CN108546141A - 一种外墙防火保温板及其制备方法 - Google Patents

一种外墙防火保温板及其制备方法 Download PDF

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CN108546141A
CN108546141A CN201810418230.8A CN201810418230A CN108546141A CN 108546141 A CN108546141 A CN 108546141A CN 201810418230 A CN201810418230 A CN 201810418230A CN 108546141 A CN108546141 A CN 108546141A
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heat insulation
insulation plate
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朱明静
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Hefei Yi Special Building Materials Co Ltd
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Abstract

本发明公开了一种外墙防火保温板及其制备方法，包括以下重量份数的原料：硅藻土30‑50份、硅酸铝25‑45份、空心微珠10‑20份、酚醛树脂5‑10份、可分散乳胶粉2‑6份、增强纤维1‑3份、聚丙烯纤维0.5‑1.5份、重质碳酸钙2‑6份、粘结剂0.2‑0.6份、固化剂0.7‑1.5份、烧结助剂0.5‑1.4份、去离子水30‑40份。本发明的防火保温板的容重小于200kg/m3，导热系数低于0.045W/m·K，抗压强度大于1.5MPa，且防火保温板遇明火不燃烧，无烟，能经受1000℃左右的高温烧蚀且不变形，防火性能A级，可满足外墙对防火保温材料的要求。

Description

一种外墙防火保温板及其制备方法
技术领域
本发明涉及建筑材料技术领域，具体涉及一种外墙防火保温板及其制备方法。
背景技术
近年来，多起建筑保温火灾事件的发生引起了社会各界对保温防火的思考。然而，很多保温材料起火都是在施工过程中产生的，如：电焊、明火、不良的施工习惯。这些材料在燃烧过程中不断产生的融滴物和毒烟，同时释放出来的氯氟烃、氢氟碳化物、氟利昂等气体对环境的危害也不容忽视。为此，住房与城乡建设部和公安部于2009年9月25日联合发布了《民用建筑 外保温系统及外墙装饰防火暂行规定》公通字[2009]46号文通知。因此，保温设计过程中防火、保温性能更出色的保温材料更能赢得市场的认可。
在中国专利（申请号：CN201010134507.8）公开了一种防火保温板用快速凝固的不燃保温材料，由体积百分比计的：低碱硫铝酸盐水泥25-45％、玻化微珠45-69％、可再分散性乳胶粉4-9％、羟丙甲基纤维素1-3％、砂浆用短纤维0.5-1.5％、砂浆保水增塑剂脂肪酸丁脂0.2-0.8％，总和为100％和玻璃纤维网格布制成。该发明可有效解决建筑材料既不易燃烧，又保温性能良好和快速凝固的问题，但是该发明的保温材料使用较多的水泥胶凝材料，这对于容重会有一定的限制，板材的压缩强度仅在0.1Mpa左右。
而在中国专利（申请号：CN201010106017.7）公开了一种水泥聚苯颗粒复合型防火外墙外保温板，其特征在于：是由快硬硫铝酸盐水泥、聚苯颗粒为主要原材料制作的保温层和快硬硫铝酸盐水泥、石英砂为主要原材料制作的防护层经复合工艺制成。该申请案采用了保温层和防护层制成，以水泥和聚苯颗粒为主要原材料，加入了膨胀玻化微珠等经复合工艺制成的外墙保温板，其制作工艺较为复杂，该发明保温层所使用的快硬硫铝酸盐水泥重量份数达到了80％以上，势必会致使容重较大。
基于此，有必要提供一种外墙防火保温板及其制备方法，以解决现有技术中存在的问题。
发明内容
为了克服上述现有技术的不足，本发明提供了一种外墙防火保温板及其制备方法。
为了解决上述技术问题，本发明采用如下技术方案：
一种外墙防火保温板，包括以下重量份数的原料：硅藻土30-50份、硅酸铝25-45份、空心微珠10-20份、酚醛树脂5-10份、可分散乳胶粉2-6份、增强纤维1-3份、聚丙烯纤维0.5-1.5份、重质碳酸钙2-6份、粘结剂0.2-0.6份、固化剂0.7-1.5份、烧结助剂0.5-1.4份、去离子水30-40份。
优选的，包括以下重量份数的原料：硅藻土40份、硅酸铝35份、空心微珠15份、酚醛树脂7.5份、可分散乳胶粉4份、增强纤维2份、聚丙烯纤维1份、重质碳酸钙4份、粘结剂0.4份、固化剂1.1份、烧结助剂0.9份、去离子水30-40份。
优选的，所述硅藻土为具有隔热性能的多孔性硅藻土。
优选的，所述空心微珠为空心玻璃微珠、空心陶瓷微珠、漂珠中的一种。
优选的，所述增强纤维为玻璃纤维、碳纤维、金属纤维中的任意一种或者几种按任意比的组合。
优选的，所述粘结剂由硅铝酸钙、碳酸钙和葡糖碳酸钠制成，且硅铝酸钙、碳酸钙和葡糖碳酸钠的重量比2:2:1。
优选的，所述固化剂为六亚甲基四胺。
优选的，所述烧结助剂为碳酸钠。
本发明还提供了上述外墙防火保温板的制备方法，包括以下步骤：
（1）按照重量份数称取各原料；
（2）将硅藻土、硅酸铝、空心微珠、酚醛树脂、重质碳酸钙加入多级磨盘机中，进行分散混合，得到混合粉料；
（3）将可分散乳胶粉、增强纤维、聚丙烯纤维、去离子水和步骤（1）制得的混合粉料加入混合机中搅拌均匀，然后加入粘结剂、固化剂、烧结助剂继续搅拌30-50分钟，将搅拌好的物料装入平板模具内并压实抚平，并将平板模具与物料同时置于加热装置内加热成型，加热温度为200-300℃，加热时间10-30分钟；
（4）将预成型后的板材脱模，将板材置于烧结炉内，再向烧结炉内以50-100ml/min的速度通入氮气，烧结成型，烧结温度为500-800℃，烧结时间为3-5h，然后冷却至室温，制得外墙防火保温板。
与现有技术相比，本发明具有如下的有益效果：
（1）本发明的防火保温板以无机保温材料硅藻土、硅酸铝、空心微珠为主要原材料，同时，防火保温板的烧结过程是在注入到加热装置中的氮气氛围中进行，烧结成型后的防火保温板有机组分含量少，成型后的防火保温板具有良好的防火性能，并且烧结后防火保温板中有机物含量低的特点也克服了有机高分子材料易老化的问题，并且加入烧结助剂有助于烧结的效果。
（2）本发明的防火保温板所采用的硅藻土、空心微珠具有质轻、表面玻化封闭、导热系数小的特点，使得防火保温板具有较好的保温效果；其所具有的中空结构，赋予防火保温板一定的隔音效果；空心微珠的吸水率小，烧结后结合紧密，使得防火保温板强度高且具有很低的吸水性能。
（3）经测试，防火保温板的容重小于200kg/m3，导热系数低于0.045W/m·K，抗压强度大于1.5MPa，且防火保温板遇明火不燃烧，无烟，能经受1000℃左右的高温烧蚀且不变形，防火性能A级。
（4）本发明的制备工艺简单，产品的原材料丰富。该工艺生产的防火保温板使用寿命长，可以与建筑物同寿命，且与墙体材料间有着很好的相容性，强度和安全稳固性也很可靠。
具体实施方式
下面结合具体实施例，进一步阐述本发明。这些实施例仅用于说明本发明而不用于限制本发明的范围。
实施例1
一种外墙防火保温板，包括以下重量份数的原料：硅藻土30份、硅酸铝25份、空心微珠10份、酚醛树脂5份、可分散乳胶粉2份、增强纤维1份、聚丙烯纤维0.5份、重质碳酸钙2份、粘结剂0.2份、固化剂0.7份、烧结助剂0.5份、去离子水30份。
其中，所述硅藻土为具有隔热性能的多孔性硅藻土。
其中，所述空心微珠为空心玻璃微珠。
其中，所述增强纤维为玻璃纤维和碳纤维按任意比的组合。
其中，所述粘结剂由硅铝酸钙、碳酸钙和葡糖碳酸钠制成，且硅铝酸钙、碳酸钙和葡糖碳酸钠的重量比2:2:1。
其中，所述固化剂为六亚甲基四胺。
其中，所述烧结助剂为碳酸钠。
本发明还提供了上述外墙防火保温板的制备方法，包括以下步骤：
（1）按照重量份数称取各原料；
（2）将硅藻土、硅酸铝、空心微珠、酚醛树脂、重质碳酸钙加入多级磨盘机中，进行分散混合，得到混合粉料；
（3）将可分散乳胶粉、增强纤维、聚丙烯纤维、去离子水和步骤（1）制得的混合粉料加入混合机中搅拌均匀，然后加入粘结剂、固化剂、烧结助剂继续搅拌30分钟，将搅拌好的物料装入平板模具内并压实抚平，并将平板模具与物料同时置于加热装置内加热成型，加热温度为200℃，加热时间10分钟；
（4）将预成型后的板材脱模，将板材置于烧结炉内，再向烧结炉内以50ml/min的速度通入氮气，烧结成型，烧结温度为500℃，烧结时间为3h，然后冷却至室温，制得外墙防火保温板。
实施例2
一种外墙防火保温板，包括以下重量份数的原料：硅藻土50份、硅酸铝45份、空心微珠20份、酚醛树脂10份、可分散乳胶粉6份、增强纤维3份、聚丙烯纤维1.5份、重质碳酸钙6份、粘结剂0.6份、固化剂1.5份、烧结助剂1.4份、去离子水40份。
其中，所述硅藻土为具有隔热性能的多孔性硅藻土。
其中，所述空心微珠为空心陶瓷微珠。
其中，所述增强纤维为碳纤维和金属纤维按任意比的组合。
其中，所述粘结剂由硅铝酸钙、碳酸钙和葡糖碳酸钠制成，且硅铝酸钙、碳酸钙和葡糖碳酸钠的重量比2:2:1。
其中，所述固化剂为六亚甲基四胺。
其中，所述烧结助剂为碳酸钠。
本发明还提供了上述外墙防火保温板的制备方法，包括以下步骤：
（1）按照重量份数称取各原料；
（2）将硅藻土、硅酸铝、空心微珠、酚醛树脂、重质碳酸钙加入多级磨盘机中，进行分散混合，得到混合粉料；
（3）将可分散乳胶粉、增强纤维、聚丙烯纤维、去离子水和步骤（1）制得的混合粉料加入混合机中搅拌均匀，然后加入粘结剂、固化剂、烧结助剂继续搅拌50分钟，将搅拌好的物料装入平板模具内并压实抚平，并将平板模具与物料同时置于加热装置内加热成型，加热温度为300℃，加热时间30分钟；
（4）将预成型后的板材脱模，将板材置于烧结炉内，再向烧结炉内以100ml/min的速度通入氮气，烧结成型，烧结温度为800℃，烧结时间为5h，然后冷却至室温，制得外墙防火保温板。
实施例3
一种外墙防火保温板，包括以下重量份数的原料：硅藻土40份、硅酸铝35份、空心微珠15份、酚醛树脂7.5份、可分散乳胶粉4份、增强纤维2份、聚丙烯纤维1份、重质碳酸钙4份、粘结剂0.4份、固化剂1.1份、烧结助剂0.9份、去离子水30-40份。
其中，所述硅藻土为具有隔热性能的多孔性硅藻土。
其中，所述空心微珠为空心玻璃微珠。
其中，所述增强纤维为玻璃纤维。
其中，所述粘结剂由硅铝酸钙、碳酸钙和葡糖碳酸钠制成，且硅铝酸钙、碳酸钙和葡糖碳酸钠的重量比2:2:1。
其中，所述固化剂为六亚甲基四胺。
其中，所述烧结助剂为碳酸钠。
本发明还提供了上述外墙防火保温板的制备方法，包括以下步骤：
（1）按照重量份数称取各原料；
（2）将硅藻土、硅酸铝、空心微珠、酚醛树脂、重质碳酸钙加入多级磨盘机中，进行分散混合，得到混合粉料；
（3）将可分散乳胶粉、增强纤维、聚丙烯纤维、去离子水和步骤（1）制得的混合粉料加入混合机中搅拌均匀，然后加入粘结剂、固化剂、烧结助剂继续搅拌40分钟，将搅拌好的物料装入平板模具内并压实抚平，并将平板模具与物料同时置于加热装置内加热成型，加热温度为250℃，加热时间20分钟；
（4）将预成型后的板材脱模，将板材置于烧结炉内，再向烧结炉内以75ml/min的速度通入氮气，烧结成型，烧结温度为650℃，烧结时间为4h，然后冷却至室温，制得外墙防火保温板。
对比例1
采用中国专利（申请号：CN201010134507.8）制得防火保温板。
对比例2
采用中国专利（申请号：CN201010106017.7）制得防火保温板。
实验例
取实施例1-3及对比例1-2制得的防火保温板进行性能测试，具体结果见表1。
表1
测试项目 强度（MPa) 导热系数（W/(m.k）） 吸水率（浸水30d） 干密度（kg/m3)
实施例1 1.63 0.042 5.8 185
实施例2 1.66 0.040 5.3 192
实施例3 1.71 0.038 5.1 180
对比例1 0.25 0.17 13 258
对比例2 0.78 0.12 11 204
由表1可知，采用本发明方法制成的防火保温板的各项指标均满足或超过相关标准要求。
综上所述，本发明的防火保温板的容重小于200kg/m3，导热系数低于0.045W/m·K，抗压强度大于1.5MPa，且防火保温板遇明火不燃烧，无烟，能经受1000℃左右的高温烧蚀且不变形，防火性能A级，可满足外墙对防火保温材料的要求。
以上所述仅是本发明的优选实施方式，本发明的保护范围并不仅局限于上述实施例，凡属于本发明思路下的技术方案均属于本发明的保护范围。应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理前提下的若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。

Claims (9)

1.一种外墙防火保温板，其特征在于，包括以下重量份数的原料：硅藻土30-50份、硅酸铝25-45份、空心微珠10-20份、酚醛树脂5-10份、可分散乳胶粉2-6份、增强纤维1-3份、聚丙烯纤维0.5-1.5份、重质碳酸钙2-6份、粘结剂0.2-0.6份、固化剂0.7-1.5份、烧结助剂0.5-1.4份、去离子水30-40份。
2.根据权利要求1所述的外墙防火保温板，其特征在于，包括以下重量份数的原料：硅藻土40份、硅酸铝35份、空心微珠15份、酚醛树脂7.5份、可分散乳胶粉4份、增强纤维2份、聚丙烯纤维1份、重质碳酸钙4份、粘结剂0.4份、固化剂1.1份、烧结助剂0.9份、去离子水30-40份。
3.根据权利要求1所述的外墙防火保温板，其特征在于，所述硅藻土为具有隔热性能的多孔性硅藻土。
4.根据权利要求1所述的外墙防火保温板，其特征在于，所述空心微珠为空心玻璃微珠、空心陶瓷微珠、漂珠中的一种。
5.根据权利要求1所述的外墙防火保温板，其特征在于，所述增强纤维为玻璃纤维、碳纤维、金属纤维中的任意一种或者几种按任意比的组合。
6.根据权利要求1所述的外墙防火保温板，其特征在于，所述粘结剂由硅铝酸钙、碳酸钙和葡糖碳酸钠制成，且硅铝酸钙、碳酸钙和葡糖碳酸钠的重量比2:2:1。
7.根据权利要求1所述的外墙防火保温板，其特征在于，所述固化剂为六亚甲基四胺。
8.根据权利要求1所述的外墙防火保温板，其特征在于，所述烧结助剂为碳酸钠。
9.根据权利要求1-8任一项所述的外墙防火保温板的制备方法，其特征在于，包括以下步骤：
（1）按照重量份数称取各原料；
（2）将硅藻土、硅酸铝、空心微珠、酚醛树脂、重质碳酸钙加入多级磨盘机中，进行分散混合，得到混合粉料；
（3）将可分散乳胶粉、增强纤维、聚丙烯纤维、去离子水和步骤（1）制得的混合粉料加入混合机中搅拌均匀，然后加入粘结剂、固化剂、烧结助剂继续搅拌30-50分钟，将搅拌好的物料装入平板模具内并压实抚平，并将平板模具与物料同时置于加热装置内加热成型，加热温度为200-300℃，加热时间10-30分钟；
（4）将预成型后的板材脱模，将板材置于烧结炉内，再向烧结炉内以50-100ml/min的速度通入氮气，烧结成型，烧结温度为500-800℃，烧结时间为3-5h，然后冷却至室温，制得外墙防火保温板。
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