JPS5821653B2 - Method for manufacturing flame-retardant cold-curing plastic foam - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a foam that improves flame retardancy and expansion ratio by adding a special fire retardant to a cold-setting plastic foam raw material.

In recent years, combustible synthetic resin foams, so-called plastic foams, have been increasingly used for building materials, automobile interior materials, and the like.

However, since there are fire prevention regulations in this type of field, nonflammable pearlite particles have been added to the plastic foam to make it flame retardant.

However, all of the various plastic foams proposed lacked practicality.

In particular, when inorganic hollow particles are added to a room-temperature curing foam, unfavorable conditions occur: oil absorption, a surface at the same temperature as the outside air, bulk and lightness, and a surface with numerous pores. For this reason, it is difficult to mix and disperse with plastic foam raw materials, and it has drawbacks such as greatly inhibiting foaming of the foam raw materials, causing variations in fire resistance, increased costs, and low productivity.

In order to eliminate these drawbacks, the present invention is limited to plastic foams, particularly room temperature curing plastic foams (hereinafter simply referred to as foams) which are easy to handle and easy to manufacture into filler foams, and which are also specially fireproof. This paper proposes a method for manufacturing foam that makes the foam raw material flame retardant without significantly inhibiting foaming by adding an agent, and improves foam expansion ratio and production speed.

The method for manufacturing flame retardant foam according to the present invention will be explained in detail below with reference to the drawings.

That is, the present invention uses a foam raw material that foams under high heat to form an inorganic foam layer, or a foamable inorganic material that is a main component, and an inorganic material that does not foam under high heat, or a gel-like material. When producing a plastic foam of a predetermined shape by adding a special fire retardant containing a mixture of one or more foaming compositions filled into the voids of inorganic hollow particles, and reacting and foaming the raw material, the foam raw material is At the start of foaming, the voids of the inorganic hollow particles shown below are filled with either a foamable inorganic material or a foaming composition, and the surface of the inorganic hollow particles is heated to 40 to 100°C depending on the temperature of the filling. This is a method of manufacturing foam by adding

More specifically, the foam raw material consists of one of a polyurethane foam raw material, a polyisocyanurate foam raw material, and a polyimide foam raw material.

The seed foam is produced by a well-known method.

For example, in the case of polyurethane foam, a liquid A consisting of an organic polyhydroxyl compound, the so-called component A, a blowing agent (e.g. CC13F), a catalyst, a crosslinking agent, a foam stabilizer, and a stabilizer, and an organic polyisocyanate, the so-called liquid B, are mixed. It foams.

The above component A is a compound having at least two or more active hydrogen atoms, such as ethylene oxide, propylene oxide, ethylene glycol, and propylene glycol.

In addition, as a foaming agent, water, Freon (CC13F) commonly known as R
-ll etc.

Furthermore, the catalyst may be an amine type, an organic tin compound type, or a special catalyst, such as triethylamine, dimethylamine, stannous oleate, dibdeltin dilaurate, and the like.

Examples of liquid B include diphenylmethane 4,4'-diisocyanate (so-called MDI), tolylene diisocyanate (so-called TD), and hexamethylene diisocyanate.

In the present invention, the foamable inorganic materials include crystal water, structured water,
For example, sodium salts and phosphates contain moisture such as interlayer water and release moisture under high heat, melt and gradually become viscous to form an inorganic foam layer.

To give a specific example, examples of the former include borax, sodium metaborate, (2゜4.6.8) sodium borate, sodium silicate, sodium metasilicate, etc., and examples of the latter include monobasic sodium phosphate, Such as dibasic sodium phosphate.

Furthermore, in the present invention, a foamed composition is one in which the selection of foaming timing for forming an inorganic foamed layer, the setting of the foaming scale, the reinforcement (densification) of the inorganic foamed layer, the selection of fire resistance, etc. are controlled. The main materials used are the above-mentioned foamable inorganic materials. These include calcium, calcium sulfite, gypsum, and light bread.

Further, as gel-like substances, EPVA, gelatin, CMC1 starch, etc. are used.

Further, in the present invention, the inorganic hollow particles are those whose hollow parts, so-called voids, are filled with the above-described foaming composition or the above-described foamable inorganic material.

Moreover, the inorganic hollow particles function as a core and a protective container during the formation of the inorganic foam layer.

Specific examples include pearlite grains, shirasu balloons,
Silica gel etc.

Further, in the present invention, the special fire retardant is one in which the voids of the inorganic hollow particles are filled with a foamable inorganic material or a foaming composition in a fine powder state or a molten state.

Moreover, when adding this to the foam raw material, the surface thereof is heated to 40 to 100°C.

As an example of a heated special fire retardant, immediately after filling inorganic hollow particles with the above-mentioned substance, the surface of the so-called inorganic porous particles is dry, but inside the filling there is a solution or a substance in the middle of solidification. It is necessary to immediately add it to the foam raw material while it is still warm.

Of course, when adding the special fire retardant to the foam raw material after a certain period of time has elapsed after its manufacture, it is added after being heated to the above-mentioned temperature.

Further, the amount of the special fire retardant added to 100 parts by weight of the foam raw material is 30 to 250 parts by weight.

Next, an example will be explained.

Assume that a panel as shown in FIG. 2 is manufactured using an apparatus as shown in FIG.

First, as a foam raw material, the A component has a hydroxyl value of 54.
8 (Tn9KOH/g), H2O-0,088% viscosity 1
0400 (CPS/25°C), PH10.5 to 100
parts by weight, 45 parts by weight of blowing agent R-11, catalyst Dabco
2 parts by weight of silicone, 1 part by weight of silicone (DKS silicone D-332 manufactured by Dai-Kogyo Seiyaku Co., Ltd.), 108 parts by weight of liquid B (crude MDI), and NCO index 110 were prepared.

In addition, as a special foaming agent, metaboric acid in which pearlite particles with an average particle diameter of 3 mmφ are melted (approximately 69°C) is used.
- A special fire retardant that has just been added to IJum (tetrahydrate), mixed and stirred, and the voids are filled with sodium metaborate by impregnation, and the surface is dry, but the inside is still solidifying. The temperature is 79°C.

Further, in FIG. 1, 1 is a foam raw material, and 2 and 3 are upper and lower mold members that sandwich the foam raw material 1 and form it into a plate of a predetermined shape.

4 and 5 are guide wheels, and 6 and 7 are drive wheels around which the upper and lower mold members are wound and rotatably mounted.

8 is a form, 9 is a mold formed by upper and lower mold members, 10 and 11 are auxiliary wheels, 12 and 13 are heating control devices, and 14 is a molding machine of a caterpillar set consisting of the above.

Reference numerals 15 and 16 are raw material storage tanks for producing the foam 8, and 17 is a mixer that mixes the two liquids and then discharges them when the product is a two-liquid reaction type such as polyurethane.

18 is a surface member, and 19 is a spreader such as a pie break, which is installed at a position where the special foaming agent B sent from the feeder A is added to the foam raw material at the time when foaming starts.

Reference numeral 20 denotes a spreader for adding other inorganic materials, such as a pie break, which is installed before or after the spreader 19, or both, and is shown installed after the spreader 19.

Reference numeral 21 denotes a backing material, such as a belt-like material made of aluminum foil laminated with paper.

Assume now that the upper and lower die members move in the direction of the arrow in the figure, and the surface material 18 (0.3 mm thick color iron plate) is fed from the left end.

Of course, it is assumed that the atmosphere of the molding machine is 40°C and the mold temperature is 50°C.

When the surface material 18 reaches directly below the mixer 17, the foam raw materials fall onto the surface material in a mixed state.

Then, the foam raw material enters the gelling stage from the cream-like unfoamed stage, and as the foaming begins, the volume of the foam raw material rapidly expands due to the foaming, and at the so-called foaming start stage when the foam raw material flows, as described above. A special foaming agent B having a warm surface is added to the foam raw material which is being reacted and foamed in an evenly dispersed manner.

Next, a backing material 21 is laminated on this foam raw material, supplied to a molding machine 14, molded and cured, and sent out from its outlet as a panel with a cross section as shown in FIG.

When the foam produced in this manner was observed, it was found that the special fire retardant B was almost uniformly distributed throughout the foam.

In addition, the expansion ratio of the foam (excluding the surface material) was improved by more than 10 times compared to before.

This is because when a special fire retardant is added as described above,
■ Oil-absorbing properties such as pearlite particles can be removed by filling with foamable inorganic material.

@ Since there is almost no adverse temperature effect on the foam raw material during reaction and foaming, it is possible to smoothly react and foam without absorbing the reaction heat of the foam raw material.

Since the large-volume O filler is added as isolated particles with a small surface area, the reaction with the foam raw material is much less than before.

○The specific gravity is moderately heavier than simple pearlite grains, and the dispersion is evened out.

(If it is light, it tends to be unevenly distributed due to the foaming pressure of the foam raw material.

)@Form raw materials can be used effectively for foam formation.

Note that 100 parts by weight of a special fire retardant was added to this foam based on 100 parts by weight of the foam.

Therefore, from this panel surface material (0.3% iron plate), 90%
When exposed to flame at 0°C, no thermal deformation or smoke generation was observed.

The special fire retardant on the surface of the iron plate was an inorganic foam made of pearlite particles as a core, forming a completely non-combustible layer between the flammable polyurethane foam and the surface material.

As described above, the method for manufacturing a flame-retardant foam according to the present invention has the characteristics shown in (1) to (4) above.

Moreover, there is an advantage that expensive foam raw materials can be used effectively.

Furthermore, the fire and heat resistance is due to the strong inorganic foam layer of the special fire retardant, which provides unprecedented fire retardant properties.

[Brief explanation of drawings]

FIG. 1 is a side view showing an embodiment of the method for manufacturing a flame-retardant foam according to the present invention, and FIG. 2 is a sectional view showing a panel manufactured by the above method. 1... Foam raw material, 2, 3... Top,
Lower mold member, 8...form, 9...mold, 14...molding machine.

Claims (1)

[Claims] 1 A single foamable inorganic material that foams under high heat to form an inorganic foam layer for room-temperature curing plastic raw materials, or an inorganic material that does not foam under high heat, or gel-like In producing a plastic foam of a predetermined shape by adding a special fire retardant in which the voids of inorganic hollow particles are filled with a foaming composition containing one or more of the following: At the start time, either a foamable inorganic material or a foaming composition is heated and melted and filled into the voids of the inorganic hollow particles, and the surface of the inorganic hollow particles is heated to a temperature of 40 to 100°C depending on the temperature of the filling material. A method for producing a flame-retardant room-temperature-curing plastic foam, which comprises adding an agent.