Flame-Retardant Wood Containing Expandable Graphite and Manufacturing Method Thereof

Method for Manufacturing Flame-Retardant Wood Boards Using Carbon Powder Flame-Retardant Additives and Sandwich Lamination

This technology involves manufacturing flame-retardant wood boards by placing a second flame-retardant wood layer containing wood chips between two first flame-retardant wood layers—formed by mixing wood flour with carbon powder-based flame-retardant additives, binders, and granulated inorganic materials—and then heat-pressing the assembly.

Wood and wood flour, widely used in architectural interiors, are highly vulnerable to fire compared to other materials, leading to larger-scale fire damage as buildings become taller and more subterranean. While research into flame-retardant composites using carbon nanomaterials has been conducted, significant challenges remain regarding production cost-effectiveness and practical application.

This technology achieves both formability and fire resistance through a sandwich structure that incorporates a high ratio of flame-retardant additives with expanded carbon structures and applies granulated inorganic materials of varying sizes to each layer. This satisfies the ISO flame-retardant wood standard of a total heat release rate of 8 MJ/m² or less. It can be applied to wall, ceiling, and floor interiors in residential and commercial buildings, significantly reducing fire spread risks while maintaining the natural texture of wood.

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Key Features:

• Step of preparing the first flame-retardant wood by drying a mixture of 80–100 mesh wood flour, 30–50 wt% of 80-mesh carbon powder flame-retardant additive, a binder, and granulated inorganic materials in a mold
• Step of manufacturing the second flame-retardant wood by drying a second mixture containing wood chips larger than the wood flour, wood flour, flame-retardant additives, a binder, and granulated inorganic materials in a mold
• Step of placing the second flame-retardant wood between multiple first flame-retardant wood layers and heat-pressing them to manufacture a sandwich-structured flame-retardant wood board
• Configuration where inorganic materials are added to metal seeds and a solution and shaken to granulate, with the granules for the second flame-retardant wood formed to a larger size by extending the shaking time

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