HEAT CONSERVATION-INSULATING MATERIAL COATED WITH UV CURING-TYPE FILM AND HAVING MAXIMIZED HEAT EFFICIENCY, AND METHOD FOR MANUFACTURING SAME

Abstract

The present invention relates to a heat conservation-insulating material which is coated with a UV film and has maximized heat efficiency, wherein: the material uses a thermosetting water-soluble acrylic adhesive to ensure the minimum uniform coating film thickness required for corrosion prevention of a pipe and strength reinforcement during curing and allow easy installation with flexibility and sufficient working time before the installation; and a surface of the insulating material is UV-coated and thermosetting-coated by dual-cure curing method so that even a part where light or ultraviolet rays cannot penetrate can be cured, a heat conservation-insulating material having vivid colors can be obtained even when dye and pigment are added to realize various colors, and the cutting processability is excellent to enable a uniform coating on various surfaces, such as metal, plastic, glass, ceramics, stone, wood, and various building materials, or even on sharply bent shapes.

Claims

1. A method for manufacturing a thermal insulation material coated with a UV film to maximize thermal insulation efficiency, the method comprising the steps of: a) preparing a photo-curable adhesive by adding a reactive acrylic monomer obtained by combining one or two or more selected from chemical formula (1), chemical formula (2), and chemical formula (3), an acrylic oligomer selected from among aliphatic urethane acrylate, aliphatic urethane diacrylate, or aliphatic urethane triacrylate, a basic aqueous solution, and a reaction initiator obtained by combining one or two or more of chemical formula (4), chemical formula (5), or chemical formula (6), a sensitizer, a crosslinking agent, and a functional additive; b) preparing a binder for an E-Glass long fiber mat by mixing the thermosetting adhesive, water, bentonite, silica, flame retardant, nitrogen-based resin, water repellent, penetrant, antifoaming agent, and dispersant; c) preparing an E-glass long fiber thermal insulation material by uniformly applying the water-soluble binder to a surface of the E-Glass long fiber mat, pressing with a roller, and stacking and forming on a cylindrical jig; d) drying the thermal insulation material separated from the forming roller at 150° C. to 200° C. for 10 minutes to 30 minutes; and e) coating a surface of a thermal insulation cover with a dual-curable coating composition prepared by synthesizing a dual-curable resin using one or two or more selected from an acrylate monomer and an oligomer and a photo initiator and then mixing the thermosetting resin, isocyanate, polyol, a photo initiator, and methyl ethyl ketone, as a solvent.

2. The method of claim 1, wherein in step (e), the acrylate monomer includes any one or two or more of 2-HEA (2-hydroxyethyl acrylate), 2-ethylhexyl acrylate (2-EHA), 2-hydroxyethyl methacrylate (2-HEMA), and 2-HPA (2-hydroxypropyl acrylate), and wherein the acrylate oligomer is any one of aliphatic urethane diacrylate, aliphatic urethane triacrylate, and aliphatic urethane hexaacrylate.

3. The method of claim 1, wherein in step (e), the isocyanate is one or two or more selected from among TDI (toluene diisocynate), MDI (diphenylmethane diisocynate), MXDI (tetramethyl xylene diisocynate), XDI (xylene diisocyanate), IPDI (isophorone diisocyanate), or HMDI (hexamethylene diisocyanate).

4. The method of claim 1, wherein in step (e), the polyol is a polyether polyol, a polyester polyol, a prolactone polyol, a polycarbonate polyol, or a polybutadiene polyol.

5. The method of claim 1, wherein in step (e), the dispersant is one or two or more selected from among polyoxyalkyl ether, sodium naphthalene sulfonate condensate, sodium alkyl diphenyl ether disulfonate, or sodium lignin sulfonate.

6. A thermal insulation material coated with a UV film to maximize thermal insulation efficiency, prepared by: a) preparing a thermosetting adhesive by adding a reactive acrylic monomer represented in chemical formula (1), an acrylic oligomer selected from among aliphatic urethane acrylate, aliphatic urethane diacrylate, and aliphatic urethane triacrylate, a basic aqueous solution, a reaction initiator represented in chemical formula (4), and a sensitizer; b) preparing a binder for an E-Glass long fiber mat by mixing the thermosetting adhesive, water, bentonite, silica, flame retardant, nitrogen-based resin, water repellent, penetrant, antifoaming agent, and dispersant; c) forming an E-glass long fiber thermal insulation material by uniformly applying the water-soluble binder to a surface of the E-Glass long fiber mat, pressing with a roller, and stacking and forming on a cylindrical jig and drying the E-glass long fiber thermal insulation material; and d) coating a surface of a thermal insulation cover with a dual-curable coating composition prepared by synthesizing a dual-curable resin using an acrylate monomer and an oligomer and a photo initiator and an acrylic acid, mixing the thermosetting resin with a polyol, a photo initiator, and methyl ethyl ketone, as a solvent.

7. The method of claim 6, wherein the polyol is a polyether polyol, a polyester polyol, a prolactone polyol, a polycarbonate polyol, or a polybutadiene polyol.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] FIG. 1 is a view illustrating a configuration of a thermal insulation material in which a surface of a protective cover for pipe insulation is coated with a UV film.

BEST MODE TO PRACTICE THE INVENTION

[0023] Unless otherwise defined, all terms including technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the embodiments of the present disclosure belong. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0024] Hereinafter, embodiments of the present invention are described in detail for a better understanding of the present invention. However, the embodiments herein amount to mere examples of the technical spirit of the present invention. There, it is apparent that the embodiments described herein are intended for describing the present invention but not for limiting the present invention and that the scope of the technical spirit of the present invention should not be limited thereto. It should be interpreted that other various changes or modifications or other specific embodiments easily inferred by one of ordinary skill in the art are included in the scope of the present invention without departing from the technical spirit of the present invention.

[0025] According to the present invention, in a thermosetting adhesive composition, a reactive acrylic monomer may be any one selected from among beta-carboxyethyl acrylate as represented in chemical formula (1), oxyethylated acrylate as represented in chemical formula (2), or 2-phenoxyehtyl acrylate or urethane acrylate as represented in chemical formula (3). A reaction initiator is composed of 2,2-dimethoxy-1,2-diphenyl-ethan-1-one as represented in chemical formula (4), 1-hydroxy-cyclohexylphenyl-ketone as represented in chemical formula (5), 2-methyl-1-[4-(methylthio)phenyl]-2-morpholino-propan-1-one as represented in chemical formula (6), or potassium persulfate as represented in chemical formula (7), and a photosensitizer, a crosslinking agent, and a functional additive may be added.

##STR00002##

<Embodiment 1-3> Synthesis of Thermosetting Water-Soluble Acrylic Adhesive

[0026] As illustrated in [Table 1], a thermosetting adhesive was synthesized by injecting an acrylic monomer, an acrylic oligomer, a basic aqueous solution, and a reaction initiator and then heating them.

TABLE-US-00001 TABLE 1 Components of adhesive Embodiment 1 Embodiment 2 Embodiment 3 Acrylic Chemical Chemical Chemical monomer formula 1 formula 2 formula 3 Acrylic Aliphatic Aliphatic Aliphatic oligomer Urethane- Urethane- Urethane- Acrylate Acrylate Acrylate Acrylate Diacrylate Triacrylate Basic aqueous —OH —OH —SO4 solution Reaction Chemical Chemical Chemical initiator formula 4 formula 5 formula 6 Sensitizer partially porfimer Taporfin purified sodium sodium

<Embodiment 4-6> Composition of Inorganic Substance-Containing Binder

[0027] As illustrated in Table 2, a binder for an E-Glass long fiber mat was prepared by mixing a curable adhesive, water, bentonite, silica, flame retardant, nitrogen-based resin, water repellent, penetrant, and antifoaming agent dispersant.

TABLE-US-00002 TABLE 2 Composition of binder Components (parts by weight) Embodiment 4 Embodiment 5 Embodiment 6 Thermosetting Embodiment 1 Embodiment 2 Embodiment 3 adhesive Adhesive: 100 Adhesive: 100 Adhesive: 100) water 20 30 40 Bentonite 30 20 40 Silica 5 5 7 Flame retardant 5 10 15 Nitrogen-based resin 2 4 6 Water repellent 2 4 6 Penetrant 6 4 2 Antifoaming agent 1 2 1 Dispersant 2 1 2

[0028] Among the components of the binder, it is preferable to contain 20-40 parts by weight of bentonite with respect to 100 parts by weight of the thermosetting adhesive. When the amount of bentonite is 40 parts by weight or more, the mechanical strength increases but the adhesive strength may reduce, and when the amount of the bentonite is 20 parts by weight or less, the mechanical strength may reduce. As the dispersant, sodium polyoxyalkylether naphthalene sulfonate-condensate was used in embodiment 4, sodium alkyl diphenyl ether disulfonate in embodiment 5, and sodium lignin sulfonate was used in embodiment 6. <Forming of thermal insulation cover>

[0029] The water-soluble binder of embodiment 4 was uniformly applied to the surface of the E-Glass long fiber mat, pressed with a roller, and then stacked and formed on a cylindrical jig, thereby producing a tube-shaped glass long fiber insulation material with various thicknesses. The tube-shaped E-Glass long fiber insulation material was dried for 2 to 6 hours at a temperature of about 180° C. to about 250° C. in a microwave and hot air drying device.

<Embodiment 7> Mixing of Dual-Curable Resin

[0030] 30% by weight of 2-HEA, 40% by weight of 2-HEMA, and 30% by weight of (2-HEMA) were mixed, and 2,2′-azo-bis-isobutylnitrile (AIBN), as a photo initiator, was added at 60° C., and they were left to react for five hours, thereby reacting with a polymer having a solid content of 40 wt %, and is then mixed with 30 mol % of acrylic acid, synthesizing an acrylic functional group in the polymerized resin and finally preparing a double-curable resin having a solid content of 35 wt %.

<Embodiment 8> Coating of Dual-Curable Composition

[0031] The dual-curable coating composition resultant from mixing 50 g of the dual-curable resin of embodiment 7, 25 g of polycarbonate polyol, 7 g of MDI, 7 g of benzoyl peroxide, as a photo initiator, and 30 g of MEK as a solvent, was coated on the thermal insulation cover of the present invention and was then dried at 60° C. for 5 minutes, then thermal-cured and aged at 50° C. for 3 hours, forming a hard coating layer.

Comparative Example

[0032] The product of the comparative example is a thermal insulation cover of E-Glass long fiber thermal insulation material coated with aluminum foil on the surface thereof.

[0033] <Functional Evaluation>

[0034] 1) Gloss

[0035] The gloss was measured at an angle of 60° using a glossmeter.

[0036] 2) Surface Hardness

[0037] The surface hardness was measured according to ASTM D3502.

[0038] 3) Scratch Resistance

[0039] The hard coating layer was pressed hard and scratched with a spoon while moving back and forth five times, and was then left for 1 minute. Thereafter, the marks left on the surface of the coating layer were observed with the naked eye, and evaluated as two stages of excellent and poor.

[0040] Excellent: ∘ (restored)

[0041] Normal: Δ (slightly restored)

[0042] Poor: X (not restored)

[0043] 4) Flexibility

[0044] It was checked with the naked eye whether a crack occurs when the thermal insulation cover was elongated by 10%.

[0045] It was classified into two grades of (crack occurrence).

[0046] [Table 3] shows the results of testing the gloss, surface hardness, scratch resistance, and flexibility.

TABLE-US-00003 TABLE 3 Surface Scratch Gloss hardness resistance Flexibility Embodiment 8 97 Smooth ∘ No crack Comparative 82 Slightly x Some cracks example rough occur

[0047] As shown from [Table 3], it was identified that the thermal insulation cover of the present invention has a gloss of 97 and has excellent surface hardness, scratch resistance, and flexibility.

INDUSTRIAL AVAILABILITY

[0048] The present invention relates to an industrial thermal insulation material coated with a UV film that maximizes thermal efficiency, and more specifically, to a waterproof, high-thermal efficiency, and high non-flammable UV film-coated thermal insulation material for use as a cover in or for petroleum chemical plants, power plants, steel making plants, chemical storage tanks, oil tanks, shipbuilding (ships), building interior and exterior materials, ground or underground pipelines, roofs, linings, etc. The present invention relates to a thermal insulation material that has good cutting processability and thus allows for a uniform coating even on highly uneven or curvy surfaces of metal, plastic, glass, ceramic, stone, wood and various building materials and a method for manufacturing the thermal insulation material.