Description ACRYL CARBIDE FIBER INCOMBUSTIBLE MATERIAL

Technical Field

[1] The present invention relates to an acryl carbide fiber incombustible material tolerable up to 1,200 ⁰ C, which is prepared by shaping an acryl carbide composite fiber. Background Art

[2] In general, the main kind of then incombustible material is a petrochemical product, for example, a product made through various binding such as a fiberglass, an asbestos cloth fiber, a metal fiber and an incombustible fiber. However, the product has weak binding force, bad curvaceousness and softness, and weak point to applied adherence, high strength, high heat and direct heat, and acordingly, tends to be exposed to a fire, and has also low compatibility to environment thereby giving various harms to environment and a human body.

[3] Although there is a fiberglass urethane PE foamed incombustible material as a general example of an incombustible heat insulator, harmful effects to environment and human body due to generation of CO ₂ and excessive dust, and provision of the cause of secondary firing are beyond description.

[4] A fiberglass is in the crisis of maintenance or abolition for its production and use, and asbestos is not used in an advanced country, either. The fiberglass or asbestos cloth is prescribed as a carcinogen, and aα»rdingly, close attention is required, the place, in which it is already set, is gradually dismantled, and cases of skin cancer, pneumoconiosis or sepsis are found.

[5] Korean Patent No. 10-0104411 discloses a method of preparing a carbon fiber comprising flame retarding process and carbonizing process by using an acrylic fiber wherein cycloaddition of nitrile group is performed up to 20 to 40% level of total by subjecting to heat treatment at 230 to 27O ⁰ C for 8 to 20 minutes at inert gas atmosphere at the initial step in the flame retarding process, the cycloaddition of nitrile group is terminated by subjecting to heat treatment at 240 to 28O ⁰ C for 20 to (D minutes at air or oxidizing gas atmosphere at the late step.

[6] Korean Patent No. 10-0134920 discloses a method of preparing a carbon fiber having high strength comprising preparing a precursor fiber and heat treatment process including flame retarding process and carbonizing process wherein the same gas as within a flame retarding apparatus 1 is filled in the inside of a roller 3 in the apparatus at flame retarding process, a slit 6 is formed in the roller so that a gas 5 within the

roller can contact with a precursor fiber 7 thereby giving flame retarding atmosphere even during passing through the roller 3, and constituting an earth circuit to enhance the flame retarding effect by removing static electricity generated during the flame retarding process.

[7] Korean Patent No. 10-0127991 discloses a method of preparing a carbon fiber reinforced carbon composite body comprising impregnating a pitch into a carbon fiber; forming it with a hot press; subjecting it to heat treatment at 300 to 500 ⁰ C for 0.5 to 24 hours; compressing it with 10 to 50 volume % of a compression rate; and subjecting it to immobilizing and carbonization.

[8] Korean Patent No. 10-0711227 discloses a flame retardant woven fabric consisting of 30 to 70% by weight of fiber A, essentially consisting of a halogen containing flame retardant fiber, comprising 100 parts by weight of an acrylic copolymer polymerized with 30 to 70% by weight of acrylonitrile, 30 to 70% by weight of a halogen containing vinyl monomer and a monomer mixture 0 to 10% by weight of containing vinyl monomer copolymerizable therewith, and 10 to 30 parts by weight of antimony compound and 8 to 30 parts by weight of zinc stannate compound; a cellulosic fiber B, wherein one side of the cellulosic fiber consists of warps and other side consists of fills, and the fabric has woven texture having faces containing more cellulosic fiber B than the fiber A essentially consisting of the halogen containing flame retardant fiber.

[9] Korean Patent No. 10-0645724 discloses a flame retardant styrenic thermoplastic resin composition comprising 1 to 30 parts by weight of at least one flame retardant selected from the group consisting of a halogen compound, a phosphorus compound and epoxy compound; 20 to 25 parts by weight of a flame retardant aid selected from the group consisting of antimony oxide, a zinc compound, barium borate, zirconium oxide, talc and mica; and 1 to 10 parts by weight of polyethylene chloride per 100 parts by weight of a mixed resin consisting of (I) 40 to 70 parts by weight of a graft copolymer containing rubber denatured styrene in which 30 to 65% by weight of a styrenic compound and 10 to 30% by weight of an acrylic or vinyl cyan compound are grafted to 10 to 60% by weight of a diene rubber, and (II) 30 to 60 parts by weight of a styrene containing copolymer of which weight average molecular weight is 50,000 to 150,000, and the content of acrylonitrile monomer is 20 to 40 parts by weight.

[10] Korean Patent No. 10-0745170 discloses a composite fiber employing a heat resistant and cold resistant composite fiber yarn prepared by weaving or knitting with a composite adiabatic fiber yarn, composed by mixing a para-aramid fiber, silica fiber and Teflon fiber which is a fhx>rine fiber.

[11] Korean Patent No. 10-0775702 discloses non-asbestos composite fiber comprising

20 to 70% by weight of aramid fiber, 10 to 70% by weight of silica fiber and 10 to 20% by weight of carbon fiber.

[12] Korean Patent Laid-Open Publication No. 10-2004-0082903 discloses an interior cork sheet, in which a flame retardant nonwoven fabric is attached, wherein the sheet comprises a flame retardant nonwoven fabric 14 attached to the rear face of thin oork 12 by an adhesive 13, a mold release paper 16 attached to the flame retardant nonwoven fabric 14 by an adhesive 15, and a flame retardant 11 treated with a spray on the surface of the thin oork 12.

[13] Korean Patent Laid-Open Publication No. 10-2007-0040775 discloses a method of preparing a functional nonwoven fabric or a functional pelt having a property that prevents flame from spreading or transferring by forming foamed incombustible carbide layer through foaming a flame retardant on contacting with flame, wherein the method comprises mixing a phosphorus-based flame retardant, a nitrogen-based retardant, a rubber coating agent with water and stirring, diluting the stirred mixture with water while fitting again to the condition of material use or application apparatus, and then attaching to a porous pelt or raw fiber of nonwoven fabric with any applying method and drying it.

[14] Korean Patent Laid-Open Publication No. 10-2007-0097618 discloses a flame retardant ds-multicore type polyester composite fiber wherein ds component or both άs component and core component comprise a flame retardant, the content of the flame retardant included in the ds component is 1,200 ppm higher than the total content of the flame retardant, and the total content of the flame retardant to total fiber is 0.5 to 1.5% by weight.

[15] Korean Utility Model Registration No. 20-0434046 discloses a flame retardant mixed yarn having 6'S to 45'S of yarn count wherein the mixed yarn is prepared by mixing a flame retardant viscous rayon staple fiber containing polysilidc add, and a modacryl staple fiber containing antimony. Disclosure of Invention Technical Problem

[16] The same fiberglass urethane PE foamed incombustible material has been proposed as a prior art, but harmful effects to environment and human body due to generation of CO ₂ and excessive dust, and provision of the cause of secondary firing are beyond description.

[17] A fiberglass is in the crisis of maintenance or abolition for its production and use, and asbestos is not used in an advanced country, either. The fiberglass or asbestos cloth is prescribed as a carcinogen, and accordingly, close attention is required, the place, in which it is already set, is gradually dismantled, and cases of skin cancer, pneumoconiosis or sepsis are found. Accordingly, It is an object of the invention to provide, as substitute advanced material capable of satisfying the need plurally required for industrial incombustible material, an inoombustible material requiring acryl carbide composite fiber according to the need for an incombustible material compatible to environment and a human body, which does not generate CO ₂ ; does not act as secondary firing cause since it endures up to near 2000 ⁰ C on firing; is convenient to use since it is soft and light; is convenient for anyone to construct due to its superior airtightness, incombustibility and workability; and overcomes the previous concept due to high strength Technical Solution

[18] In order to solve the above problems of the incombustible adiabatic material, according to one aspect of the invention, there is provided an acryl carbide fiber incombustible material prepared by subjecting acryl fiber to heat treatment at 2,100 to 2,500 ⁰ C for flame retarding process, collecting according to the size (lmm to 100mm) of the complex forming oondition by employing the acryl carbide fiber, and forming in the form of board and whole cloth according to a typical mold so that density, weight and shape of a product can differ.

Advantageous Effects

[19] As described above, an acryl carbide inoombustible material according to the present invention has high strength, softness and convenient adhesion, has excellent flame retardant, incombustible, durable and anti-flammable properties tolerable up to 2,100 to 2,500 ⁰ C, and is free to cut and sew into an inoombustible product applicable to various industrial fields, and is human body- and environment- friendly in manufacturing a formed product since it nontoxic and nonirritant.

[20] The acryl carbide inoombustible material according to the present invention overcomes the limit of the prior flame retardant material since it does not corrode and deform, and is good in lubricancy and oompressibility; provides excellent inoombustible effect due to low heat oonductivity in applying to an industry, and prevents a dropped welding spark in an industrial company and a dockyard.

[21] The acryl carbide inoombustible material according to the present invention does not

occur secondary industrial accident, is capable of manufacturing small, middle and large products acording to the forming method in manufacturing an article, is free to select thickness and width, and is not deformed by nature and light on long exposure. [22] The acryl carbide incombustible material according to the present invention insulates and is carbonized while maintaining original form and not shrinking, and thus does not cause a burn even when it oontacts with a user s skin in heating or insulating state, although previous flame retardant or incombustible fiber causes coagulation of the fiber, smoke and a burn when heated highly. Brief Description of the Drawings

[23] FIG. 1 illustrates total fillet according to the present invention; and

[24] FIG. 2 illustrates the cylinder body according to the present invention.

Mode for the Invention

[25] In order to accomplish the above object, the present invention relates to an acryl carbide fiber incombustible material prepared by subjecting acryl fiber to heat treatment at 2,100 to 2,500 ⁰ C for flame retarding process, collecting according to the size (lmm to 100mm) of the complex forming condition by employing the acryl carbide fiber, and forming in the form of board and whole cloth according to a typical mold so that density, weight and shape of a product can differ.

[26] The present invention is a product incombustible at high heat such as 2,100 to

2,500 ⁰ C, and a new material prepared by firing and carbonizing acryl carbide fiber, having chemical-resistance and playing a role in highly buffering action. Although prior flame retardant product provides the cause of a secondary accident, the present invention is not fired in air, melted or coagulated, and does not generated CO ₂ dust, and is not fired on firing. Since a method of preparing by using an inert gas as an atmosphere gas in order to carbonize smoothly in the carbonization process, and a carbonizing apparatus are widely used, they are not described in detail in the present invention.

[27] According to the present invention, acryl carbide fiber passes between the needles of many L type fillets set in the roll of the fillet and on the surface of a guide roll, and thus the fiber is collected therein.

[28] In the above aspect, since a fiber passes between a pin and a L-letter type pin, raw material is not disrupted and the fiber is protected thereby achieving the object, and accordingly, acryl carbide composite formed product is formed and collected by crossing the machine up and down according to the standard. The product can be subjected to

the second process according to the standard and whole cloth to prepare board and whole cloth.

[29] The present invention may be similar to a method of manufacturing nonwoven fabrics in that the method of manufacturing acryl carbide fiber inoombustible material according to the present invention employs a collecting method, not a method of manufacturing fabrics by employing acryl carbide composite fiber.

[30] The present invention is not a wire type method fabricating previous fiber and filleting method. Previous fillet pin has wide interval, and thus is not well transferred, cylinder becomes straight pin shape, and the fiber is combined and transferred between their gaps thereby forming a product. When carbide fiber is prepared with previous spinning and fabricating machine, raw fiber material is disrupted to dust powder, and thus its essence is deformed so that the technical objects cannot be achieved.

[31] Examples of the acrylic carbon fiber used in the present invention include usually used acrylic carbon fiber.

[32] The acrylic carbon fiber is an acrylic polymer constituting an acryl fiber (precursor fiber), i.e., a source fiber. Examples of the acrylic polymer include at least 90 mole% of acrylonitrile and up to 10 mole% of copolymerizable vinyl monomer, e.g., acrylic acid, methacrylic acid, itaconic aid and their alkali metal salts and ammonium salts, lower alkyl esters, acrylamide and a derivative thereof, allyl sulfonic acid, methacryl sulfonic aid and their salts or alkyl esters.

[33] Examples of the spinning methods include wet spinning, dry-wet spinning or dry spinning methods. The dry-wet spinning method capable of providing dense precursor fibers is preferable.

[34] Hereinafter, the present invention will be described in detail with reference to examples.

[35] Example 1

[36] An acryl carbide inoombustible material was prepared as follows.

[37] Much acryl fiber prepared by a general process is subjected to heat treatment and flame retarding process at 300 ⁰ C in air, is subjected to heat treatment at 1,400 ⁰ C in vacuum to prepare a;ryl carbide fiber, and then to heat treatment at 2,100 to 2,500 ⁰ C to prepare acryl carbide inoombustible flame-retardant fiber while nitrogen gas is infused as an atmosphere gas to the acryl carbide fiber, and then the acryl carbide incombustible flame-retardant fiber prepared above is passed through a fillet to prepare a sheet- shaped acryl carbide fiber.

[38] The a;ryl carbide incombustible flame-retardant fiber is passed between first guide

rolls 1-1 having an L-shaped needle 20 mounted on the surfaces of the rolls consisting of two upper and lower parts, is passed through a first roll 2- 1 located on the rear surface of the first guide roll 1-1 and having an L-shaped needle 20 mounted on its surface, and then is passed through a second guide roll 1-2 located on the rear surface of the first roll 2-1 and having an L-shaped needle 20 mounted on its surface.

[39] The passed acryl carbide inoombustible flame-retardant fiber is passed through a second roll 2-2, a third roll 2-3, a fourth roll 2-4, a fifth roll 2-5, a sixth roll 2-6 installed in this order and having an L-shaped needle 20 mounted on its surface, and then is passed through a third guide roll 1-3 having an L-shaped needle 20 mounted on its surface, which is installed on the rear surface of the sixth roll 2-6, thereby collecting acryl carbide fiber to prepare an acryl carbide inoombustible material.

[40] Example 2

[41] Another acryl carbide incombustible material was prepared as follows.

[42] Much acryl fiber is subjected to heat treatment and flame retarding process at 300 ⁰ C in air, is subjected to heat treatment at 1,400 ⁰ C in vacuum to prepare acryl carbide fiber, and then to heat treatment at 2,100 to 2,500 ⁰ C while infusing nitrogen gas as an atmosphere gas to prepare an acryl carbide inoombustible flame-retardant fiber.

[43] An adhesive is added to the acryl carbide incombustible flame-retardant fiber and the fiber is passed between compressing rollers preheated to 50 ⁰ C to prepare a sheet- shaped acryl carbide inoombustible material.

[44] Hereinafter, the cylinder of the fillet in an apparatus for preparing the acryl carbide incombustible material according to the present invention is described in detail with reference to the drawings.

[45] FIG. 1 illustrates total fillet according to the present invention. FIG. 2 illustrates the cylinder body according to the present invention. In the drawings, the first and the second guide roll (1-1, 1-2), the first to sixth rolls (2-1, 2-2, 2-3, 2-4, 2-5, 2-6), and the needle 20 are described.

[46] An apparatus for preparing an acryl carbide incombustible material according to the present invention is constituted as follows.

[47] L-shaped needles 20 of a fillet are provided on the surfaces of the first to six rolls

(2-1, 2-2, 2-3, 2-4, 2-5, 2-6), and L-shaped needles having different size are provided in the first and the second guide rolls (1-1, 1-2) guiding an acryl carbide fiber.

[48] The apparatus includes the first guide roll 1-1, consisting of two upper and lower parts so as to guide an acryl carbide incombustible flame-retardant fiber; the first roll 2-1 mounted on the rear surface of the first guide roll 1-1; and the second guide roll

1-2 mounted on the rear surface of the first roll 2-1, wherein two guide rolls 1-2 are connected to each other vertically.

[49] The apparatus includes the second roll 2-2, the third roll 2-3, the fourth roll 2-4, the fifth roll 2-5, the sixth roll 2-6 mounted on the rear surface of the second guide roll 1-2, and connected in this order; and the third guide roll mounted on the rear surface of the sixth roll 2-6.

[50] The size of the second roll 2-2 is larger than that of the first roll 2- 1 , and the size of the fifth roll 2-5 is larger than that of the second roll 2-2.

[51] Comparative example 1 [52] The product according to the present invention prepared in Example 1 was compared with other products, and the results were obtained as in Table 1 below.

[53] Experiment method: JIS A type- 1323 A [54] Table 1 [Table 1] [Table ]

[55] [55] From the experiment results, it can be found that in the present invention, the tensile strength is lowest, stretch is similar to aramid fiber, and the specific resistance is highest.

[57] Although the present invention has been described with reference to several embodiments of the invention, the description is illustrative of the invention and is not to be construed as limiting the invention. Various modifications and variations may oαur to those skilled in the art, without departing from the spirit and scope of the invention as defined by the appended claims.

Industrial Applicability

[58] An acryl carbide incombustible material according to the present invention has high strength, softness and convenient adhesion, has excellent flame retardant, incombustible, durable and anti-flammable properties tolerable up to 2,100 to 2,500 ⁰ C, and is free to cut and sew into an incombustible product applicable to various industrial fields, and is human body- and environment-friendly in manufacturing a formed product since it nontoxic and nonirritant.