KR20240170675A - Water-based semi-incombustible coating composition comprising volcanic stone and manufacturing method thereof - Google Patents

Abstract

The present invention relates to a water-based semi-combustible coating composition containing volcanic rock, which is environmentally friendly because it is based on water, has easy control of viscosity, has excellent adhesion to the surface of a combustible material, and does not contain halogen compounds, so it generates little toxic gas while exhibiting excellent non-combustible performance.
In particular, the water-based semi-fireproof coating composition containing volcanic rock according to the present invention contains volcanic rock in addition to an inorganic flame retardant such as aluminum hydroxide, magnesium hydroxide, etc., thereby improving the flame retardancy grade and, at the same time, lowering the temperature rise in a heating test and a flame test, thereby improving the non-flammability characteristics. In particular, when the inorganic flame retardant, volcanic rock, and silicone resin are used together, the temperature rise in the heating test and the flame test is the lowest compared to when only the inorganic flame retardant and the silicone resin are used together.

Description

{Water-based semi-incombustible coating composition comprising volcanic stone and manufacturing method thereof}

The present invention relates to a water-based semi-fireproof coating composition containing volcanic rock and a method for producing the same, and more particularly, to a water-based semi-fireproof coating composition containing volcanic rock suitable for improving the fireproof properties of a product with a minimum coating thickness and maintaining a constant thickness to produce a uniform product, and a method for producing the same.

The content described below only provides background information related to the present invention and does not constitute prior art.

Various types of flammable materials such as paper, wood, Styrofoam, and synthetic resin are commonly used as building materials for construction of buildings. Such flammable building materials not only rapidly ignite when a fire breaks out, but also generate a large amount of gas, which can directly cause major accidents such as loss of life. Therefore, in order to minimize human and material damage in response to various fires, the standards for semi-fireproof performance and fire spread prevention structures are being strengthened for building finishing materials including plastics, sheets, hoses, and fibers, interior boards, and even fire doors.

In order to meet the non-combustibility standards for fire prevention, a method of adding a flame retardant coating to the surface of a combustible material is generally used. The flame retardant coating forms a flame retardant film, which blocks or delays ignition by high-temperature heat or flames when a fire occurs, prevents the spread of combustion, provides time to extinguish the fire, or increases evacuation time, thereby preventing major fire-related accidents.

Flame retardants used in coatings include halogen-based, phosphorus-based, inorganic-based, or mixtures thereof. Halogen-based flame retardants containing bromine or chlorine are the most commonly used. While these halogen-based flame retardants have the advantage of being inexpensive, they have the problem of generating a large amount of toxic gases when burned. In addition, phosphorus-based flame retardants have the advantage of having a superior flame retardant effect compared to halogen-based flame retardants, but they have the problem that the effect of reducing toxic gases is minimal at high temperatures above 1,200℃.

In addition, inorganic flame retardants have the advantage of not generating toxic gases, but although they have a flame retardant effect at low temperatures below 600℃, their flame retardant effect is minimal at temperatures exceeding 600℃, and so they must be added in excessive amounts to increase the flame retardant effect. Therefore, when used as a coating agent, the adhesive strength of the coating agent is low, making it difficult to introduce them to the process of coating the surface of flammable materials such as paper, foam resin, and fabric.

Therefore, there is a need to develop a non-flammable coating that can be easily applied to the surface of various combustible materials, exhibits excellent non-flammability performance while producing little toxic gases.

The present invention relates to a water-based semi-fireproof coating composition containing volcanic rock and a method for producing the same, and aims to provide a fireproof coating that can be easily applied to the surface of various combustible materials and exhibits excellent fireproof performance while generating little toxic gas.

The water-based semi-fireproof coating composition comprising volcanic rock according to the present invention comprises a binder resin, a phosphorus-based flame retardant, a melamine-based flame retardant, an inorganic flame retardant, and volcanic rock.

The above binder resin may include EVA, the phosphorus-based flame retardant may include ammonium polyphosphate, the melamine-based flame retardant may include melamine, and the inorganic flame retardant may include aluminum hydroxide and magnesium hydroxide.

The EVA binder according to the present invention can provide excellent adhesion to a coating composition.

The water-based semi-flame-retardant coating composition comprising volcanic rock according to the present invention may further comprise a silicone resin, and preferably comprises a two-component curable silicone resin. In particular, by using the silicone resin and the inorganic flame retardant together, the flame retardancy is improved, and the temperature value according to the heating test and the flame test is lowered, so that the flame retardant property can be improved. In addition, the two-component curable silicone resin not only imparts a certain strength and hardness to the coating composition while also helping to attach the flame retardant well to the substrate, but also maintains the substrate's own characteristics (softness, flexibility, etc.).

The water-based semi-fireproof coating composition comprising volcanic rock according to the present invention may include 10 to 25 wt% of binder resin, 25 to 60 wt% of water, 5 to 20 wt% of ammonium polyphosphate, 10 to 25 wt% of melamine, 5 to 20 wt% of aluminum hydroxide, 5 to 20 wt% of magnesium hydroxide, and 3 to 25 wt% of volcanic rock.

The aqueous semi-fireproof coating composition comprising volcanic rock according to the present invention may further comprise 3 to 15 wt% of a silicone resin, preferably a two-component curable silicone resin.

The present invention provides a method for producing a water-based semi-fireproof coating composition containing volcanic rock, wherein the method may include a step of mixing a binder resin, a phosphorus-based flame retardant, a melamine-based flame retardant, and an inorganic flame retardant with water, and a step of dispersing and mixing volcanic rock in the mixture.

The manufacturing method according to the present invention enables a mixture including a binder resin, a flame retardant, etc. to penetrate and bind into the pores of volcanic rock to form a uniform mixture, and a coating formed using the composition forms a type of composite, thereby improving the physical properties and non-flammability performance of the coated composition.

In addition, the manufacturing method may include a step of mixing a binder resin, a phosphorus-based flame retardant, a melamine-based flame retardant, an inorganic flame retardant, and a silicone resin with water, and a step of dispersing and mixing volcanic rock into the mixture.

The water-based semi-combustible coating composition containing volcanic rock according to the present invention is based on water and is therefore environmentally friendly, and its viscosity can be easily controlled, so that it can be easily coated on the surfaces of various materials. In addition, it has excellent adhesion to the surface of combustible materials, does not contain halogen compounds, generates little toxic gases, and exhibits excellent electrical insulation and non-combustibility.

Figure 1 schematically shows the heating test method.
Figure 2 schematically shows the flame test method.

The terminology used herein is for the purpose of describing embodiments only and is not intended to limit the invention. In this specification, the singular also includes the plural unless specifically stated otherwise. The term "comprises" as used in the specification does not exclude the presence or addition of one or more other components other than the mentioned components.

Unless otherwise defined, all terms (including technical and scientific terms) used in this specification may be used with the meaning commonly understood by those skilled in the art to which the present invention belongs. In addition, terms defined in commonly used dictionaries shall not be ideally or excessively interpreted unless explicitly specifically defined.

Hereinafter, embodiments of the present invention will be described in detail with reference to the attached drawings so that those skilled in the art can easily carry out the invention. However, the present invention may be implemented in various different forms and is not limited to the embodiments described herein.

The water-based semi-combustible coating composition containing volcanic rock according to the present invention contains a binder resin, and the binder resin can be used in an amount of 10 to 25 wt%. If the binder resin is less than 10 wt%, the adhesive strength is insufficient, and if it exceeds 25 wt%, the non-combustible property deteriorates. An EVA (Ethylene-Vinyl Acetate copolymer) resin binder can be used as the binder.

The water-based semi-fireproof coating composition containing volcanic rock according to the present invention may contain water in an amount of 25 to 60 wt%. If the amount of water is less than 25 wt%, the viscosity of the composition becomes excessively high, making the coating process difficult, and if it exceeds 60 wt%, the fireproof properties deteriorate.

The water-based semi-fireproof coating composition containing volcanic rock according to the present invention may contain a phosphorus-based flame retardant and a melamine-based flame retardant, and the phosphorus-based flame retardant may be contained in an amount of 15 to 35 wt%, and the melamine-based flame retardant may be contained in an amount of 10 to 25 wt%. The phosphorus-based flame retardant may contain ammonium polyphosphate, and the melamine-based flame retardant may contain melamine. If the content of the flame retardant is small, sufficient fire resistance cannot be ensured, and if it is too large, it is difficult to form a uniform coating film.

The water-based semi-fireproof coating composition containing volcanic rock according to the present invention may contain an inorganic flame retardant, and the inorganic flame retardant may contain aluminum hydroxide and magnesium hydroxide, and the aluminum hydroxide and magnesium hydroxide may be used in an amount of 5 to 20 wt%, respectively. If the amount of the inorganic flame retardant is less than the above range, the flame retardancy grade is lowered, and if it exceeds the above range, the adhesion and coating performance are deteriorated.

The water-based semi-fireproof coating composition containing volcanic rock according to the present invention may contain volcanic rock, and the volcanic rock may be used in an amount of 3 to 25 wt%. If the volcanic rock is less than the above content, the fireproofness may deteriorate, and if the content exceeds the above content, the adhesion and coating performance may deteriorate.

The water-based semi-flame retardant coating composition comprising volcanic rock according to the present invention may further contain a silicone resin, and the silicone resin may be used in an amount of 3 to 15 wt%, and preferably a two-component curable silicone resin may be used. The use of the silicone resin may improve the non-flammability and flame retardancy properties of the coating composition, but if used in excessive amounts, the adhesiveness may be reduced. In addition, the two-component curable silicone resin not only imparts a certain strength and hardness to the coating composition while allowing the flame retardant to adhere well to the substrate, but also maintains the substrate's own properties (flexibility, softness, etc.).

The water-based semi-fireproof coating composition containing volcanic rock according to the present invention may further contain one or more additives selected from a surfactant, an adhesive, an anti-foaming agent, an antioxidant, etc., and the additives may be used in an amount of 1 to 5 wt% as needed.

It is preferable that the binder resin, melamine, polyphosphate, silicone resin, etc. according to the present invention be pretreated and used in a form that can be dispersed in water.

Hereinafter, examples of a water-based semi-fireproof coating composition containing volcanic rock according to the present invention and a method for producing the same will be described in detail.

A water-based semi-fireproof coating composition having a composition ratio as described in Table 1 below was prepared.

First, in the case of a composition that does not include volcanic rock, such as Examples 1 to 5, each raw material processed into a form that can be dispersed in water is weighed so that the final components have the composition ratio shown in Table 1, and then mixed using a ribbon-type mixer. At this time, the composition is prepared by stirring at a low rotation speed of 300 to 500 rpm for 20 to 30 minutes so that the high-viscosity binder resin can be sufficiently stirred, mixed, and homogenized, and then sufficiently stirring at a high speed of 1,000 rpm or higher for 3 to 5 minutes.

As shown in Table 1 above, in the present invention, non-halogen flame retardants, such as phosphorus-based flame retardants and melamine-based flame retardants, were used as flame retardants, and aluminum hydroxide and magnesium hydroxide were used as inorganic flame retardants.

Meanwhile, in cases where volcanic rock is included, such as in Examples 6 to 8, the other components except for volcanic rock were first mixed in the same manner as in Examples 1 to 5, and then volcanic rock was added to the mixture, and the volcanic rock was mixed and dispersed in the same manner to prepare a composition. This is because, when volcanic rock with a porous structure is directly added to a liquid raw material such as water, the volcanic rock absorbs the liquid raw material first, and the volcanic rock is not uniformly mixed with the other mixture, which adversely affects the non-combustibility of the composition.

In contrast, when raw materials other than volcanic rock are uniformly mixed and then volcanic rock is added, a mixture including binder resin, flame retardant, etc. penetrates and combines into the pores of the volcanic rock to form a uniform mixture, and a coating formed using the composition forms a type of composite, which can improve the physical properties and non-flammability performance of the coated composition.

(Unit; weight%) <Ingredients> Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 Example 8 Binder resin 1 ¹⁾ 20 15 15 15 15 15 Binder resin 2 ²⁾ 20 Binder resin 3 ³⁾ 20 water 40 40 40 30 30 30 25 25 polyphosphoric acid
ammonium 17 17 17 17 17 17 12 12 Melamine 20 20 20 15 15 15 15 15 Hydroxide
Aluminum 10 5 5 5 5 Hydroxide
magnesium 10 5 5 5 5 volcanic rock 10 15 10 Silicone resin ⁴⁾ 10 5 10 Additive ⁵⁾ 3 3 3 3 3 3 3 3 <Performance> Adhesiveness
(kg/㎡) 3 or more 0.5~1 0.5~1 3 or more 3 or more 3 or more 3 or more 3 or more Flame retardant rating V1 V1 V1 V1 V0 V0 V0 V0 Withstanding voltage (kV) 4.0 4.0 4.0 4.0 4.5 4.5 4.5 4.5 Heating test (℃) 160 158 160 148 140 125 118 124 Flame test (℃) 360 355 360 340 278 250 237 240

¹⁾ EVA (Ethylene-Vinyl Acetate copolymer)

²⁾ PVAc(Poly(vinyl acetate))

³⁾ Poly(2-ethoxyethyl acrylate)

⁴⁾ Two-component curing silicone

⁵⁾ Surfactants, adhesives, antioxidants

The coating composition manufactured according to Table 1 above was spray-coated on a polyester nonwoven fabric, dried, and then left at 25°C for 24 hours to dry. The coating weight after drying was 500 g/㎡, and the total thickness of the nonwoven fabric after coating was approximately 0.2 mm.

The flame retardancy, voltage withstanding, and flame blocking performances of the above-mentioned coated and dried nonwoven fabric were evaluated. The flame retardancy rating was measured according to UL-94, and the voltage withstanding was measured according to ASTM D-149. The adhesive strength was measured between the coating layer and the nonwoven fabric on a 3 cm wide specimen using a universal testing machine (UTM).

As illustrated in Fig. 1, the heating test is the result of measuring the temperature rise on the surface of the other side of the specimen while heating one side of the specimen to 700°C using a silicon carbide (SIC) heater. As illustrated in Fig. 2, the flame test is the result of placing the specimen between brackets that have a thickness of 6 mm and a hole that has a diameter of 50 mm, and then irradiating a flame on one side of the specimen with a butane gas torch while maintaining the temperature of one side at 1,100°C and measuring the surface temperature of the other side. In other words, the lower the temperatures measured in the heating test and flame test, the better the high temperature and flame blocking performance, i.e., non-flammability, of the coating material.

As seen in Examples 1 to 3, there was no significant difference in flame retardancy, voltage withstanding, and temperature resistance depending on the type of binder, and when PVAc (Poly(vinyl acetate)) was used as the binder resin (Example 2), the temperature values of the heating test and flame test were measured to be lower than those of other binders. However, the adhesive strength between the polyester nonwoven fabric and the coating agent was found to be the highest in the composition using EVA (Ethylene-Vinyl Acetate copolymer) as the binder resin (Example 1).

As can be seen in Example 4, the temperature values of the heating test and flame test are lowered by the addition of inorganic flame retardants, such as aluminum hydroxide and magnesium hydroxide, but the flame retardancy grade does not change significantly.

However, when silicone resin and inorganic flame retardant are used together (see Example 5), it can be seen that the flame retardancy is improved and the temperature values in the heating test and flame test are lowered, thereby improving the non-flammability characteristics. This is thought to be because when the silicone resin undergoes thermal decomposition, amorphous silica (SiO ₂ ) is formed on the surface of the polymer that is combusted, which acts as a barrier between the polymer and the heat source, blocking the heat supplied from the heat source and preventing the inflow of oxygen.

Silicone resin, including two-component curable silicone, not only provides a certain strength and hardness to the coating composition while also helping the flame retardant adhere well to the substrate, but also has the effect of maintaining the substrate's own characteristics (i.e. flexibility, softness, etc.).

As can be seen in Examples 6 to 8, when an inorganic flame retardant and volcanic rock are used together, the flame retardancy grade is improved compared to when the inorganic flame retardant is used alone (Example 4), and the temperature rise according to the heating test and flame test is reduced, so it can be seen that the non-flammability performance is improved.

In particular, when an inorganic flame retardant, volcanic rock, and silicone resin are used together (Examples 8 and 9), it can be confirmed that the temperature rise in the heating test and flame test is the lowest compared to when only an inorganic flame retardant and silicone resin are used together (Example 5).

The composition according to the present invention can exhibit excellent fire resistance by being manufactured including volcanic rock and an inorganic flame retardant, and particularly exhibits even more excellent fire resistance by being used in combination with a silicone resin. That is, the water-based semi-fire resistance coating composition according to the present invention improves the flame retardancy grade by using volcanic rock in addition to an inorganic flame retardant such as aluminum hydroxide, magnesium hydroxide, etc., and at the same time, the temperature rise according to a heating test and a flame test is reduced, thereby improving the fire resistance, and particularly, when the inorganic flame retardant, volcanic rock, and silicone resin are used together, it exhibits superior fire resistance characteristics compared to when only the inorganic flame retardant and the silicone resin are used in combination.

Therefore, a coating agent is provided that does not generate toxic gases due to the use of halogen-based flame retardants, has excellent electrical insulation properties, and can be applied to various substrates to impart quasi-fireproof properties.

In addition, the water-based semi-flame retardant coating composition containing volcanic rock according to the present invention is not only environmentally friendly because it is manufactured based on water, but also has the advantage of excellent coating processability on a substrate. More specifically, there is no clogging of a nozzle due to the inclusion of an inorganic flame retardant, and damage to the roll due to solid content can be prevented when coating using a roll. Since the composition according to the present invention has excellent adhesiveness to a substrate, it can prevent the flame retardant from being detached from the finished product, so that not only can the flame retardant properties be maintained for a long time, but also a product with excellent withstand voltage and electrical insulation can be implemented.

In the above examples, a ribbon-type mixer is used as an example for producing a water-based semi-combustible coating composition. However, the mixer may be a V-mixer, an azithromy mixer, a dissolver, a drum mixer, or a Henschel mixer, but is not limited thereto.

And although the above examples describe that the water-based semi-flammable coating composition is applied to a polyester nonwoven fabric by spraying, the substrate to which the composition is coated may be used without limitation as long as it is a substrate that requires non-flammability, such as a synthetic resin material such as polystyrene, paper, wood, various fabrics and nonwovens, and metal materials, and may be applied by a method such as dipping or gravure coating depending on the type and need of the substrate, but is not limited thereto.

In addition, the water-based semi-fireproof coating composition according to the present invention can be used as a coating agent for fireproof sheets and fireproof foams for electric vehicle batteries, an insulating tape for aircraft or automobiles, a fireproof coating agent for suffocating fire extinguishing cloths for electric vehicle fires, fireproof paint, etc., but is not limited thereto.

Claims (11)

A water-based semi-fireproof coating composition comprising a binder resin, a phosphorus flame retardant, a melamine-based flame retardant, an inorganic flame retardant and volcanic rock A water-based semi-fireproof coating composition comprising volcanic rock, characterized in that in claim 1, the binder resin comprises EVA, the phosphorus-based flame retardant comprises ammonium polyphosphate, the melamine-based flame retardant comprises melamine, and the inorganic flame retardant comprises aluminum hydroxide and magnesium hydroxide. A water-based semi-fireproof coating composition comprising volcanic rock, characterized in that it further comprises a silicone resin according to claim 1 or 2 In claim 3, a water-based semi-fireproof coating composition including volcanic rock characterized in that the silicone resin is a two-component curable silicone resin. A water-based semi-fireproof coating composition comprising volcanic rock, characterized in that the composition comprises 10 to 25 wt% of binder resin, 25 to 60 wt% of water, 5 to 20 wt% of ammonium polyphosphate, 10 to 25 wt% of melamine, 5 to 20 wt% of aluminum hydroxide, 5 to 20 wt% of magnesium hydroxide, and 3 to 25 wt% of volcanic rock according to claim 2. A water-based semi-fireproof coating composition comprising volcanic rock, characterized in that in claim 5, it further comprises 3 to 15 wt% of a two-component curable silicone resin. A method for producing a water-based semi-fireproof coating composition comprising a binder resin, a phosphorus flame retardant, a melamine-based flame retardant, an inorganic flame retardant and volcanic rock,
Step of mixing binder resin, phosphorus flame retardant, melamine flame retardant, and inorganic flame retardant with water;
A method for producing an aqueous semi-fireproof coating composition comprising volcanic rock, comprising the step of dispersing and mixing volcanic rock in the above mixture. A method for producing an aqueous semi-fireproof coating composition comprising volcanic rock, characterized in that in claim 7, the binder resin comprises EVA, the phosphorus-based flame retardant comprises ammonium polyphosphate, the melamine-based flame retardant comprises melamine, and the inorganic flame retardant comprises aluminum hydroxide and magnesium hydroxide. In claim 8, a method for producing a water-based semi-fireproof coating composition comprising volcanic rock, characterized in that the water-based semi-fireproof coating composition comprising volcanic rock comprises 10 to 25 wt% of binder resin, 25 to 60 wt% of water, 5 to 20 wt% of polyphosphate, 10 to 25 wt% of melamine, 5 to 20 wt% of aluminum hydroxide, 5 to 20 wt% of magnesium hydroxide, and 3 to 25 wt% of volcanic rock. A method for producing an aqueous semi-fireproof coating composition comprising volcanic rock, characterized in that in claim 7, the step of mixing the binder resin, phosphorus-based flame retardant, melamine-based flame retardant, and inorganic flame retardant with water further includes a step of mixing a silicone resin. In claim 10, a method for producing a water-based semi-fireproof coating composition comprising volcanic rock, characterized in that the water-based semi-fireproof coating composition comprising volcanic rock comprises 10 to 25 wt% of binder resin, 25 to 60 wt% of water, 5 to 20 wt% of polyphosphate, 10 to 25 wt% of melamine, 5 to 20 wt% of aluminum hydroxide, 5 to 20 wt% of magnesium hydroxide, 3 to 25 wt% of volcanic rock, and 3 to 15 wt% of silicone resin.

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