam may be impregnated into some of the pores of the insulating material, and may exist in a state of being filled in some of the pores of the insulating material.

[0124] According to a second embodiment of the present invention, the foam may be a foam formed by foaming inside the fire door as described above, and since it is not a product of cutting and processing a pre-manufactured insulating material, there is no need to use a separate adhesive to bond the front panel member, the rear panel member, and the side cover member to the insulating material. Accordingly, the fire door may not include a separate adhesive (BD) component other than the foam at the interface between the front panel member and the core material, between the rear panel member and the core material, and between the side cover member and the core material. Here, the separate adhesive (BD) component other than the core material may mean all components other than the components derived from the insulating material and the core material reactant for forming the core material.

[0125] According to a second embodiment of the present invention, when the front panel member or the rear panel member is separated from the fire door using only pressure without a cut surface, the fire door may be separated together with a portion of the foam attached to the surface of the separated front panel member or the separated rear panel member facing the inner side of the fire door. Here, separating the front panel member or the rear panel member from the fire door using only pressure without a cut surface means separating the front panel member or the rear panel member from the fire door by applying a pressure greater than the ductility of the foam without using a separate cutting device. As described above, the foam may be present in a state of being filled in the space formed by the front panel member, the rear panel member, the side cover member, and / or the insulation, and since the foam is formed in a state of being attached to the front panel member, the rear panel member, the side cover member, and / or the insulation by itself without being bonded to the front panel member, the rear panel member, the side cover member, and / or the insulation by an adhesive, the interfacial adhesive strength between the front panel member, the rear panel member, the side cover member, and / or the insulation and the foam may be very excellent. Accordingly, when the front panel member or the rear panel member is separated from the fire door by pressure alone without a cut surface, the foam may be torn off together while still being bonded to the front panel member or the rear panel member, and a part of the foam may be attached to the surface of the separated front panel member or the separated rear panel member facing the inner surface of the fire door and may be separated together.

[0126] According to a second embodiment of the present invention, the front panel member, the rear panel member, and the side cover member may not have a solution injection port (IH) or a sealing portion of the solution injection port (IH). In order to form the foam, when a foaming solution for forming an insulation material is injected into the inside of a fire door as described above, there is a problem that the foaming solution exhibits uneven flowability and spreadability when discharged, and eddies are formed, causing a deviation in the density of the foaming solution, and accordingly, the skin layer becomes uneven, causing a problem that the adhesion to the fire door is reduced. In addition, such a density deviation lowers the mechanical strength and flame retardant performance of the foaming solution, and becomes a factor that increases voids at the top and bottom. In addition, when the foaming solution is injected into the inside of the fire door through a single injection port (IH), partial shrinkage of the core material occurs due to uneven foam formation, which increases the possibility of changes over time such as product banding, air pockets, and wave phenomena. Additionally, eddies can cause a skin layer to form in the thickness direction, creating internal holes that degrade insulation performance. Furthermore, because an inlet hole (IH) must be machined to inject foaming solution into the fire door, unnecessary perforations can easily allow flame penetration, making it difficult to achieve fire resistance.However, the fire door according to the second embodiment of the present invention, like the fire door manufacturing method described below, fills a space formed by one side of a front panel member or a rear panel member and a side cover member and / or an insulating material by discharging a foam reactant, and as a more specific example, since the discharge port (O) arranged in a direction perpendicular to one side of the front panel member or the rear panel member continuously moves (OD) in an upward or downward direction from the lower or upper side of one side of the front panel member or the rear panel member while discharging (FD) the foam reactant, the foam is uniformly filled, and there is no need to artificially form a solution injection port (IH) in the front panel member, the rear panel member, and / or the side cover member. Accordingly, according to the second embodiment of the present invention, the fire door does not have a solution injection port (IH) in the front panel member, the rear panel member, and the side cover member, or a sealing portion for sealing the solution injection port after manufacturing the fire door, and can prevent all problems caused by the solution injection port (IH).

[0127]

[0128] The present invention provides a method for manufacturing a fire door according to a second embodiment.

[0129] According to a second embodiment of the present invention, the method for manufacturing a fire door may be a method for manufacturing a fire door according to the second embodiment described above. As a specific example, the method for manufacturing a fire door includes the steps of: (S100) disposing an insulating material in a space formed by one side of a front panel member or a rear panel member and a side cover member at 50% by volume or less; (S200) discharging and filling a foam reactant into a space formed by one side of the front panel member or the rear panel member and the side cover member, where no insulating material is disposed; And in the step (S200), one side of the rear panel member or the front panel member is covered on the foam reactant filled in the step, so as to correspond to one side of the front panel member or the rear panel member, and the other side of the front panel member or the rear panel member and the other side of the rear panel member or the front panel member are pressed against each other to the thickness of the fire door using a vertically driven compression press to harden the foam reactant, and the foam reactant includes a polyol mixture and an isocyanate compound in a weight ratio of 1:0.95 or more and 2.75 or less, and the polyol mixture includes 65 wt% or more and 100 wt% or less of an ester polyol and 0 wt% or more and 35 wt% or less of an ether polyol, and in the step (S200), the discharge pressure of the foam reactant is 100 bar or more and 200 bar or less, and in the step (S300), the discharge pressure of the foam reactant is 100 bar or more and 200 bar or less, and in the step (S300), the discharge pressure of the vertically driven compression press is 100 bar or more and 200 bar or less. The temperature may be 35°C or higher and 85°C or lower, and the curing time may be 8 minutes or longer.

[0130] According to a second embodiment of the present invention, the step (S100) may be performed by placing the insulation so that it comes into contact with an area corresponding to the inner surface of the front panel member or the rear panel member. At this time, the step (S200) may be performed by discharging and filling a foam reactant into a space formed by the other surface of the insulation that comes into contact with an area corresponding to the inner surface of the front panel member or the rear panel member and the side cover member.

[0131] According to a second embodiment of the present invention, the step (S100) may be performed by arranging the insulating material so that it comes into contact with at least one surface of the inner surface of the upper surface, the lower surface, the first side surface, and the second side surface of the fire door formed by the side cover member. In this case, the step (S200) may be performed by discharging and filling a foam reactant into a space formed by the front panel member, the rear panel member, the side cover member, and the insulating material.

[0132] According to a second embodiment of the present invention, the step (S100) may be performed by placing the insulation so that it comes into contact with the inner surfaces of the upper surface, lower surface, first side surface, and second side surface of the fire door formed by the side cover member, respectively, in areas corresponding to those of the inner surfaces. At this time, the step (S200) may be performed by discharging and filling the space formed by the front panel member, the rear panel member, and the insulation member with a foam reactant.

[0133] According to a second embodiment of the present invention, the step (S200) may be a step of filling a space formed by a front panel member, a rear panel member, a side cover member, and / or an insulating material by discharging a foam reactant to form a foam. The discharged foam reactant gradually expands through a chemical reaction and begins to fill the space formed by the front panel member, the rear panel member, the side cover member, and / or the insulating material of the fire door.

[0134] According to the second embodiment of the present invention, in the step (S200), the discharge can be performed while the discharge port arranged in a direction perpendicular to one side of the front panel member or the rear panel member continuously moves upward or downward from the lower part or upper part of one side of the front panel member or the rear panel member. That is, as illustrated in FIG. 3 (E-S1), the discharge is performed while the discharge port (O) is fixed so that the foam reactant does not accumulate and spread at one point in the space formed by the one side of the front panel member or the rear panel member and the side cover member, but continuously moves (OD) upward or downward from the lower part or upper part of one side of the front panel member or the rear panel member, thereby allowing the foam reactant to be poured more uniformly into the space formed by the front panel member, the rear panel member, the side cover member, and / or the insulation material.

[0135] According to the second embodiment of the present invention, the foam reactant may be the same as the core reactant of the first embodiment.

[0136] According to a second embodiment of the present invention, in step (S200), the polyol mixture and the isocyanate compound may be mixed during discharge. As a specific example, in step (S200), the discharge may be performed using a high-pressure foamer, and thus, the foam reactant may be foamed during discharge.

[0137] According to the second embodiment of the present invention, in the step (S200), the discharge pressure of the foam reactant may be 100 bar or more and 200 bar or less. If the discharge pressure is less than 100 bar, the stirring efficiency is insufficient, which causes a problem of a decrease in the conversion rate of isocyanate. If the discharge pressure exceeds 200 bar, the discharge passage of the foam reactant may be blocked, causing the discharge to be difficult, making it impossible to produce a uniform foam.

[0138] According to a second embodiment of the present invention, the step (S300) may be a step for forming a core material together with an insulating material from the foam reactant inside the fire door by covering the foam reactant filled in the step (S10) so that one side of the rear panel member or the front panel member corresponds to one side of the front panel member or the rear panel member, and using a vertically driven compression press, pressing the other side of the front panel member or the rear panel member and the other side of the rear panel member or the front panel member to make them adhere to the thickness of the fire door and hardening the foam reactant. Through such a step, a core material formed of the insulation and the foam can be formed.

[0139] According to the second embodiment of the present invention, in the step (S300), the temperature of the vertical drive compression press may be 35°C or higher and 85°C or lower. The temperature of the vertical drive compression press may be a processing temperature of the vertical drive compression press. As a specific example, the temperature of the vertical drive compression press may be 35°C or higher, 36°C or higher, 37°C or higher, 38°C or higher, 39°C or higher, or 40°C or higher, and may also be 85°C or lower, 84°C or lower, 83°C or lower, 82°C or lower, 81°C or lower, or 80°C or lower. When using the above-mentioned vertical driving compression press, if the temperature is below the lower limit, sufficient thermal curing does not occur, which causes a problem in that the conversion rate of isocyanate decreases, and if the temperature exceeds the upper limit, the foam reactant may swell within the fire door during the above-mentioned (S300) step, and thermal curing may be completed before it is completely filled, resulting in an unfilled area.

[0140] According to the second embodiment of the present invention, in the step (S300), when the other surface of the front panel member or the rear panel member and the other surface of the rear panel member or the front panel member are pressed and pressed to the thickness of the fire door using a vertical driving compression press to harden the foam reactant, the hardening time may be 8 minutes or more. As a specific example, the hardening time may be 8 minutes or more, 9 minutes or more, or 10 minutes or more, and may also be 60 minutes or less, 55 minutes or less, 50 minutes or less, 45 minutes or less, 40 minutes or less, 35 minutes or less, or 30 minutes or less. If the hardening time is less than 8 minutes, the hardening of the foam in which the reaction has occurred may not be completed, which may cause problems such as shrinkage of the foam and product banding inside the fire door. In addition, if the hardening time is controlled within the upper limit range, productivity can be further improved.

[0141] According to a second embodiment of the present invention, the foam reactant may include a polyol mixture and an isocyanate compound. That is, the foam reactant may be a reactant for forming polyurethane.

[0142] According to a second embodiment of the present invention, the reaction of the foam reactant may have a gelling time of 100 seconds or more and 240 seconds or less. First, depending on the reaction time of the foam to be foamed, it can be divided into cream time, rising time, and gelling time. The time from the time when the polyol mixture and the isocyanate compound are mixed at a certain ratio at a temperature of 20℃ to the time when the foam reactant begins to swell is called the cream time. In addition, the time until the foam reactant swells and reaches its maximum height is called the rising time. In addition, the time when the foam solidifies while having elasticity after the rising time is passed is called the gelling time. Here, it may be preferable that the foam reactant have a gelling time of 100 seconds or more and 240 seconds or less. When the gelling time is adjusted within the above range, in the step (S300), the foam reactant is covered so that either one side of the rear panel member or the front panel member corresponds to either one side of the front panel member or the rear panel member, and before being placed in the vertical driving compression press, the foam reactant is prevented from swelling, thereby allowing the foam to sufficiently settle, and the reaction and curing times are prevented from becoming too long, thereby further reducing costs along with improved productivity.

[0143] According to a second embodiment of the present invention, the foam reactant may have an isocyanate conversion rate of 80% or more. For example, the foam reactant may have an isocyanate conversion rate of 80% or more, 81% or more, 82% or more, 83% or more, 84% or more, or 85% or more, and may also have an isocyanate conversion rate of 100% or less, 95% or less, or 90% or less. When the isocyanate conversion rate is controlled within the above range, the chemical reaction can be prevented from continuing even after the foam is formed due to residual isocyanate, and thus shrinkage and deformation of the foam can be prevented in the long term, thereby preventing deformation of the fire door. The isocyanate conversion rate can be confirmed through FT-IR measurement. The peak of FT-IR indicating isocyanate is 2275 cm -1 It appears in , and the lower the peak height, the more consumed it can be judged. The peak area of ​​pure isocyanate that has not reacted at all is set as the conversion rate of 0%, and the peak area of ​​the isocyanate of the foam that has completed the reaction is set as 100% as the standard, and then by sampling the foam that has completed the chemical reaction through the actual process and measuring FT-IR, the conversion rate of the isocyanate can be derived.

[0144] According to a second embodiment of the present invention, the foam reactant may include a polyol mixture and an isocyanate-based compound in a weight ratio of 1:0.95 or more and 2.75 or less. As a specific example, the foam reactant may include a polyol mixture and an isocyanate-based compound in a weight ratio of 1:0.95 or more, 0.96 or more, 0.97 or more, 0.98 or more, 0.99 or more, 1 or more, 1.1 or more, 1.2 or more, or 1.3 or more, and also 2.75 or less, 2.7 or less, 2.65 or less, 2.6 or less, 2.55 or less, 2.5 or less, 2.45 or less, 2.4 or less, 2.35 or less, 2.3 or less, 2.25 or less, 2.2 or less, 2.15 or less, 2.1 or less, 2.05 or less, or 2 or less. In the above weight ratio, if the weight ratio of the isocyanate compound to the polyol mixture exceeds the lower limit, there is a problem of reduced flame retardancy, and if it exceeds the upper limit, there is a problem of reduced conversion rate of isocyanate due to an excess of isocyanate.

[0145] According to a second embodiment of the present invention, the polyol mixture may include an ester polyol and an ether polyol. As a specific example, the polyol mixture may include the ester polyol in an amount of 65 wt% or more, 66 wt% or more, 67 wt% or more, 68 wt% or more, 69 wt% or more, or 70 wt% or more, and further may include the ester polyol in an amount of 100 wt% or less, 99 wt% or less, 98 wt% or less, 97 wt% or less, 96 wt% or less, 95 wt% or less, 94 wt% or less, 93 wt% or less, 92 wt% or less, 91 wt% or less, or 90 wt% or less. Accordingly, the polyol mixture may contain the ether polyol as a remainder of 0 wt% or more, 1 wt% or more, 2 wt% or more, 3 wt% or more, 4 wt% or more, 5 wt% or more, 6 wt% or more, 7 wt% or more, 8 wt% or more, 9 wt% or more, or 10 wt% or more, and may also contain 35 wt% or less, 34 wt% or less, 33 wt% or less, 32 wt% or less, 31 wt% or less, or 30 wt% or less. If the ester polyol is contained in a content less than the above range in the components of the polyol mixture, the problem of reduced flame retardancy may occur, and in particular, as the content of the ether polyol increases, the shrinkage phenomenon of the foam inside the fire door increases, which may generate an unfilled area and cause deformation of the fire door.

[0146] According to a second embodiment of the present invention, the ester-based polyol may include a first ester-based polyol and a second ester-based polyol. Here, the first ester-based polyol and the second ester-based polyol may be of a series of ester-based polyols, but may be of different types, or may be of the same type but have different viscosities. As a specific example, the first ester-based polyol may have a viscosity of 13,000 cP (centipoise) or more and 19,000 cP (centipoise) or less at 25°C, and the second ester-based polyol may have a viscosity of 7,500 cP (centipoise) or more and 16,000 cP (centipoise) or less at 25°C. When the viscosity of the above ester polyol is adjusted within the above range, the occurrence of bubbles within the foam reactant can be minimized, thereby preventing the occurrence of holes or voids within the core material after the chemical reaction, and the occurrence of unfilled areas can be further prevented by sufficiently securing the rate at which the foam rises after the foam reactant is discharged.

[0147] According to a second embodiment of the present invention, the ester polyol may be polymerized using phthalic anhydride, isophthalic acid, terephthalic acid, PET, benzoic acid or adipic acid, and ethylene oxide, propylene oxide or a mixture thereof as raw materials.

[0148] According to a second embodiment of the present invention, the ether polyol may be polymerized using at least one selected from the group consisting of ethylene glycol, 1,2-propane glycol, 1,3-propylene glycol, butylene glycol, 1,6-hexanediol, 1,8-octanediol, neopentyl glycol, 2-methyl-1,3-propanediol, glycerol, trimethylolpropane, 1,2,3-hexanetriol, 1,2,4-butanetriol, trimethylolmethane, pentaerythritol, diethylene glycol, triethylene glycol, polyethylene glycol, tripropylene glycol, polypropylene glycol, dibutylene glycol, polybutylene glycol, sorbitol, sucrose, hydroquinone, resorcinol, catechol, and bisphenol, and ethylene oxide, propylene oxide, or a mixture thereof as a raw material.

[0149] According to a second embodiment of the present invention, the ether polyol may have a viscosity of 13,500 cP (centipoise) or more and 17,000 cP (centipoise) or less at 25°C. When the viscosity of the ether polyol is adjusted within the above range, the generation of bubbles within the foam reactant can be minimized, thereby preventing the generation of holes or voids within the foam after the chemical reaction, and the rate at which the foam rises after the foam reactant is discharged can be sufficiently secured, thereby further preventing the generation of unfilled areas.

[0150] According to the second embodiment of the present invention, the isocyanate compound may be m-MDI (monomeric-methylene diisocyanate), p-MDI (polymericmethylene diisocyanate), TDI (toluene diisocyanate), derivatives thereof, or mixtures thereof.

[0151] According to a second embodiment of the present invention, the foam reactant may include at least one selected from the group consisting of a catalyst, a flame retardant, a foaming agent, and a blowing agent. Here, when the foam reactant includes at least one selected from the group consisting of a catalyst, a flame retardant, a foaming agent, and a blowing agent, the at least one selected from the group consisting of the catalyst, the flame retardant, the foaming agent, and the blowing agent may be mixed with an isocyanate compound when discharged in a mixed state in a polyol mixture.

[0152] According to a second embodiment of the present invention, the catalyst may include a trimerization catalyst. As a specific example, the trimerization catalyst may include a tertiary amine, a triazine, and a metal salt trimerization catalyst, and the metal salt trimerization catalyst may be an alkali metal salt of an organic carboxylic acid. The organic carboxylic acid may be acetic acid or 2-ethylhexanoic acid, and the alkali metal may be potassium or sodium.

[0153] According to a second embodiment of the present invention, when the foam reactant includes the catalyst, the catalyst may be included in an amount of 0.1 part by weight or more, 0.2 part by weight or more, 0.3 part by weight or more, 0.5 part by weight or more, 0.6 part by weight or more, 0.7 part by weight or more, 0.8 part by weight or more, 0.9 part by weight or more, or 1 part by weight or more, based on 100 parts by weight of the polyol mixture, and may also be included in an amount of 5 parts by weight or less, 4.5 parts by weight or less, 4 parts by weight or less, 3.5 parts by weight or less, or 3 parts by weight or less.

[0154] According to a second embodiment of the present invention, the flame retardant may be at least one selected from the group consisting of a phosphorus-based flame retardant, a metal hydrate or metal ion-based flame retardant, a halogen-based flame retardant, an inorganic flame retardant, nanoclay, carbon nanotubes, or a mixture thereof.

[0155] According to a second embodiment of the present invention, when the foam reactant includes the flame retardant, the flame retardant may be included in an amount of 5 parts by weight or more, 10 parts by weight or more, 15 parts by weight or more, 20 parts by weight or more, or 25 parts by weight or more, based on 100 parts by weight of the polyol mixture, and may also be included in an amount of 50 parts by weight or less, 45 parts by weight or less, 40 parts by weight or less, 35 parts by weight or less, or 30 parts by weight or less.

[0156] According to a second embodiment of the present invention, the foam stabilizer may be a silicone-based foam stabilizer and / or a non-silicone-based foam stabilizer. As a specific example, the silicone-based foam stabilizer may be a copolymer based on silicon, which may include or be combined with it, and the non-silicone-based foam stabilizer may be a copolymer based on silicon, which may include or be combined with dinonylphenol, methyl glucoside, methyl propanediol, vinyl ether maleic acid, vegetable oil, and the like.

[0157] According to a second embodiment of the present invention, when the foam reactant includes the foam stabilizer, the foam stabilizer may be included in an amount of 0.1 part by weight or more, 0.2 part by weight or more, 0.3 part by weight or more, 0.5 part by weight or more, 0.6 part by weight or more, 0.7 part by weight or more, 0.8 part by weight or more, 0.9 part by weight or more, or 1 part by weight or more, based on 100 parts by weight of the polyol mixture, and may also be included in an amount of 5 parts by weight or less, 4.5 parts by weight or less, 4 parts by weight or less, 3.5 parts by weight or less, or 3 parts by weight or less.

[0158] According to a second embodiment of the present invention, the blowing agent may be at least one selected from the group consisting of cyclopentane, chlorofluorocarbon, isopentane, normal pentane, hydrochlorofluorocarbon, hydrofluorocarbon, and water.

[0159] According to a second embodiment of the present invention, when the foam reactant includes the foaming agent, the foaming agent may be included in an amount of 5 parts by weight or more, 10 parts by weight or more, 15 parts by weight or more, or 20 parts by weight or more, based on 100 parts by weight of the polyol mixture, and may also be included in an amount of 50 parts by weight or less, 45 parts by weight or less, 40 parts by weight or less, 35 parts by weight or less, 30 parts by weight or less, or 25 parts by weight or less.

[0160] According to the second embodiment of the present invention, the foam formed by curing in the step (S300) may have a shrinkage rate calculated by Equation 1 below of less than 4%. As a specific example, the foam formed by curing in the step (S300) may have a shrinkage rate calculated by Equation 1 below of less than 4%, 3.5% or less, 3% or less, 2.5% or less, or 2% or less. This is an indicator of shrinkage of the foam over time, and when the shrinkage rate calculated by Equation 1 below is within the above range, it can be seen that the deterioration of the insulation over time over the period of use is prevented, and deformation of the fire door is minimized.

[0161] [Formula 1]

[0162] Contraction ratio = {(V1 - V2) / V1} X 100

[0163] In the above equation 1, V1 is the volume of the foam immediately after being formed by hardening, and V2 is the volume of the foam after 24 hours.

[0164]

[0165] Hereinafter, embodiments of the present invention will be described in detail so that those skilled in the art can easily implement them. However, the present invention may be implemented in various different forms and is not limited to the embodiments described herein.

[0166]

[0167] Experimental Example 1: Change in the weight ratio of polyol mixture and isocyanate compound

[0168] Examples 1 to 5 and Comparative Examples 1 to 9

[0169] For each example and comparative example, a foaming reactant was mixed using the following components, and a polyol mixture (Part 1) and an isocyanate-based compound (Part 2) were foamed using a high-pressure foamer while moving the discharge port from the bottom to the top in the space formed by one side of the front panel member and the side cover member. At this time, the discharge pressure of the discharge port was 150 bar. After the foaming was completed, the discharged foaming reactant was covered with one side of the rear panel member, and using a vertically driven compression press, the other side of the front panel member and the other side of the rear panel member were pressurized at a temperature of 60°C for 20 minutes to seal the other side of the front panel member and the other side of the rear panel member to the thickness of the fire door, and the foaming reactant was hardened to manufacture a fire door.

[0170] The content of each component is based on 100 parts by weight of polyol mixture (POL), and the weight of the polyol mixture and the isocyanate compound is expressed as a ratio (POL:ISO).

[0171]

[0172] - First ester polyol (ESP1): AK POL-7001 (viscosity 13,000 cP to 19,000 cP at 25 ℃) from Aekyung Chemical Co., Ltd. was used.

[0173] - Second ester polyol (ESP2): AK POL-4005 (viscosity 7,500 cP to 16,000 cP at 25 ℃) from Aekyung Chemical Co., Ltd. was used.

[0174] - Ether polyol (EP): Kumho Petrochemical's PPG 391 (viscosity 13,500 cP to 17,000 cP at 25 ℃) was used.

[0175] - Isocyanate compound (ISO): Kumho Mitsui Chemicals’ M-200 (p-MDI, polymeric-methylene diisocyanate) was used.

[0176] - Catalyst composition (CA): A catalyst composition containing an acid catalyst, N-(2-dimethylamino)ethyl-N,N',N'-triethyl-1,2-ethanediamine (Evonik), and 2-trimethylammonium formate hydroxypropyl (Evonik) was used.

[0177] - Flame retardant (FR): Triethyl phosphate was used.

[0178] - Stabilizer (SF): Siloxane polyalkylene oxide or a mixture containing the same was used.

[0179] - Solid flame retardant (SFR): Red phosphorus was used.

[0180] - Blowing agent (FA): 1,1-dichloro-1-fluoromethane or a mixture containing the same was used.

[0181]

[0182] For the fire doors manufactured in Examples 1 to 5 and Comparative Examples 1 to 9, the NCO Index, isocyanate conversion rate, and flame retardancy were measured using the following methods, and the results are shown in Tables 1 and 2 below.

[0183]

[0184] * NCO Index: Calculated using Equation 2 based on the contents of the first ester polyol (ESP1), the second ester polyol (ESP2), the ether polyol (EP), and the isocyanate compound (ISO) used in the manufacture of the fire door in Examples 1 to 5 and Comparative Examples 1 to 9.

[0185] [Formula 2]

[0186] NCO Index = (56,100 X NCO % of ISO input X Total input of polyol mixture X Liquid ratio of ISO and polyol mixture) / [{(Input of ESP1 X OH-value of ESP1) + (Input of ESP2 X OH-value of ESP2) + (Input of EP X OH-value of EP)} X 4,200]

[0187] In the above formula 2, the polyol mixture means a mixture of a first ester polyol (ESP1), a second ester polyol (ESP2), and an ether polyol (EP), 56,100 is a constant representing the molecular weight of KOH, 4,200 is a constant representing the molecular weight of NCO, the NCO % of the input ISO is applied as a percentage value excluding the % unit, the total input amount of the polyol mixture is based on parts by weight, and the liquid ratio of the ISO and the polyol mixture is a weight ratio according to each part by weight.

[0188]

[0189] * Isocyanate conversion rate (%): As shown in Figure 1, 2275 cm represents pure isocyanate. -1 The area of ​​the FT-IR peak at 2275 cm is set to 0% conversion, and the area of ​​the FT-IR peak at 2275 cm is set to 0% conversion. -1 The area of ​​the FT-IR peak at 100% conversion was used as the standard, and after removing the rear panel members of the fire doors manufactured in Examples 1 to 5 and Comparative Examples 1 to 9, the FT-IR of the core material formed inside, i.e., the foam manufactured in the actual process, was measured. Here, 2275 cm -1 The conversion rate was calculated by measuring the area of ​​the FT-IR peak.

[0190]

[0191] * Flame retardancy (MJ / m 2): After removing the rear panel members of the fire doors manufactured in Examples 1 to 5 and Comparative Examples 1 to 9, the total heat release rate after 10 minutes of combustion was measured for the core material formed inside according to the test method of ISO 5660-1.

[0192]

[0193] Classification Example 12345 Mixing conditions POLE SP 140 40 40 40 40 EPS 230 30 30 30 EP 30 30 30 30 CA 2.8 2.8 2.8 2.8 2.8 2.8 FE 20 20 20 20 20 SF 22 22 SFR 7.3 57 357 357 357 357 35 Water 1.3 1.3 1.3 1.3 1.3 1.3 FA 21 21 21 21 21 Molding conditions POL: ISO 1:11:1.3 1:1.5 1:21:2.5 NCO Index 16 0 20 5 23 6 31 5 39 3 Isocyanate conversion rate (%) 85 or more 85 or more 85 or more 85 or more 85 or more Flame retardancy (MJ / m 2 )7.45.54.25.36.8

[0194] Classification Comparison Example 123456789 Mixing Conditions POLE SP 14040404040404040404040EPS 2303030303030303030EP 303030303030303030CA 2.82.82.82.82.82.82.82.82.8FE 202020202020202020SF 222222222SFR 7.357.357.357.357.357.357.357.357.357.357.35Water 1.31.31.31.31.31.31.31.31.3FA 212121212121212121 Molding Conditions POL:ISO1:0.11:0.31:0.61:0.91:2.81:31:3.21:3.51:4 NCO Index164795140410470505550630 Isocyanate Conversion Rate (%) 90 or more 90 or more 90 or more 90 or more Less than 80 Less than 60 Less than 60 Less than 60 Less than 60 Flame Retardancy (MJ / m 2 )1412.510.18.28.18.49.19.39.5

[0195] As shown in Tables 1 and 2 above, Examples 1 to 5, which were manufactured by adjusting the weight ratio of the polyol mixture and the isocyanate compound within the range limited by the present invention, exhibited an NCO Index of 150 or more and 400 or less, an isocyanate conversion rate of 85% or more, and a flame retardancy of 8 MJ / m 2 It was confirmed that it appeared as .

[0196] On the other hand, in Comparative Examples 1 to 4 where the weight ratio of the isocyanate compound to the polyol mixture was low, the isocyanate conversion rate was high, but it was confirmed that the flame retardancy was significantly reduced.

[0197] In addition, in the case of Comparative Examples 5 to 9 where the weight ratio of the isocyanate compound to the polyol mixture was high, it was confirmed that the flame retardancy improvement effect was minimal and the isocyanate conversion rate was very low.

[0198]

[0199] Experimental Example 2: Change in discharge pressure

[0200] Examples 6 to 10 and Comparative Examples 10 to 17

[0201] For each example and comparative example, the foam reactants were mixed using the same ingredients as in Experimental Example 1, and a polyol mixture (Part 1) and an isocyanate-based compound (Part 2) were foamed using a high-pressure foamer while moving the discharge port from the bottom to the top in the space formed by one side of the front panel member and the side cover member. At this time, the discharge pressure of the discharge port was adjusted to the pressures shown in Tables 3 and 4 below. After the foaming was completed, the discharged foam reactants were covered with one side of the rear panel member, and using an up-and-down compression press, the other side of the front panel member and the other side of the rear panel member were pressurized at a temperature of 60°C for 20 minutes to seal them to the thickness of the fire door, and the foam reactants were cured to manufacture a fire door.

[0202] The content of each component is based on 100 parts by weight of polyol mixture (POL), and the weight of the polyol mixture and the isocyanate compound is expressed as a ratio (POL:ISO).

[0203]

[0204] For the fire doors manufactured in Examples 6 to 10 and Comparative Examples 10 to 17, the average cell size was measured using the following method, and the formation and appearance were observed with the naked eye, and are shown in Tables 3 and 4 below. In addition, the isocyanate conversion rate was measured using the same method as in Experimental Example 1, and is also shown in Tables 3 and 4 below.

[0205]

[0206] * Average cell size (㎛): Specimens measuring 20 mm in width X 20 mm in height X 1 mm in thickness were collected from the core materials of the fire doors manufactured in Examples 6 to 10 and Comparative Examples 10 to 17, and then measured at 150x magnification using SEM. Using the measured SEM images, the cell sizes of 20 cells were measured based on the horizontal and vertical cell diameters through image scanning, and then the average cell size was calculated by taking the arithmetic mean from the sizes of each measured cell.

[0207]

[0208] Classification Example 678910 Mixing Conditions POLE SP 1 40 40 40 40 40 EPS 2 30 30 30 30 EP 3 0 30 30 30 AC 1 1 1 1 EC 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 FE 2 2 2 2 2 2 2 SF 2 2 2 2 2 2 SFR 7 3 5 ... And appearance normal isocyanate conversion rate (%) 85 or more 85 or more 85 or more 85 or more 85 or more

[0209] Classification Comparison Example 10 1 1 1 2 1 3 1 4 1 5 1 6 1 7 Mixing Conditions POLE SP 1 4 0 ... Conditions POL:ISO1:1.61:1.61:1.61:1.61:1.61:1.61:1.61:1.61:1.61:1.6POL / ISO Discharge pressure (bar) 50 / 50 70 / 70 80 / 80 90 / 90 210 / 210 230 / 230 240 / 240 250 / 250 Average cell size (㎛) 320 318 290 276 Not possible to manufacture (foamer pressure limitation) Shape and appearance Discoloration Good appearance Isocyanate conversion rate (%) Less than 80 Less than 80 Less than 80 Less than 80

[0210] As shown in Tables 3 and 4 above, it was confirmed that Examples 6 to 10, which were manufactured by controlling the discharge pressure within the range limited by the present invention, had an average cell size of 270 ㎛ or less, an isocyanate conversion rate of 85% or more, and a normal shape and appearance.

[0211] On the other hand, in the case of Comparative Examples 1 and 2 in which the discharge pressure was controlled very low, it was confirmed that the average cell size was very large, exceeding 300 ㎛, the isocyanate conversion rate was less than 80%, and discoloration occurred.

[0212] In addition, in the case of comparative examples 3 and 4 in which the discharge pressure was adjusted low, it was confirmed that the average cell size was still large at 290 ㎛ and 276 ㎛, and the isocyanate conversion rate was less than 80%.

[0213] Meanwhile, in the case of comparative examples 14 to 17 in which the discharge pressure was adjusted high, the production of the fire door itself was impossible due to the pressure limit of the foamer.

[0214]

[0215] Experimental Example 3: Temperature and curing time changes in a vertical compression press

[0216] Examples 11 to 16 and Comparative Examples 18 to 24

[0217] For each example and comparative example, the foam reactants were mixed using the same ingredients as in Experimental Example 1, and a polyol mixture (Part 1) and an isocyanate-based compound (Part 2) were foamed using a high-pressure foamer while moving the discharge port from the bottom to the top in the space formed by one side of the front panel member and the side cover member. At this time, the discharge pressure of the discharge port was 150 bar. After the foaming was completed, the discharged foam reactants were covered with one side of the rear panel member, and using an up-and-down compression press, the other side of the front panel member and the other side of the rear panel member were pressurized at the temperature shown in Tables 5 and 6 below for the time shown in Tables 5 and 6 below to seal them tightly to the thickness of the fire door, thereby hardening the foam reactants and manufacturing a fire door.

[0218] The content of each component is based on 100 parts by weight of polyol mixture (POL), and the weight of the polyol mixture and the isocyanate compound is expressed as a ratio (POL:ISO).

[0219]

[0220] For the fire doors manufactured in Examples 11 to 16 and Comparative Examples 18 to 24, the filling ratio, substrate adhesion, and shrinkage ratio were measured using the following methods, and are shown in Tables 5 and 6 below. In addition, the isocyanate conversion rate was measured using the same method as Experimental Example 1, and is also shown in Tables 5 and 6 below.

[0221]

[0222] * Filling ratio (volume %): The filling ratio of the base material without core material inside the fire door was set as 0 volume%, and the filling ratio of the base material with core material tightly filled was set as 100 volume%. The filling ratio was calculated based on the area of ​​core material filled in the base material.

[0223]

[0224] * Adhesion of substrate: The test was conducted by referring to KS M 3871-1:2010, Rigid foamed plastics - Spray-type medium-density polyurethane foam - Part 1: Specifications, Section 6.10, Adhesion of substrate. At this time, the adhesion tester can check the measurement value for adhesion using a commercially available push-pull gauge.

[0225]

[0226] * Shrinkage rate: After removing the rear panel member of the fire door manufactured in Examples 11 to 16 and Comparative Examples 18 to 24, a sample measuring 300 mm in width X 300 mm in length X 50 mm in thickness was taken from the core material formed inside, and after 24 hours, the width, length, and thickness of the sample were measured, and the shrinkage rate was calculated according to the following Equation 1.

[0227] [Formula 1]

[0228] Contraction ratio = {(V1 - V2) / V1} X 100

[0229] In the above equation 1,

[0230] V1 is the volume of the foam immediately after it has been hardened and formed,

[0231] V2 is the volume of the foam after 24 hours

[0232]

[0233] Classification Example 111213141516 Mixing Conditions POLE SP 140404040404040 EPS 23030303030 EP 303030303030 AC 111111 EC 1.81.81.81.81.81.8 FE 202020202020 SF 222222 SFR 7.357.357.357.357.357.357.35 Water 1.31.31.31.31.31.3 FA 212121212121 Molding Condition POL:ISO1:1.61:1.61:1.61:1.61:1.61:1.61:1.6 Temperature (℃) 40 50 60 70 40 80 Time (min) 20 20 20 30 10 Filling ratio (%) 100 100 100 100 100 100 Isocyanate conversion rate (%) 85 or more 85 or more 85 or more 85 or more 85 or more 85 or more 85 or more Substrate adhesion Good Good Good Good Good Good Shrinkage rate (%) 2 or less 2 or less 2 or less 2 or less 2 or less 2 or less

[0234] Classification Comparison Example 18 19 20 21 22 2 32 4 Mixing Conditions POLE SP 1 4 0 ... Condition POL:ISO1:1.61:1.61:1.61:1.61:1.61:1.61:1.61:1.6Temperature(℃)2030203090100100Time(min)202055555Filling rate(%)100100100100959085Isocyanate conversion rate(%)70 or less70 or less70 or less70 or less85 or more85 or more85 or moreSubstrate adhesionPoorPoorPoorPoorGoodGoodGoodShrinkage rate(%)4~54~510 or more10 or more2 or less2 or less2 or less

[0235] As shown in Tables 5 and 6 above, in Examples 11 to 16 in which the temperature and curing time of the vertical drive compression press were controlled within the ranges limited by the present invention, it was confirmed that the core material was fully filled, the isocyanate conversion rate was 85% or more, the substrate adhesion was excellent, and the shrinkage rate was minimized.

[0236] On the other hand, it was confirmed that Comparative Examples 18 and 19, in which the temperature of the vertical drive compression press was low, had a low isocyanate conversion rate, poor substrate adhesion, and high shrinkage rate.

[0237] In addition, it was confirmed that Comparative Examples 20 and 21, in which the temperature of the vertical drive compression press was low and the curing time was controlled to be short, had a low isocyanate conversion rate, poor substrate adhesion, and very high shrinkage rate.

[0238] Meanwhile, in the case of comparative examples 22 to 24 in which the temperature of the vertical drive compression press was increased, it was confirmed that an area in which the core material was not filled occurred, and in particular, it was confirmed that the unfilled area increased as the temperature increased.

[0239]

[0240] Experimental Example 4: Weight change of ester polyol

[0241] Examples 17 to 22 and Comparative Examples 25 to 31

[0242] For each example and comparative example, the foam reactants were mixed using the same ingredients as in Experimental Example 1, and a polyol mixture (Part 1) and an isocyanate-based compound (Part 2) were foamed using a high-pressure foamer while moving the discharge port from the bottom to the top in the space formed by one side of the front panel member and the side cover member. At this time, the discharge pressure of the discharge port was 150 bar. After the foaming was completed, the discharged foam reactant was covered with one side of the rear panel member, and using an up-and-down compression press, the other side of the front panel member and the other side of the rear panel member were pressurized at a temperature of 60 ℃ for 20 minutes to seal them to the thickness of the fire door, and the foam reactants were hardened to manufacture a fire door.

[0243] The content of each component is based on 100 parts by weight of polyol mixture (POL), and the weight of the polyol mixture and the isocyanate compound is expressed as a ratio (POL:ISO).

[0244]

[0245] For the fire doors manufactured in Examples 17 to 22 and Comparative Examples 25 to 31, the flame retardancy was measured using the same method as in Experimental Example 1, and the shrinkage rate was measured using the same method as in Experimental Example 3, and the results are shown in Tables 7 and 8 below.

[0246]

[0247] Classification Example 17 18 19 20 2 12 2 Mixing Conditions POLE SP 1 4 0 3 0 4 0 5 0 4 0 5 0 EPS 2 3 0 4 0 4 0 5 5 0 EP 3 0 3 0 2 0 1 0 5 0 AC 1 1 1 1 1 1 EC 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 FE 2 2 2 2 2 2 2 2 2 2 SFR 7 3 5 ... 2 )4.24.44.13.83.73.3Shrinkage rate (%)2 or less2 or less2 or less2 or less2 or less3 or less

[0248] Classification Comparison Example 25 26 27 28 29 30 31 Mixing Conditions POLE SP 1 300 50 20 10 100 EPS 2 30 50 0 20 10 00 EP 4 0 50 50 60 80 90 100 AC 1 1 1 1 1 1 EC 1 8 ... 2 )8.18.48.28.88.78.99Shrinkage rate (%)2 or less2 or less2 or less3 or less5 or more5 or moreShrinkage occurs immediately after foaming

[0249] As shown in Tables 7 and 8 above, in the case of Examples 17 to 22 in which the content of ester polyol and ether polyol was adjusted within the range limited by the present invention for the polyol mixture, it was confirmed that the flame retardancy was excellent and the shrinkage rate was minimized.

[0250] On the other hand, in the case of Comparative Examples 25 to 31 in which the content of ether-based polyol was increased, it was confirmed that the flame retardancy was reduced, and in particular, it was confirmed that the shrinkage rate increased as the content of ether-based polyol increased, and in particular, in the case of Comparative Example 31 in which only ether-based polyol was used, it was confirmed that shrinkage occurred immediately after foaming.

[0251]

[0252] [Explanation of symbols]

[0253] 100: Fire door

[0254] 10: Front panel absence or rear panel absence

[0255] 20: Side panel member

[0256] 30: Rear panel absence or front panel absence

[0257] 40: Insulation

[0258] 41: Insulation material in the inner direction of the upper surface of the fire door formed by the side cover member

[0259] 42: Insulation material in the inner direction of the lower surface of the fire door formed by the side cover member

[0260] 43: Insulation material in the inner direction of the first side of the fire door formed by the side cover member

[0261] 44: Insulation material in the inner direction of the second side of the fire door formed by the side cover member

[0262] 50: Foam

[0263] IM: Shim Jae

[0264] O: outlet

[0265] OD: Direction of movement of outlet

[0266] FD: Discharge direction

[0267] UB: Urethane board

[0268] BD: Bond

[0269] IH: Inlet

[0270] DH: Door handle forming part

Claims

1. Including a front panel member; a rear panel member; a side cover member; and a core material, The above heart material, It exists in a filled state in the space formed by the front panel member, the rear panel member and the side cover member, and the filling rate exceeds 95 volume%, The average cell size is less than 275 ㎛, A total heat release rate of 8 MJ / m2 after 10 minutes of combustion as measured by the test method of ISO 5660-1. 2 Fire door as follows.

2. In paragraph 1, Fire doors with an NCO index of 120 or more and 400 or less.

3. In paragraph 1, A fire door wherein the side cover member is integrated with the front panel member or the rear panel member.

4. In paragraph 1, The above fire door is made of foam.

5. In paragraph 1, A fire door in which the above core material has no cross-section.

6. In paragraph 1, The above fire door, A fire door that does not contain a separate adhesive component other than the core material at the interface between the front panel member and the core material, between the rear panel member and the core material, and between the side cover member and the core material.

7. In paragraph 1, The above fire door, When the front panel member or the rear panel member is separated from the fire door by pressure alone without a cut surface, A fire door in which a part of the core material is attached to the inner surface of the fire door of a separated front panel member or a separated rear panel member and is separated together.

8. In paragraph 1, A fire door wherein the front panel member, the rear panel member and the side cover member do not have a solution injection port or a sealing portion of the solution injection port.

9. A step (S10) of discharging and filling a core reactant into a space formed by one side of the front panel member or the rear panel member and the side cover member; and In the step (S10), one side of the rear panel member or the front panel member is covered on the core reactant filled in the step, so as to correspond to one side of the front panel member or the rear panel member, and the other side of the front panel member or the rear panel member and the other side of the rear panel member or the front panel member are pressed using a vertically driven compression press to make them adhere to each other to the thickness of the fire door, thereby hardening the core reactant (S20). The above core reactant comprises a polyol mixture and an isocyanate compound in a weight ratio of 1:0.95 or more and 2.75 or less, The above polyol mixture comprises 65 wt% or more and 100 wt% or less of ester-based polyol, and 0 wt% or more and 35 wt% or less of ether-based polyol. In the above step (S10), the discharge pressure of the core reactant is 100 bar or more and 200 bar or less, A method for manufacturing a fire door, wherein, in the step (S20), the temperature of the upper and lower driving compression press is 35°C or higher and 85°C or lower, and the curing time is 8 minutes or longer.

10. In paragraph 9, A method for manufacturing a fire door, wherein in the step (S10), the polyol mixture and the isocyanate compound are mixed during discharge.

11. In paragraph 9, A method for manufacturing a fire door, wherein, in the step (S10), the core reactant foams when discharged.

12. In paragraph 9, A method for manufacturing a fire door, wherein, in the step (S10), the discharge is performed by continuously moving an discharge port arranged in a direction perpendicular to one side of the front panel member or the rear panel member in an upward or downward direction from the lower or upper side of one side of the front panel member or the rear panel member.

13. In paragraph 9, A method for manufacturing a fire door, wherein the core reactant has a gelling time of 100 seconds or more and 240 seconds or less.

14. In paragraph 9, A method for manufacturing a fireproof door, wherein the core reactant has an isocyanate conversion rate of 80% or more.

15. In paragraph 9, A method for manufacturing a fireproof door, wherein the ester polyol comprises a first ester polyol and a second ester polyol.

16. In paragraph 15, A method for manufacturing a fire door, wherein the first ester polyol has a viscosity of 13,000 cP or more and 19,000 cP or less at 25°C.

17. In paragraph 15, A method for manufacturing a fire door, wherein the second ester polyol has a viscosity of 7,500 cP or more and 16,000 cP or less at 25°C.

18. In paragraph 9, A method for manufacturing a fire door, wherein the above ether polyol has a viscosity of 13,500 cP or more and 17,000 cP or less at 25°C.

19. In paragraph 9, A method for manufacturing a fire door, wherein the core reactant comprises at least one selected from the group consisting of a catalyst, a flame retardant, a foaming agent, and a foaming agent.

20. In paragraph 9, A method for manufacturing a fire door, wherein the foam formed by hardening in the above step (S20) has a shrinkage rate of less than 4% calculated by the following equation 1: [Formula 1] Contraction ratio = {(V1 - V2) / V1} X 100 In the above equation 1, V1 is the volume of the foam immediately after it has been hardened and formed, V2 is the volume of the foam after 24 hours.

Images