CN105462163B - 一种生物质泡沫夹芯复合隔墙材料的制备方法 - Google Patents

一种生物质泡沫夹芯复合隔墙材料的制备方法 Download PDF

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CN105462163B
CN105462163B CN201510998490.3A CN201510998490A CN105462163B CN 105462163 B CN105462163 B CN 105462163B CN 201510998490 A CN201510998490 A CN 201510998490A CN 105462163 B CN105462163 B CN 105462163B
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foam core
biomass
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CN105462163A (zh
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孙丰文
鹿甫坤
储呈浩
巫佳洁
郑家妍
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Nanjing Forestry University
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Abstract

本发明公开了一种生物质泡沫夹芯复合隔墙材料的制备方法。该方法包括生物质泡沫夹芯材料的制备、生物质泡沫夹芯材料与面板的胶合等工艺步骤。本发明采用苯酚、聚乙二醇、环碳酸酯多相复合液化剂，及浓硫酸和磷酸的混合催化剂，不仅加快液化转化率，而且引入了阻燃性含磷基团；在树脂化过程中用固体多聚甲醛替代甲醛溶液、并加入甲基葡萄糖甙形成多相工具体系，进步提高反应活性、降低甲醛释放量，并使得树脂的柔韧性进一步增强，改善泡沫材料的硬脆性和掉渣缺陷，同时使树脂固体含量达到适宜发泡的75％以上；在发泡过程中选择甲基苯磺酸与N‑羟甲基丙烯酰胺复配；不仅可以提高固化效率，也可提高阻燃效果。

Description

一种生物质泡沫夹芯复合隔墙材料的制备方法
技术领域
本发明属于木材科学与技术、绿色节能建材技术领域。具体涉及一种生物质泡沫夹芯复合隔墙材料的制备方法。是利用秸秆等农业剩余物或木竹加工剩余物通过液化、树脂化、发泡及复合等工序制备而成。
背景技术
塑料泡沫材料具有质轻、隔热、吸声、防潮等优良性能，因而作为夹芯材料大量地应用于轻型快装墙体、轻型包装、居室装修等领域；但由于塑料泡沫的生产不仅消耗大量的石化资源，且塑料泡沫易燃、难以降解，对能源供应、环境安全带来极大的危害。因此利用可再生天然生物质材料替代石化产品开发具有阻燃和环保的轻型节能建材具有重要意义。
发明内容
本发明的目的是提供一种生物质泡沫夹芯复合隔墙材料及其方法。是利用农林生物质材料制备生物质泡沫夹芯复合隔墙材料的方法，以提高生物质材料的利用价值，降低能源物质消耗，改善产品的物理力学、阻燃和环保性能。
本发明的技术解决方案：一种生物质泡沫夹芯复合隔墙材料的制备方法，该方法包括如下生物质泡沫夹芯材料的制备、生物质泡沫夹芯材料与面板的胶合等工艺步骤：
(一)生物质泡沫材料的制备
⑴将熔融苯酚、聚乙二醇和环碳酸酯总量的20％注入反应釜，同时将浓硫酸和磷酸混合催化剂总量的20％注入反应釜，搅拌均匀并升温至40-60℃；将干燥并粉碎后的生物质粉末投入反应釜，将剩余的80％的熔融苯酚、聚乙二醇和环碳酸酯缓慢注入反应釜，同时将剩余80％的浓硫酸和磷酸混合催化剂缓慢注入反应釜；持续搅拌并升温至110-140℃，持续反应60～120min；降温至80℃以下，缓慢加入浓度为40％的烧碱溶液，调整pH值为10.0～13.0，持续冷却降温至50℃；加入甲基葡萄糖甙、多聚甲醛，搅拌20～40min，升温至80～90℃，继续反应40～120min，冷却到40℃以下，放料，制成发泡型生物质液化树脂。
⑵将上述制成的发泡型生物质液化树脂与表面活性剂(吐温-80与OP-10的混合物)、发泡剂(正戊烷+石油醚的混合物)、固化剂(甲基苯磺酸与N-羟甲基丙烯酰胺)依次加入到容器中，快速搅拌均匀，迅速倒入模具中，并置于放入60～90℃的环境中发泡固化，75～105℃熟化60～180min，取出脱模，冷却，制得生物质泡沫夹芯材料。
(二)生物质泡沫夹芯材料与面板的胶合
⑶将准备好的薄型面底板的内表面轻微砂光，并在内薄面涂布常温固化胶粘剂，将上述制备的生物质泡沫夹芯材料置于涂胶后的面、底板之间，在0.1-0.3MPa的单位压力下加压20-120min，卸压取出后堆放24h以上，齐边制成生物质泡沫夹芯复合隔墙材料。
本发明的优点在于：
1、农林废弃剩余物和木竹加工剩余物液化过程中采用苯酚、聚乙二醇、环碳酸酯多相复合液化剂，及浓硫酸和磷酸的混合催化剂，不仅加快液化转化率、使其转化成具有高反应活性的酚型、糠醛型、多元醇类、多元羧酸类软硬兼顾的低分子结构物，而且引入了阻燃性含磷基团；
2、在树脂化过程中用固体多聚甲醛替代甲醛溶液、并加入甲基葡萄糖甙形成多相工具体系，进步提高反应活性、降低甲醛释放量，并使得树脂的柔韧性进一步增强，改善泡沫材料的硬脆性和掉渣缺陷，同时使树脂固体含量达到适宜发泡的75％以上；
3、在发泡过程中选择甲基苯磺酸与N-羟甲基丙烯酰胺复配；不仅可以提高固化效率，也可扑捉甲醛、提高阻燃效果；采用薄型面板贴面后形成的生物质泡沫夹芯复合材料抗压强度和抗弯强度显著提高、表面装饰效果佳，且具有优良的质轻、阻燃、吸声、防潮、隔热性能。
具体实施方式
实施例1
将熔融的苯酚250g、聚乙二醇150g、碳酸乙烯酯50g，浓硫酸4g和3g浓磷酸依次加入反应釜，开启搅拌器，搅拌均匀后并升温至40℃，分次缓慢加入375g木粉，并同时缓慢加入浓硫酸16g和12g浓磷酸；搅拌并升温至135℃，反应90min后，冷却降温至80℃，加入中和烧碱溶液(质量浓度40％)140g，温度降至60℃以下缓慢滴加烧碱溶液(质量浓度40％)240g，搅拌20min后，温度降至45℃加入甲基葡萄糖甙82.5g、固体多聚甲醛375g，缓慢升温到85℃，反应90min，降温冷却至40℃，放料备用。
上述条件制得的生物质液化发泡型树脂为棕褐色粘稠不透明液体，粘度为5240mPa.s,固体含量78.5％，pH值11.5，贮存期不低于20天。
将生物质液化发泡型树脂100g，吐温-80与OP-10(1:1)复配表面活性剂8g，正戊烷和石油醚混合(按质量比为8：2混合)发泡剂10g，固化剂甲基苯磺酸10g和N-羟甲基丙烯酰胺2g，依次加入容器中，快速搅拌均匀，迅速倒入模具中，并置于放入75℃的环境中发泡固化，在95℃的环境中熟化90min，取出脱模，冷却，制得生物质泡沫夹芯材料。
上述条件制得的生物质泡沫夹芯材料的表观密度为0.15g/cm3，发泡倍率为6倍，压缩强度为0.42MPa，吸水率为6.2％。泡沫导热系数为0.031w/m.k，在中频区(250～1200Hz)的平均吸声系数为0.504，极限氧指数为40.7。
将3mm厚的中密度纤维板2张，单面砂光并涂布聚氨酯胶粘剂(120g/m2)，将上述制备的厚度为24mm的生物质泡沫夹芯板置于中间，上下面各铺设1张涂胶后的中密度纤维板形成板坯；将板坯置于压机中在单位压力0.15MPa的压力下压制40min，取出放置24h，齐边制成30mm厚的生物质泡沫夹芯复合板。
该复合板的密度为0.25g/cm3，抗压强度0.62MPa，抗弯强度8.5MPa，抗弯模量95.1MPa，泡沫导热系数为0.039w/m.k，在中频区(250～1200Hz)的平均吸声系数为0.412，极限氧指数为38.4。该复合板非常适宜用作室内轻质隔墙材料。实施例2
将熔融的苯酚200g、聚乙二醇200g、碳酸乙烯酯50g，浓硫酸4g和3g浓磷酸依次加入反应釜，开启搅拌器，搅拌均匀后并升温至40℃，分次缓慢加入375g稻草粉，并同时缓慢加入浓硫酸16g和12g浓磷酸；搅拌并升温至135℃，反应90min后，冷却降温至80℃，加入中和烧碱溶液(浓度40％)140g，温度降至60℃以下缓慢滴加烧碱溶液(浓度40％)240g,搅拌20min后，温度降至45℃加入甲基葡萄糖甙85g、固体多聚甲醛400g，缓慢升温到85℃，反应120min，降温冷却至40℃，放料备用。
将生物质液化发泡型树脂100g，吐温-80与OP-10(1:1)复配表面活性剂8g，正戊烷与石油醚混合(混合质量比8:2)发泡剂9g，固化剂甲基苯磺酸9g和N-羟甲基丙烯酰胺1g，依次加入容器中，快速搅拌均匀，迅速倒入模具中，并置于放入75℃的环境中发泡固化，在95℃的环境中熟化90min，取出脱模，冷却，制得生物质泡沫夹芯材料。
将3mm厚的饰面胶合板2张，背面砂光并涂布丙烯酸-醋酸乙烯酯共聚乳液胶粘剂(130g/m2)，将上述制备的厚度为24mm的生物质泡沫夹芯板置于中间，上下面各铺设1张涂胶后的饰面胶合板形成板坯；将板坯置于压机中在单位压力0.15MPa的压力下压制60min，取出放置24h，齐边制成30mm厚的生物质泡沫夹芯复合轻质隔板。
实施例3
将熔融的苯酚300g、聚乙二醇100g、碳酸乙烯酯25g，浓硫酸4g和3g浓磷酸依次加入反应釜，开启搅拌器，搅拌均匀后并升温至40℃，分次缓慢加入375g竹屑粉，并同时缓慢加入浓硫酸16g和12g浓磷酸；搅拌并升温至135℃，反应90min后，冷却降温至80℃，加入中和烧碱溶液(浓度40％)140g，温度降至60℃以下缓慢滴加烧碱溶液(浓度40％)240g,搅拌20min后，温度降至45℃加入甲基葡萄糖甙75g、固体多聚甲醛345g，缓慢升温到85℃，反应120min，降温冷却至40℃，放料备用。
将生物质液化发泡型树脂100g，吐温-80与OP-10(1:1)复配表面活性剂8g，正戊烷与石油醚混合(混合质量比6:4)发泡剂12g，固化剂甲基苯磺酸8g和N-羟甲基丙烯酰胺2g，依次加入容器中，快速搅拌均匀，迅速倒入模具中，并置于放入75℃的环境中发泡固化，在95℃的环境中熟化90min，取出脱模，冷却，制得生物质泡沫夹芯材料。
将2mm厚的塑钢板2张，单面砂磨并涂布环氧树脂胶粘剂(100g/m2)，将上述制备的厚度为26mm的生物质泡沫夹芯板置于中间，上下面各铺设1张涂胶后的塑钢板形成板坯；将板坯置于压机中在单位压力0.15MPa的压力下压制20min，取出放置24h，齐边制成30mm厚的生物质泡沫夹芯复合板。

Claims (3)

1.一种生物质泡沫夹芯复合隔墙材料的制备方法，其特征在于，该方法包括以下步骤：
⑴ 将熔融苯酚、聚乙二醇和环碳酸酯总量的20%注入反应釜，同时将浓硫酸和磷酸混合催化剂总量的20%注入反应釜，搅拌均匀并升温至40-60℃；将秸秆农业剩余物或木竹加工剩余物干燥并粉碎后投入反应釜，将剩余的80%的熔融苯酚、聚乙二醇和环碳酸酯缓慢注入反应釜，同时将剩余80%的浓硫酸和磷酸混合催化剂缓慢注入反应釜；持续搅拌并升温至110-140℃，持续反应60～120min；降温至80℃以下，缓慢加入烧碱溶液，调整pH值，持续冷却降温至50℃以下；加入甲基葡萄糖甙、多聚甲醛，搅拌，升温至80～90℃，继续反应，反应结束后冷却到40℃以下，放料，制成发泡型生物质液化树脂；
⑵ 将上述制成的发泡型生物质液化树脂与表面活性剂吐温-80与OP-10的混合物、发泡剂正戊烷与石油醚的混合物、固化剂甲基苯磺酸与N-羟甲基丙烯酰胺的混合物依次加入到容器中，快速搅拌均匀，迅速倒入模具中，并置于放入60～90℃的环境中发泡固化，75～105℃熟化60～180min，取出脱模，冷却，制得生物质泡沫夹芯材料；
⑶ 将准备好的薄型面底板的内表面轻微砂光，并在内薄面涂布常温固化胶粘剂，将上述制备的生物质泡沫夹芯材料置于涂胶后的面、底板之间，加压，卸压取出后堆放24h以上，齐边制成生物质泡沫夹芯复合隔墙材料。
2.根据权利要求1所述生物质泡沫夹芯复合隔墙材料的制备方法，其特征在于，步骤（1）中烧碱溶液的质量浓度为40%，调整pH值为10.0～13.0。
3.根据权利要求1所述生物质泡沫夹芯复合隔墙材料的制备方法，其特征在于，步骤（3）中在0.1-0.3MPa的单位压力下加压20-120min。
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