CN104476892B - 一种防火泡沫复合板的制备方法 - Google Patents

一种防火泡沫复合板的制备方法 Download PDF

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CN104476892B
CN104476892B CN201410663246.7A CN201410663246A CN104476892B CN 104476892 B CN104476892 B CN 104476892B CN 201410663246 A CN201410663246 A CN 201410663246A CN 104476892 B CN104476892 B CN 104476892B
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钱和革
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Ma'anshan Hengda Mould Material Co ltd
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Abstract

本发明涉及建筑、包装材料，一种防火泡沫复合板的制备方法，包括EPS泡沫颗粒，其特征在于复合板中的EPS泡沫颗粒外面包覆两层材料：第一层为防火、防水材料，其组分和重量百分比是：气凝性无机胶凝材料60%~80%，甲基硅酸粉体20%~40%；第二层为保温、粘接材料，其组分和重量百分比是：矿渣棉微粉末50%~85%，有机树脂10%~30%，涂料助剂2%~20%。制备时将EPS泡沫颗粒用上述配方进行两次覆膜和熟化，然后用制板机热压成型，优点是采用层层外包覆防火涂层技术，利用无机材料与有机材料的完美结合，大大提高了EPS泡沫复合板的防火等级，燃烧性能达到A1级的性能。本发明生产工艺简单，设备要求低，适合各类大、中、小微型企业生产，可作为保温、防火材料广泛应用于建筑外墙等。

Description

一种防火泡沫复合板的制备方法
技术领域
本发明涉及一种建筑、包装行业使用的防火、防潮、保温材料，具体涉及一种EPS泡沫颗粒复合板材及其制备方法。
背景技术
EPS泡沫颗粒是聚苯乙烯泡沫颗粒的英文缩写，也叫膨胀聚苯乙烯泡沫塑料， EPS因其具有导热系数极低、吸水性低、保温、隔热、介电性能优良、力学性能好等特点，而被广泛应用于包装和建筑等行业。但它是一种有机碳氢化合物,氧指数仅有18.0%。是一种极其易燃烧的材料，即使移走火源仍然能持续燃烧，燃烧过程中伴随着浓烟并出现明显的收缩现象，因此EPS泡沫塑料的严重不足之处在于其极易燃烧。按国家建筑、消防验收规定，是禁止在建筑外墙保温使用不防火的材料。有人将EPS泡沫颗粒的外面涂上一层阻燃剂，根据国家公安部消防局、城乡建设部节能司等各相关部委出台的标准：《建筑材料及制品燃烧性能分级》（GB-8624-2012），覆膜阻燃剂的EPS泡沫颗粒最多只能达到A2级的防火性能，效果并不理想。
《材料产烟毒性危险分级》（GB/T 20285-2006）的规定，禁止在建筑外墙保温使用不防火的材料，普通的EPS泡沫塑料被禁止在需要防火的墙体使用。
发明内容
本发明要解决的问题是将现有的EPS泡沫颗粒进形改进，使EPS泡沫颗粒板增加防火的性能。
为了解决上述技术问题，本发明提供了一种防火泡沫复合板，包括EPS泡沫颗粒，其特征在于复合板中的EPS泡沫颗粒外面包覆两层材料：第一层为防火、防水材料，其组分和重量百分比是：气凝性无机胶凝材料60%~80%，甲基硅酸粉体20%~40%；第二层为保温、粘接材料，其组分和重量百分比是：矿渣棉微粉末50%~85%，有机树脂10%~30%，涂料助剂2%~20%，所述矿渣棉微粉末是铟矿渣微粉末、锡矿渣微粉末、玻璃矿渣粉末中的任意一种、两种或多种的混合物，所述有机树脂是丙烯酸树脂、苯丙树脂、丁晴橡胶树脂中的任意一种、两种或多种的混合物；
所述一种防火泡沫复合板的制备方法，其特征在于包含以下步骤：
（1）将气凝性无机胶凝材料和甲基硅酸粉体按权利要求1所述比例混合加水搅拌均匀，制成液态的防水、防火材料，再将其加入盛有EPS泡沫颗粒的搅拌容器中，充分搅拌，混合均匀；
（2）将上述搅拌后的表面包覆有放水、防火材料的EPS泡沫颗粒打入熟化仓内进行熟化，在熟化仓内与空气接触，使泡沫颗粒表面覆膜材料气凝硬化，结一层不易脱落的防水、防火涂层壳膜，完成第一次覆膜；
（3）将矿渣棉微粉末和液态的有机树脂按权利要求1所述的比例混合，制成保温、粘接材料，将保温、粘接材料与上述完成第一次覆膜的EPS泡沫颗粒在容器中进行充分的搅拌混合，加入权利要求1所述比例的涂料助剂，充分搅拌，使EPS泡沫颗粒表面均匀包覆一层保温、粘接材料；
（4）将上述搅拌后的表面包覆有保温、粘接材料的EPS泡沫颗粒打入熟化仓内进行熟化，完成二次覆膜；
（5）将上述进行过两次覆膜的EPS泡沫颗粒打入制板机内，采用蒸汽热压成型制板工艺，使泡沫颗粒在高温蒸汽热压的作用下定型，压制5-8分钟后快速风冷后挤出，进入烘干室，烘干后按尺寸切割，制成板材成品。
所述气凝性无机胶凝材料是硅酸盐、硫酸镁、高铝水泥、石膏粉、石灰中的任意一种、两种或多种的混合物。
所述甲基硅酸是甲基硅酸钾粉体、甲基硅酸钠粉体、有机硅微粉中的任意一种、两种或多种的混合物，其粒径目数为800-1500μm。
所述矿渣棉微粉末粒径目数为800-2000μm。
所述有机树脂固含量在40%~55%。
所述涂料助剂包括湿润剂、增稠剂、流平剂、分散剂、成膜助剂中的任意一种、两种或多种的混合物。
本发明完全不同于原有通过添加阻燃剂改变EPS类材料性能的技术路径，导入了大分子结构的高分子材料，采用了有机材料和无机材料层层包覆EPS泡沫颗粒的全新技术方案：先将易燃的EPS泡沫颗粒外表包覆一层气凝性无机胶凝材料，然后再用有机高分子树脂和无机矿渣棉微粉进行二次包覆，当有机高分子树脂在受热膨胀过程中，带动了无机矿渣棉微粉中微粒子的游离，这样使有机材料和无机材料相互运动，有力结合在一起，附着在EPS泡沫颗粒外表，类似滚雪球的方式，最终使矿渣棉微粉末在EPS泡沫颗粒外表包覆形成了致密的防火涂层，每一个有机大分子的基团形成相对独立的防火个体，从而有效阻断了热量的传导和火焰的侵蚀，达到了“含有机材料不燃烧”的最佳防火效果。
本发明的防火泡沫复合板可以采用原有传统的生产设备制备，省去了花重金购买国外EPS的生产设备的费用，引进费用高达数百万甚至上千万的设备，所生产出的EPS泡沫颗粒最高可达到耐火极限为B1级。本发明可是使用普通小企业传统的生产设备进行生产，易于普及应用。
本发明的防火泡沫复合板与传统保温板的性能和技术方法是完全不同，其优点是：采用层层外包覆防火涂层技术，尤其是采用了导热系数极低的几种矿渣棉微粉末，利用独特的无机材料与有机材料的完美结合，大大提高了EPS泡沫复合板防火等级，同时也保留了材料原有的保温、隔热等各项优良性能。经国家防火建筑材料质量监督检验中心依据《建筑材料及制品燃烧性能分级》（GB8624-2012）和《材料产烟毒性危险分级》（GB/T 20285-2006）标准对样品进行的检验，燃烧性能符合A1级的规定要求。这完全可以杜绝因EPS材料易造成火灾的隐患。本发明的生产工艺简单，设备要求低，适合各类大、中、小微型企业生产，可作为保温、防火材料广泛应用于建筑外墙等。
具体实施方式
实施例1：
一种防火泡沫复合板的制备方法，主材为EPS泡沫颗粒，对EPS泡沫颗粒外面包覆两层材料：第一层为防火、防水材料，其组分和重量百分比是：气凝性无机胶凝材料60%，甲基硅酸粉体40%；第二层为保温、粘接材料，其组分和重量百分比是：矿渣棉微粉末65%，有机树脂30%，涂料助剂5%。本实施例中，气凝性无机胶凝材料取硅酸盐、硫酸镁的混合物，甲基硅酸是甲基硅酸钾粉体、甲基硅酸钠粉体的混合物，其粒径目数为1000μm；矿渣棉微粉末取铟矿渣微粉末、锡矿渣微粉末、玻璃矿渣粉末中的任意一种、两种或多种的混合物，其粒径目数为1000μm；有机树脂是丙烯酸树脂、苯丙树脂、丁晴橡胶树脂中的任意一种、两种或多种)的混合物，其固含量为45%。所述涂料助剂包括湿润剂、增稠剂、流平剂、分散剂、成膜助剂中的任意一种、两种或多种的混合物。
利用上述物质制备防火泡沫复合板的方法，包含以下步骤：
（1）将气凝性无机胶凝材料和甲基硅酸粉体按权利要求1所述比例混合加水搅拌均匀，制成液态的防水、防火材料，再将其加入盛有EPS泡沫颗粒的搅拌容器中，充分搅拌，混合均匀；
（2）将上述搅拌后的表面包覆有放水、防火材料的EPS泡沫颗粒打入熟化仓内进行熟化，熟化过程控制在40分钟，在熟化仓内与空气接触，使泡沫颗粒表面覆膜材料气凝硬化，结一层不易脱落的防水、防火涂层壳膜，完成第一次覆膜；
（3）将矿渣棉微粉末和液态的有机树脂按权利要求1所述的比例混合，制成保温、粘接材料，将保温、粘接材料与上述完成第一次覆膜的EPS泡沫颗粒在容器中进行充分的搅拌混合，加入权利要求1所述比例的涂料助剂，充分搅拌，使EPS泡沫颗粒表面均匀包覆一层保温、粘接材料；
（4） 将上述搅拌后的表面包覆有保温、粘接材料的EPS泡沫颗粒打入熟化仓内进行熟化，熟化过程控制在35分钟，完成二次覆膜；
（5） 将上述进行过两次覆膜的EPS泡沫颗粒打入制板机内，制板机内蒸汽的温度为110℃，采用蒸汽热压成型制板工艺，使泡沫颗粒在高温蒸汽热压的作用下定型，压制5-8分钟后快速风冷后挤出，进入烘干室，烘干后按尺寸切割，制成板材成品。
实施例2：
防火泡沫复合板，主材为EPS泡沫颗粒，对EPS泡沫颗粒外面包覆两层材料：第一层的组分重量百分比是：气凝性无机胶凝材料75%，甲基硅酸粉体25%；第二层为保温、粘接材料，其组分和重量百分比是：矿渣棉微粉末80%，有机树脂18%，涂料助剂2%。本实施例中，气凝性无机胶凝材料取高铝水泥、石膏粉、石灰混合物，甲基硅酸取甲基硅酸钠粉体、有机硅微粉的混合物，其粒径目数为1300μm；矿渣棉微粉末取锡矿渣微粉末、玻璃矿渣粉末的混合物，其粒径目数为1200μm；有机树脂取丁晴橡胶树脂，其固含量为50%，所述涂料助剂是流平剂、分散剂、成膜助剂混合物。
制备包覆防火涂层的EPS泡沫复合板的方法同实施例1。
用以上这种配方按上述制备方法制备的包覆防火涂层的EPS泡沫复合板均具备A1级的防火等级，属于优质的外墙保温隔热防火材料。

Claims (8)

1.一种防火泡沫复合板的制备方法，所述防火泡沫复合板包括EPS泡沫颗粒，其特征在于复合板中的EPS泡沫颗粒外面包覆两层材料：第一层为防火、防水材料，其组分和重量百分比是：气凝性无机胶凝材料60%~80%，甲基硅酸粉体20%~40%；第二层为保温、粘接材料，其组分和重量百分比是：矿渣棉微粉末50%~85%，有机树脂10%~30%，涂料助剂2%~20%，所述矿渣棉微粉末是铟矿渣微粉末、锡矿渣微粉末、玻璃矿渣粉末中的任意一种、两种或多种的混合物，所述有机树脂是丙烯酸树脂、苯丙树脂、丁晴橡胶树脂中的任意一种、两种或多种的混合物；
所述一种防火泡沫复合板的制备方法，其特征在于包含以下步骤：
1)将气凝性无机胶凝材料和甲基硅酸粉体按所述比例混合加水搅拌均匀，制成液态的防水、防火材料，再将其加入盛有EPS泡沫颗粒的搅拌容器中，充分搅拌，混合均匀；
2)将上述搅拌后的表面包覆有防水、防火材料的EPS泡沫颗粒打入熟化仓内进行熟化，在熟化仓内与空气接触，使泡沫颗粒表面覆膜材料气凝硬化，结一层不易脱落的防水、防火涂层壳膜，完成第一次覆膜；
3)将矿渣棉微粉末和液态的有机树脂按所述的比例混合，制成保温、粘接材料，将保温、粘接材料与上述完成第一次覆膜的EPS泡沫颗粒在容器中进行充分的搅拌混合，加入所述比例的涂料助剂，充分搅拌，使EPS泡沫颗粒表面均匀包覆一层保温、粘接材料；
4)将上述搅拌后的表面包覆有保温、粘接材料的EPS泡沫颗粒打入熟化仓内进行熟化，完成二次覆膜；
5)将上述进行过两次覆膜的EPS泡沫颗粒打入制板机内，采用蒸汽热压成型制板工艺，使泡沫颗粒在高温蒸汽热压的作用下定型，压制5-8分钟后快速风冷后挤出，进入烘干室，烘干后按尺寸切割，制成板材成品。
2.根据权利要求1所述的一种防火泡沫复合板，其特征在于：所述气凝性无机胶凝材料是硅酸盐、硫酸镁、高铝水泥、石膏粉、石灰中的任意一种、两种或多种的混合物。
3.根据权利要求1所述的一种防火泡沫复合板，其特征在于：所述甲基硅酸是甲基硅酸钾粉体、甲基硅酸钠粉体、有机硅微粉中的任意一种、两种或多种的混合物，其粒径目数为800-1500μm。
4.根据权利要求1所述的一种防火泡沫复合板，其特征在于：所述矿渣棉微粉末粒径目数为800-2000μm。
5.根据权利要求1所述的一种防火泡沫复合板，其特征在于：所述有机树脂固含量在40%~55%。
6.根据权利要求1所述的一种防火泡沫复合板，其特征在于：所述涂料助剂包括湿润剂、增稠剂、流平剂、分散剂、成膜助剂中的任意一种、两种或多种的混合物。
7.根据权利要求1所述一种防火泡沫复合板的制备方法，其特征在于所述熟化过程控制在30-50分钟。
8.根据权利要求1所述一种防火泡沫复合板的制备方法，其特征在于所述制板机内蒸汽的温度为80-120℃。
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