CN103953127A - 带功能层的钢结构防火卷材及其制备方法 - Google Patents

带功能层的钢结构防火卷材及其制备方法 Download PDF

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CN103953127A
CN103953127A CN201410205433.0A CN201410205433A CN103953127A CN 103953127 A CN103953127 A CN 103953127A CN 201410205433 A CN201410205433 A CN 201410205433A CN 103953127 A CN103953127 A CN 103953127A
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张建春
张璇璇
张安振
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Tianjin Baochen Hengyuan Technology Co ltd
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NERO CARBIDE BEIJING TECHNOLOGY Co Ltd
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Abstract

本发明涉及带功能层的钢结构防火卷材及其制备方法，属于防火材料领域。该防火卷材，由防火层和功能层组成，所述防火层由高分子固体树脂、膨胀型阻燃剂、分散助剂、增强助剂组成，功能层是在防火层的材料基础上外加功能填料制成；两层分别经混和、挤出造粒、延压成片，再复合延压、收卷成卷材。本发明可以在生产线上连续化生产，一次加工成所需厚度的卷材，生产效率高、设备简单，生产过程安全环保，不存在废水、废气等工业污染；该防火卷材可以根据防火设计要求，生产不同厚度的片材，满足各种不同条件的防火设计需求。使用时能够在钢结构表面快速贴覆，一次性粘贴到防火设计厚度，无需多次重复刷涂，工作效率高、工序简单、施工环保、方便。

Description

带功能层的钢结构防火卷材及其制备方法
技术领域
本发明属于防火材料技术领域，尤其涉及一种钢结构防火卷材及其制备方法。
背景技术
随着我国经济建设的快速发展，钢结构建筑因其强度高、承载能力强、自质轻、构件制造与安装方便、结构美观、施工快捷、抗震性及稳定性好等优点，已经越来越多地应用于各类大空间工业厂房及民用建筑中。虽然钢结构本身为不燃烧材料，但其屈服应力和抗拉强度在600℃以上时急剧减少为原来的50％～60％，故其耐火极限仅为15min，无法满足设计耐火极限要求。要使钢结构材料在实际应用中克服防火方面的不足，必须进行防火处理，其目的就是将钢结构的耐火极限至少提高到设计规范规定的极限范围。钢结构构件的防火方法主要有涂料保护、防火板保护、混凝土保护、无机纤维保护、结构内通水冷却保护等。
钢结构建筑采用防火涂料进行防火处理是目前普遍的措施，根据所使用分散剂的不同，钢结构防火涂料分为溶剂型与水性涂料。溶剂型涂料具有较好的硬度、光泽、耐水性、耐化学腐蚀性，但是其使用有机溶剂作为分散剂，在生产与施工过程中会大量挥发，污染环境，对人体产生危害，同时浪费能源、安全隐患大；漆膜的透气性差，又有疏水性，如在潮湿的基层上施工，容易产生起皮、脱落；随着时间的变长，涂层越来越坚硬，变得易碎，如墙体发生热胀冷缩的情况就会发生开裂。水性涂料以水为溶剂，具有环保、安全、作用方便的特点，涂层透气性比较好，基层内部的水蒸气可以向外扩散，但是也存在着耐水性能、涂层硬度差的缺点。最重要的是，无论是水性还是溶剂型钢结构防火涂料都存在着施工周期长，需多次重复涂刷，工序复杂，现场施工不方便，生产中存在废液、废气等污染，刷涂厚度难以掌握，导致涂层厚薄不均，装饰性差，施工损耗严重等缺点。
如果想要在防火涂料层外加功能层，如防紫外线等，可以提高防火涂料层的寿命，提高其防火涂料层的效果，现在的防火涂料层或施工工艺根本无法实现。
现有市场上防火卷材均不适用于钢结构的包裹，不能满足钢结构防火性能的需求。
发明内容
针对上述领域中的需求，本发明提供一种带功能层的钢结构防火卷材，可以在生产线上连续化生产，一次加工成所需厚度的卷材，生产效率高、设备简单，生产过程安全环保，不存在废水、废气等工业污染，使用时能够在钢结构表面快速贴覆，一次性粘贴到防火设计厚度，无需多次重复刷涂，工作效率高、工序简单、施工环保、方便。该钢结构防火卷材具有广阔的市场前景。
带功能层的钢结构防火卷材，由防火层和功能层组成，所述防火层由高分子固体树脂、膨胀型阻燃剂、分散助剂、增强助剂组成，功能层是在防火层的材料基础上外加功能填料制成；两层分别经混和、挤出造粒、延压成片，再复合延压、收卷成卷材，所述膨胀型阻燃剂以磷酸盐为酸源、胺类化合物为气源和多羟基化合物为炭源组成；所述功能层为装饰层、抗紫外线层，厚度0.1～0.5mm，所述功能填料为颜料、紫外线吸收剂。
所述高分子固体树脂为聚丙烯、聚乙烯、聚氯乙烯、丙烯酸树脂、乙烯-醋酸乙烯共聚物、聚氨酯、尼龙、环氧树脂、聚碳酸酯、三元乙丙橡胶、天然橡胶或氯丁橡胶。
所述增强剂为玻璃纤维、玄武岩纤维、聚丙烯纤维、碳纤维、陶瓷纤维或聚乙烯纤维。
所述膨胀型阻燃剂的酸源为聚磷酸铵、磷酸酯、磷酸铵；炭源为季戊四醇、双季戊四醇、蔗糖、淀粉、糊精；气源为三聚氰胺、尿素、聚酰胺、双氰胺。
所述功能层颜料为矿物颜料与有机颜料；紫外线吸收剂为邻羟基苯甲酸苯酯、苯并三氮唑、二羟基二苯甲酮和/或单苯甲酸间苯二酚酯。
所述分散助剂为钛白粉。
所述磷酸盐、胺类化合物、多羟基化合物、分散助剂、增强助剂、高分子固体树脂的重量份比为：70-100：30-40：20-50：20-50：1：40-50，功能填料的重量份为0.5-2.5。
所述磷酸盐、胺类化合物、多羟基化合物、分散助剂、增强助剂、高分子固体树脂的重量份比为：100：30-40：40-50：20-30：1：40-50，功能填料的重量份为0.5-2.5。
其制备方法包括如下步骤：
(1)以磷酸盐为酸源、多羟基化合物为炭源、胺类化合物为气源混合制备膨胀型阻燃剂；
(2)膨胀型阻燃剂与增强助剂、分散助剂进行预混合处理，或者膨胀型阻燃剂与增强助剂、分散助剂、功能填料进行预混合处理；
(3)将高分子树脂与预处理粉体混合造粒，分别制备防火层颗粒与功能层颗粒；
(4)将颗粒分别压延成防火层与功能层片材；
(5)功能层与防火层片材进行二次延压复合；
(6)对复合层进行收卷，获得成品。
所述混合造粒采用螺杆挤出机，所述压延成片材采用延压机。
上述带功能层的钢结构防火卷材在钢结构防火、木质建筑防火、金属面板防火、墙体防火中的应用。
本发明涉及的是一种钢结构防火卷材，改进了传统涂料的原料、制备工艺、涂料形态等，采用高分子固体树脂作为基体原料，添加高效膨胀型阻燃剂与分散助剂、增强助剂、功能填料等，通过挤出造粒、延压成型的工艺，制备的具有高效防火性能与优异理化性能的防火卷材，同时具有生产安全环保、损耗小、工序简单，施工效率高，装饰性好、功能防护性强等优点；并且该防火卷材可以根据防火设计要求，生产不同厚度的片材，满足各种不同条件的防火设计需求。可代替现有涂料应用于各种钢结构进行防火保护，该防火卷材在遇火时发生膨胀阻火，不会发生脱落、裂缝、形变等影响耐火性能的缺陷，达到高效防火保护作用。
本发明的特点：
本发明通过采用新原材料、新工艺、新技术代替传统液态涂料，制备了钢结构防火卷材，其优点在于采用来源广泛的高分子固体树脂作为基体，以高效膨胀阻燃剂作为填料，通过挤出造粒、延压成型一次加工成所需厚度的卷材，生产效率高、设备简单，生产过程安全环保，不存在废水、废气等工业污染；可根据防火设计需求，生产相应厚度卷材，使用时能够在钢结构表面快速贴覆，一次性粘贴到防火设计厚度，无需多次重复刷涂，工作效率高、工序简单、施工环保、方便，在火灾中能够迅速膨胀，达到高效防火保护作用。
具体实施方式
下面结合实施例对本发明做进一步的详细说明。
实施例1：
将70份聚磷酸铵、30份聚酰胺、20份双季戊四醇、50份钛白粉、1份玻纤进行充分混合，将混合后的粉体与50份聚丙烯树脂进行混合，采用挤出机挤出造粒，将复合颗粒采用压延机进行压延成型，制备出防火层；防火层组成基础上加入1份颜料，压制装饰层；防火层与装饰层再次延压复合，获得带装饰层的防火卷材，最后通过切边机、收卷机等收卷制备装饰性聚丙烯基钢结构防火卷材，切割边角料通过一道压延机可再次加工成片材。
实施例2
将100份聚磷酸铵、40份三聚氰胺、45份双季戊四醇、20份钛白粉、1份聚丙烯纤维进行充分混合，将混合后的粉体与40份低密度聚乙烯树脂进行混合，采用挤出机挤出造粒，将复合颗粒采用压延机进行压延成型，制备出防火层；防火层组成基础上加入1份苯并三氮唑，压制抗紫外线层；防火层与抗紫外线层再次延压复合，最后通过切边机、收卷机等收卷制备抗紫外线聚乙烯基钢结构防火卷材，切割边角料通过一道压延机可再次加工成片材。
实施例3
将100份聚磷酸铵、30份三聚氰胺、45份季戊四醇、30份钛白粉、1份玄武岩纤维进行充分混合，将混合后的粉体与40份丙烯酸酯树脂进行混合，采用挤出机挤出造粒，将复合颗粒采用压延机进行压延成型，制备出防火层；防火层组成基础上加入0.5份邻羟基苯甲酸苯酯，压制抗紫外线层；防火层与抗紫外线层再次延压复合，最后通过切边机、收卷机等收卷制备抗紫外线丙烯酸酯基钢结构防火卷材，切割边角料通过一道压延机可再次加工成片材。
实施例4
将100份聚磷酸铵、40份三聚氰胺、45份淀粉、30份钛白粉、1份玻纤进行充分混合，将混合后的粉体与40份乙烯-醋酸乙烯共聚物(EVA)进行混合，采用挤出机挤出造粒，将复合颗粒采用压延机进行压延成型，制备出防火层；防火层组成基础上加入2份单苯甲酸间苯二酚酯，压制抗紫外线层；防火层与抗紫外线层再次延压进复合，最后通过切边机、收卷机等收卷制备抗紫外线EVA基钢结构防火卷材，切割边角料通过一道压延机可再次加工成片材。
实施例5
将100份聚磷酸铵、40份尿素、45淀粉、30份钛白粉、1份玻纤进行充分混合，将混合后的粉体与40份乙烯-醋酸乙烯共聚物(EVA)进行混合，采用挤出机挤出造粒，将复合颗粒采用压延机进行压延成型，制备出防火层；防火层组成基础上加入1份单苯甲酸间苯二酚酯，压制抗紫外线层；防火层与抗紫外线层再次延压进复合，最后通过切边机、收卷机等收卷制备抗紫外线EVA基钢结构防火卷材，切割边角料通过一道压延机可再次加工成片材。
实验例1：钢结构防火卷材厚度与耐火时间的关系(实施案例4，功能层厚度0.2mm)钢结构防火涂料耐火性能检测按照GB14907-2002检测
表1卷材厚度与耐火时间关系
结论：不同的设计对钢结构防火有不同的时间要求，可以根据防火要求来选择、设计卷材的厚度。
实验例2钢结构防火卷材理化性能(实施案例4，功能层厚度0.2mm，防火层厚度1.8mm)按GB14907-2002检测
表2钢结构防火卷材理化性能
结论：理化性能检测表明该卷材满足所规定的使用要求，同时能够耐紫外线、耐腐蚀等；
满足防火要求要根据防火设计要求，和表中涂层厚度与防火时间的关系来选择卷材的最低厚度即可。
实验例3涂层抗紫外线性能对比(实施案例4，抗紫外线层厚度0.2mm，防火层厚度1.8mm，
紫外线照射试验按照GB/T14522表C.1规定的第二种暴露周期类型进行实验；隔热效率实验条件按照GB/T9978.1中6.1规定进行)
检测表明，复合功能层后，涂层的抗紫外线性能大大提高。

Claims (10)

1.带功能层的钢结构防火卷材，由防火层和功能层组成，所述防火层由高分子固体树脂、膨胀型阻燃剂、分散助剂、增强助剂组成，功能层是在防火层的材料基础上外加功能填料制成；两层分别经混和、挤出造粒、延压成片，再复合延压、收卷成卷材，所述膨胀型阻燃剂以磷酸盐为酸源、胺类化合物为气源和多羟基化合物为炭源组成；所述功能层为装饰层、抗紫外线层，厚度0.1～0.5mm，所述功能填料为颜料、紫外线吸收剂。
2.根据权利要求1所述的带功能层的钢结构防火卷材，所述高分子固体树脂为聚丙烯、聚乙烯、聚氯乙烯、丙烯酸树脂、乙烯-醋酸乙烯共聚物、聚氨酯、尼龙、环氧树脂、聚碳酸酯、三元乙丙橡胶、天然橡胶或氯丁橡胶。
3.根据权利要求1所述的带功能层的钢结构防火卷材，所述增强剂为玻璃纤维、玄武岩纤维、聚丙烯纤维、碳纤维、陶瓷纤维或聚乙烯纤维。
4.根据权利要求1所述的带功能层的钢结构防火卷材，所述膨胀型阻燃剂的酸源为聚磷酸铵、磷酸酯、磷酸铵；炭源为季戊四醇、双季戊四醇、蔗糖、淀粉、糊精；气源为三聚氰胺、尿素、聚酰胺、双氰胺，所述分散助剂为钛白粉。
5.根据权利要求1所述的带功能层的钢结构防火卷材，所述功能层颜料为矿物颜料与有机颜料；紫外线吸收剂为邻羟基苯甲酸苯酯、苯并三氮唑、二羟基二苯甲酮和/或单苯甲酸间苯二酚酯。
6.根据权利要求1所述的带功能层的钢结构防火卷材，所述磷酸盐、胺类化合物、多羟基化合物、分散助剂、增强助剂、高分子固体树脂的重量份比为：70-100：30-40：20-50：20-50：1：40-50，功能填料的重量份为0.5-2.5。
7.根据权利要求6所述的带功能层的钢结构防火卷材，所述磷酸盐、胺类化合物、多羟基化合物、分散助剂、增强助剂、高分子固体树脂的重量份比为：100：30-40：40-50：20-30：1：40-50，功能填料的重量份为0.5-2.5。
8.权利要求1-7任一所述的带功能层的钢结构防火卷材的制备方法，包括如下步骤：
(1)以磷酸盐为酸源、多羟基化合物为炭源、胺类化合物为气源混合制备膨胀型阻燃剂；
(2)膨胀型阻燃剂与增强助剂、分散助剂进行预混合处理，或者膨胀型阻燃剂与增强助剂、分散助剂、功能填料进行预混合处理；
(3)将高分子树脂与预处理粉体混合造粒，分别制备防火层颗粒与功能层颗粒；
(4)将颗粒分别压延成防火层与功能层片材；
(5)功能层与防火层片材进行二次延压复合；
(6)对复合层进行收卷，获得成品。
9.权利要求8所述的制备方法，所述混合造粒采用螺杆挤出机，所述压延成片材采用延压机。
10.权利要求1-7任一所述带功能层的钢结构防火卷材在钢结构防火、木质建筑防火、金属面板防火、墙体防火中的应用。
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