CN101374644A - 酚醛泡沫板 - Google Patents

酚醛泡沫板 Download PDF

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CN101374644A
CN101374644A CNA2007800039264A CN200780003926A CN101374644A CN 101374644 A CN101374644 A CN 101374644A CN A2007800039264 A CNA2007800039264 A CN A2007800039264A CN 200780003926 A CN200780003926 A CN 200780003926A CN 101374644 A CN101374644 A CN 101374644A
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surface layer
foams
phenolic
metal forming
layered product
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CN101374644B (zh
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V·科波克
R·泽格盖拉
R·韦纳姆
L·霍布斯
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Kingspan Holdings IRL Ltd
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Kingspan Holdings IRL Ltd
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  • Thermal Insulation (AREA)

Abstract

本发明涉及一种硬的绝热酚醛泡沫体(8)，其具有至少一个预穿孔的面层(1)。优选在将该面层(1)粘合到泡沫体上之前对面层(1)进行穿孔。面层(1)可以是不透气的材料例如金属箔。与具有透气面层的酚醛泡沫体相比，不透气材料中的穿孔(5)减少了酚醛泡沫体的干燥和固化时间。

Description

酚醛泡沫板
酚醛泡沫体由于其优良的热绝缘性能和火性能而被用于工程材料的绝缘应用，其中所述火性能包括低排烟性和良好的耐火性。
酚醛泡沫体通常通过膨胀和固化可发泡组合物而制得，所述可发泡组合物是通过均匀混合可熔可溶酚醛树脂(由苯酚和甲醛在碱性催化剂的存在下进行缩聚反应而制得)、发泡剂(通常是导热系数比空气低的挥发性液体或气体)、表面活性剂、和固化促进剂来制备的。还可以任选向树脂中混入其它的添加剂，例如增塑剂、阻燃剂和颜料。
泡沫绝热板通常具有不透气面层如箔面层。通过利用发泡树脂本身固有的粘合能力，将这些面层与泡沫芯粘合到一起，而不需要额外的粘合剂。这被称为自粘合。不透气面层例如铝箔面层，用于减少产品的辐射率。辐射率是面层发射出的能量对理想黑体发射出的能量的比值，辐射率数值低表明面层良好的热反射，这对最终产品的绝热值具有积极作用。
在苯酚和甲醛缩聚反应期间，将有大量的水形成。这些水通常必须在高温下在单独的干燥或固化步骤通过干燥除去，以得到具有良好尺寸稳定性的产品。当使用不透气面层例如铝箔时，为了干燥产品，将需要非常长的固化时间。固化这些产品不能使用太高的温度(即高于100℃)，因为汽化的水将在闭合的泡沫孔中造成过大的压力，导致这些孔的破裂和发泡剂的流失，这样得到的绝热值相对较差，因为发泡剂被空气代替。
实践中，两面都覆盖有不透气面层的绝热板的固化时间将依赖于产品的厚度。干燥和固化带有不透气面层的绝热板，比干燥和固化带有透气面层的绝热板需要超过3倍长的时间。
覆盖有不透气面层如铝箔的产品由于其增加的处理成本而在商业上并不可行，所述面层在固化后粘合于产品上。
发明内容
本发明的酚醛泡沫绝热产品在不透气面层材料上具有穿孔。与带有透气面层的产品相比，这些穿孔减少了干燥和固化时间。该种产品的老化导热率也得到了提高。优选在制造酚醛绝热板之前，在不透气面层材料上制得穿孔。通过在生产过程中发生自粘合使其两面都覆盖有穿孔的不透气面层材料时，酚醛泡沫绝热板的老化导热率小于0.02W/m.K。所述穿孔的直径可以是0.05-2mm，并且可间隔2-50mm。穿孔直径通常是0.1-1.5mm，并且间隔3-30mm。
可以在面层的一面或者双面形成穿孔。穿孔可以是任何形状的，并且可以使用工具来形成，所述工具的形状例如是管状的、圆锥状的或锥状的。锥状钉齿可以得到X状穿孔，其宽度通常为1.0mm，中心距通常为3.8mm。
根据本发明，其提供一种具有预穿孔面层的硬酚醛绝热泡沫体。
在一种实施方案中，所述面层包括基本不透气的材料。该面层可以包括金属箔，例如铝箔。面层可以是层压体，例如将金属箔层压到玻璃薄纱或将金属箔层压到牛皮纸上。
在一种实施方案中，所述泡沫体包括具有上表面和下表面的板，且在板的至少一个表面上施加不透气面层。通常，在板的上、下表面都施加面层。
本发明还提供一种制造泡沫体的方法，其包括以下步骤：
将基底面层引导到铺放区；
将液体泡沫反应物铺放到所述基底面层上；
对至少一个面层进行预穿孔；
将上部面层引导到泡沫反应物上面；
将这样形成的层状结构引导着穿过加热炉；和
将这样形成的泡沫板切割成期望的长度。
两个面层都可以进行预穿孔。
至少一个面层可以包括一种基本不透气的材料。面层可以包括金属箔例如铝箔。面层可以是层压体，例如将金属箔层压到玻璃薄纱上或者将金属箔层压到牛皮纸上。
本发明还提供一种具有穿孔面层的硬的绝热聚合酚醛泡沫体。所述面层可以包括通常不透气的材料例如金属箔，如铝箔。面层可以是层压体，例如将金属箔层压到玻璃薄纱上或者将金属箔层压到牛皮纸上。
在一种实施方案中，泡沫体包括具有上表面和下表面的板，且在板的至少一个表面上施加面层。面层也可以同时施加在板的上下表面上。
本发明还提供一种制造酚醛泡沫体的方法，其包括以下步骤：
将基底面层引导到铺放区；
将液态酚醛泡沫反应物铺放到所述基底面层上；
将上部面层引导到所述泡沫反应物上面；
将这样形成的层状结构引导着穿过加热炉；
对至少一个面层进行穿孔；和
将这样形成的泡沫板切割成期望的长度。
在一种实施方案中，两个面层都进行了穿孔。
至少一个面层可以包括基本不透气的材料，例如金属箔，如铝箔。面层可以是层压体，例如将金属箔层压到玻璃薄纱上或者将金属箔层压到牛皮纸上。
附图说明
本发明可以通过参考附图，从以下说明中借助实施例得到更清楚的理解：
图1(a)和1(b)是用于预穿孔面层的穿孔图案的示意图；
图2是另一种穿孔图案的示意图；
图3是利用钉齿辊在面层上形成穿孔的图示；
图4是穿孔面层的平面图；
图5是穿孔面层的透视图；
图6是在面层上形成穿孔的另一图示；
图7(a)和7(b)是在面层上形成穿孔的图示；
图8是带有预穿孔面层的泡沫板的图示；
图9是在泡沫板的面层中形成穿孔的侧视图；和
图10是使用图9的设备形成穿孔的横截面视图。
具体实施方式
已经惊喜地发现，在不透气面层上存在的小的穿孔，将在生产出绝热板后导致对其进行干燥(固化)的时间的缩短。这种缩短的干燥时间可以与同样厚度的、带有透气面层例如玻璃纤维面层的泡沫绝热制品所需的干燥时间相当。
优选在将泡沫体施加到面层上之前，在酚醛泡沫绝热板的面层上形成穿孔。或者，可以在形成泡沫板之后，在面层中引入小的穿孔。当在施加泡沫体之前对面层进行穿孔的情况下，仔细选择孔的尺寸和间距(通常为0.1-1.5mm，一般小于1mm)以避免漏出液体预聚物。
实施例1
在该情况下，在发泡步骤前，在面层自身中形成穿孔。
为了这一目的，对两种不同的面层进行穿孔并用来制造泡沫板。第一面层是由铝箔层压到玻璃薄纱上构成。
参考图3-8，面层1可以用带有多个钉齿3的钉齿辊2进行穿孔，所述多个钉齿3在面层1中形成多个穿孔5。钉齿辊在GB-A-2,383,971中有描述。
图1(a)中示出了铝-玻璃纤维面层的穿孔图案，且穿孔尺寸为0.7mm。
在两个面层都进行了穿孔后，生产出厚度为50mm的酚醛泡沫绝热板8。
生产厚度为50mm的苯酚甲醛泡沫绝热板，其带有包括层压到玻璃薄纱上的铝箔的不透气面层。在板的两面都使用穿孔的面层。根据本发明的制造酚醛泡沫体的方法，将可发泡的酚醛树脂组合物排放到连续移动的穿孔面层上，并穿过加热区以进行发泡并模制为预定形状的酚醛泡沫产品。在该制造过程中，酚醛树脂组合物排放在由传送带支撑的移动的穿孔面层上，进入通常为50-100℃的加热炉2-15分钟。正在发泡的泡沫组合物的上表面用另一由上部传送带运载的穿孔面层材料压住。将泡沫厚度控制在预定厚度。离开加热炉的酚醛泡沫体随后被切割为预定长度。
利用与上述同样的方法，用包括牛皮纸-铝箔层压体的面层生产泡沫板。铝-牛皮纸面层的穿孔图案以及0.1mm的穿孔尺寸在图1(b)中示出。如上文所述，可以利用螺旋状钉齿辊对面层进行穿孔。在板的两面都使用穿孔的面层。
作为对照参考，制造出同样厚度的带有同样的面层，但是没有穿孔的板试样。这些试样在80℃的加热炉中干燥5小时。
表1示出了在80℃下干燥5小时后，产品的重量损失。
表1：厚度为50mm的板的穿孔和未穿孔面层的重量损失
 
说明 重量损失(％)
穿孔的铝牛皮纸层压体(穿孔直径为0.1mm) 7.5
未穿孔的铝牛皮纸层压体 4.6
穿孔的铝-玻璃薄纱层压体(穿孔直径为0.7mm) 10.8
未穿孔的铝玻璃薄纱层压体 4.7
对箔进行穿孔，使泡沫板产品的干燥速率增加。0.1mm的穿孔尺寸大约使干燥速率加倍。本发明优选的实施方案是如实施例1所述的对面层进行预穿孔，因为这样做的优点在于：消除在面层和泡沫体表面之间偶然形成气泡。在用气密性面层生产时，在生产过程中，(来自水蒸气或发泡剂的)气体从泡沫体中释放出来，无法穿过不透气面层时，发生这些气泡，导致在面层和泡沫体表面之间形成气泡，使得该区域的面层粘合力受损。这些气泡的尺寸可以从几毫米到几十厘米变化，无论从审美角度还是从其减少了面层张力方面来讲，这些气泡都是人们所不期望的。
实施例2
生产厚度为80mm的苯酚甲醛泡沫绝热板，其两面都带有不透气的双层铝箔-玻璃薄纱层压体面层。该双层面层的排列使得双层面层的玻璃纤维层粘合到酚醛泡沫体上。根据本发明的制造酚醛泡沫体的方法，将可发泡的酚醛树脂组合物排放到连续移动的面层上，并穿过加热区以进行发泡并模制为预定形状的酚醛泡沫产品。在该制造过程中，酚醛树脂组合物排放在由传送带支撑的移动的面层材料上，进入通常为50-100℃的加热炉中2-15分钟。正在发泡的泡沫组合物的上表面被另一由上部传送带运载的面层材料压住。将泡沫体厚度控制在所需预定厚度。离开加热炉的酚醛泡沫体随后被切割为预定长度。
此后，利用在GB-A-2,383,971中描述的螺旋状钉齿辊，对这些泡沫绝热板中的一个在一面进行穿孔。穿孔的图案和深度在图2中给出。每个穿孔的直径为约0.5mm。
根据图2给出的图案，利用同样的螺旋状钉齿装置对另一个厚度为80mm的两面都覆盖有同样的铝箔-玻璃纤维薄纱面层的苯酚甲醛泡沫绝热板在两面都进行穿孔。该装置在图9和10中示出，其中泡沫板10穿过两个带有钉齿11a、12a的螺旋状钉齿辊11、12，以形成两面带有面层14、15的泡沫板13。两个面层14、15都进行了穿孔。
这些穿孔的试样，与两面带有同样的铝箔-玻璃薄纱面层但未穿孔的酚醛泡沫板试样、和带有普通透气玻璃薄纱的绝热板一起，放于70℃的加热炉中。在4、8和12小时之后，测定这些试样的重量损失。
表2给出了这四个试样的重量损失相对于干燥时间的函数。
表2：重量损失与干燥时间的函数
Figure A200780003926D00111
表2显示，双面穿孔的产品的重量损失与覆盖有透气面层如纤维玻璃薄纱的产品的重量损失相当。
表3是这些80mm厚试样在70℃下干燥8小时后的物理性能。所有的测量都是根据EN13166 2001进行的。
表3：穿孔产品的物理性能
 
说明 压缩强度[kPa] 脱层强度[kPa] 70℃下4天后的初始导热率(W/m.k) 70℃+23℃/50％RH下25周后的导热率(W/m.k)
双面覆盖有铝箔-玻璃纤维薄纱的产品(未穿孔) 171 85 0.0194 0.0211
双面覆盖有铝箔-玻璃纤维薄纱的产品(单面穿孔) 164 92 0.0185 0.0194
双面覆盖有铝箔-玻璃纤维薄纱的产品(双面穿孔) 175 102 0.0185 0.0195
双面玻璃薄纱(参照试样) 169 95 0.0180 0.0190
所有产品的压缩强度都是相当的。
对面层穿孔，似乎使脱层强度略为提高。
在加速老化之后，穿孔产品的导热率和带有透气面层的产品的导热率相当。带有穿孔的铝-玻璃纤维薄纱的产品的初始导热率略微更高。这归功于铝面层，其在导热率测量仪器上给出略高的读数(Fox Laser comp 314)。
没有穿孔的产品具有更高的初始导热率，热老化之后导热率的增加比穿孔产品更高。
实施例3
生产厚度为40mm的酚醛泡沫体。以与实施例2中相同的方式，在产品的两面都覆盖不透气的双层铝-玻璃薄纱面层。然后，如上所述，对该绝热板试样在一面进行穿孔。穿孔的图案和深度示于图2。
和实施例2一样，将这些试样放于70℃下的干燥炉进行调节。和这些试样一起的还有未穿孔的参照试样。在这一轮评价中，还有覆盖有普通玻璃薄纱的试样。
表4给出了三种试样的重量损失相对于干燥时间的函数。
表4：重量损失相对于干燥时间的函数(产品厚度为40mm)
Figure A200780003926D00131
表4显示，单面穿孔的产品的重量损失，与覆盖有不透气面层的产品的重量损失相比，要高得多。
表5示出了这些40mm厚的试样在70℃下干燥4小时之后的产品性能。
所有得测量都是根据EN13166 2001进行的。
表5：穿孔产品的物理性能(产品厚度为40mm)
 
说明 压缩强度[kPa] 脱层强度[kPa] 初始导热率(W/m.k) 70℃下25周后的导热率(W/m.k)
双面覆盖有铝箔-玻璃纤维的产品(未穿孔) 162 89 0.0197 0.0201
双面覆盖有铝箔-玻璃纤维的产品(单面穿孔) 152 84 0.0188 0.0196
玻璃薄纱(参照试样) 169 87 0.0177 0.0188
本发明并不局限于这里所列的实施方案，其可以作出细节上的改变。

Claims (33)

1.一种硬的绝热酚醛绝缘泡沫体，其具有预穿孔的面层。
2.如权利要求1所述的泡沫体，其中所述面层包括基本不透气的材料。
3.如权利要求2所述的泡沫体，其中所述面层包括金属箔。
4.如权利要求2或3所述的泡沫体，其中所述面层包括铝箔。
5.如权利要求3或4所述的泡沫体，其中所述面层是层压体。
6.如权利要求5所述的泡沫体，其中所述层压体包括层压到玻璃薄纱上的金属箔。
7.如权利要求5所述的泡沫体，其中所述层压体包括层压到牛皮纸上的金属箔。
8.如权利要求1-7任一所述的泡沫体，其中所述泡沫体包括具有上表面和下表面的板，且在该板的至少一个表面上施加所述面层。
9.如权利要求8所述的泡沫体，其中在所述板的上表面和下表面都施加面层。
10.一种制造酚醛泡沫体的方法，其包括以下步骤：
将基底面层引导到铺放区；
将液体酚醛泡沫反应物铺放到所述基底面层上；
将上部面层引导到所述泡沫反应物上面；
其中对至少一个面层进行预穿孔；
将这样形成的层状结构引导穿过加热炉；和
将这样形成的泡沫板切割成期望的长度。
11.如权利要求10所述的方法，其中对两个所述面层都进行预穿孔。
12.如权利要求10或11所述的方法，其中至少一个所述面层包括基本不透气的材料。
13.如权利要求12所述的方法，其中所述面层包括金属箔。
14.如权利要求13所述的方法，其中所述面层包括铝箔。
15.如权利要求13或14所述的方法，其中所述面层是层压体。
16.如权利要求15所述的方法，其中所述层压体包括层压到玻璃薄纱上的金属箔。
17.如权利要求15所述的方法，其中所述层压体包括层压到牛皮纸上的金属箔。
18.一种硬的绝热聚合酚醛泡沫体，其具有预穿孔的面层。
19.如权利要求18所述的酚醛泡沫体，其中所述面层包括通常不透气的材料。
20.如权利要求19所述的酚醛泡沫体，其中所述面层包括金属箔。
21.如权利要求19或20所述的酚醛泡沫体，其中所述面层包括铝箔。
22.如权利要求20或21所述的泡沫体，其中所述面层是层压体。
23.如权利要求22所述的泡沫体，其中所述层压体包括层压到玻璃薄纱上的金属箔。
24.如权利要求22所述的泡沫体，其中所述层压体包括层压到牛皮纸上的金属箔。
25.如权利要求18-24任一所述的酚醛泡沫体，其中所述泡沫体包括具有上表面和下表面的板，且在该板的至少一个表面上施加所述面层。
26.如权利要求25所述的酚醛泡沫体，其中在所述板的上表面和下表面都施加面层。
27.一种制造酚醛泡沫体的方法，其包括以下步骤：
将基底面层引导到铺放区；
将液体酚醛泡沫反应物铺放到所述基底面层上；
将上部面层引导到泡沫反应物上面；
将这样形成的层状结构引导穿过加热炉；
在所述面层已经粘合到泡沫体上之后对至少一个所述面层进行穿孔；和
将这样形成的泡沫板切割成期望的长度。
28.如权利要求27所述的方法，其中对两个所述面层都进行穿孔。
29.如权利要求27或28所述的方法，其中至少一个所述面层包括基本不透气的材料。
30.如权利要求29所述的方法，其中所述面层包括金属箔。
31.如权利要求30所述的方法，其中所述面层包括铝箔。
32.一种基本上如前所述的酚醛泡沫体。
33.一种基本上如前所述的制造泡沫体的方法。
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