CN108951900A - 一种波特兰水泥基防火保温板 - Google Patents
一种波特兰水泥基防火保温板 Download PDFInfo
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- CN108951900A CN108951900A CN201811020347.7A CN201811020347A CN108951900A CN 108951900 A CN108951900 A CN 108951900A CN 201811020347 A CN201811020347 A CN 201811020347A CN 108951900 A CN108951900 A CN 108951900A
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- organic foam
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- portland cement
- insulation boards
- composite insulation
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- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 claims abstract description 25
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 10
- -1 Aluminum ions Chemical class 0.000 claims description 8
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- 239000003638 chemical reducing agent Substances 0.000 claims description 7
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- UFWIBTONFRDIAS-UHFFFAOYSA-N Naphthalene Chemical class C1=CC=CC2=CC=CC=C21 UFWIBTONFRDIAS-UHFFFAOYSA-N 0.000 description 1
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- 239000011575 calcium Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 229910001424 calcium ion Inorganic materials 0.000 description 1
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 1
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- 229910052742 iron Inorganic materials 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
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- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910000000 metal hydroxide Inorganic materials 0.000 description 1
- 150000004692 metal hydroxides Chemical class 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 229920000620 organic polymer Polymers 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
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- 239000000126 substance Substances 0.000 description 1
- BDHFUVZGWQCTTF-UHFFFAOYSA-M sulfonate Chemical compound [O-]S(=O)=O BDHFUVZGWQCTTF-UHFFFAOYSA-M 0.000 description 1
- XNYYNDAEXFUXBD-UHFFFAOYSA-N tert-butylbenzene ethene Chemical group C=C.C(C)(C)(C)C1=CC=CC=C1 XNYYNDAEXFUXBD-UHFFFAOYSA-N 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
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Classifications
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- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
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- C—CHEMISTRY; METALLURGY
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
- C04B20/10—Coating or impregnating
- C04B20/1055—Coating or impregnating with inorganic materials
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- C—CHEMISTRY; METALLURGY
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/04—Portland cements
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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- E04B1/94—Protection against other undesired influences or dangers against fire
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- C—CHEMISTRY; METALLURGY
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
- C04B2201/20—Mortars, concrete or artificial stone characterised by specific physical values for the density
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- C—CHEMISTRY; METALLURGY
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
- C04B2201/30—Mortars, concrete or artificial stone characterised by specific physical values for heat transfer properties such as thermal insulation values, e.g. R-values
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
- C04B2201/50—Mortars, concrete or artificial stone characterised by specific physical values for the mechanical strength
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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- Structural Engineering (AREA)
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- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Acoustics & Sound (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
- Building Environments (AREA)
Abstract
本发明公开了一种波特兰水泥基复合保温板。它是一种具有优越的绝热性、防火性、和机械性能的复合保温板。保温板的组成包含一种有机泡沫颗粒，一种磷酸盐涂层，和一种波特兰水泥粘结剂,其特征是:所述磷酸盐涂层包裹在所述有机泡沫颗粒的表面形成改性有机泡沫颗粒；所述改性有机泡沫颗粒分布于所述波特兰水泥粘结剂的介质中。
Description
技术领域
本发明属于保温板，涉及一种具有优越的绝热性能、防火性能、和机械性能的复合保温板。
背景技术
有机泡沫材料，如聚苯乙烯泡沫、聚氨酯泡沫和酚醛泡沫塑料，已被广泛用于住宅、商业和工业建筑结构的外墙保温。然而，这种有机泡沫材料即使含有阻燃也表现出非常差的耐火性。当暴露于火焰时，有机泡沫材料会快速燃烧，并产生有害烟雾。这些有机泡沫材料作为外墙保温材料已导致许多致命火灾事故。
不可燃保温板被用作建筑物的绝热材料包括泡沫玻璃、泡沫陶瓷、玻璃纤维板、岩棉板、和泡沫混凝土，等。泡沫玻璃和泡沫陶瓷通常是昂贵的，因为它们的生产涉及高温处理。此外，泡沫玻璃和泡沫陶瓷由于其脆性而难以安装。同样，玻璃纤维板和岩棉板的生产也消耗大量的能量，因为它们需要高温操作。此外，玻璃纤维板和岩棉板可以很容易地吸水并失去其保温性能。当玻璃纤维板和岩棉板吸水时，它们往往会从墙壁脱落，造成潜在的危险。此外，纤维绝缘材料安装方法复杂。泡沫混凝土可以以相对较低的成本生产。然而，泡沫混凝土的机械性能，如抗压强度，非常差。此外，泡沫混凝土的力学性能在潮湿时急剧下降。
另外一种抗燃烧性能较好的保温板是一种由有机泡沫颗粒和无机粘合剂形成的复合保温板，这种保温材料具备了有机泡沫颗粒的优越的绝热性能，同时，由于无机粘合剂的使用，无机粘合剂包裹了有机颗粒，使得这种材料能够达到有效的抗燃烧效果。为了满足市场的需求，目前，该类保温板的绝热性能和机械强度还需进一步提高。
发明内容
本发明是一种轻质、不燃、导热系数低、机械强度高的波特兰水泥基复合保温板。该保温板包含：一种有机泡沫颗粒；一种磷酸盐涂层；和，一种波特兰水泥粘结剂,其特征是:所述磷酸盐涂层分布于所述有机泡沫颗粒的表面形成改性有机泡沫颗粒；所述改性有机泡沫颗粒分布于所述波特兰水泥粘结剂介质中。
本发明的保温板包含一种有机泡沫颗粒。所述的有机泡沫颗粒包括由有机聚合物材料制成的任何颗粒。所述有机泡沫颗粒包括热塑性均聚物或共聚物，所述共聚物选自乙烯基芳族单体，包括苯乙烯、异丙基苯乙烯、α-甲基苯乙烯、甲基苯乙烯、氯乙烯、叔丁基苯乙烯等。所述有机泡沫颗粒优选是膨胀聚苯乙烯或膨胀石墨聚苯乙烯。
所述的有机泡沫颗粒可是球状、不规则颗粒、或其他形式的颗粒。有机泡沫颗粒的尺寸可为0.5至5毫米，优选为0.6至4毫米，最优选为0.6至1.5毫米。
所述的有机泡沫颗粒的堆积密度优选为4至30kg/m3，更优选为5至15kg/m3，最优选为5至10kg/m3。
本发明的保温板包含一种磷酸盐涂层。所述磷酸盐涂层是由一种磷酸盐水溶液与一种固化剂混合生成。磷酸盐水溶液含磷酸根离子和金属离子，如铝离子、镁离子、锌离子、铁离子，钙离子等。优选的磷酸盐水溶液含磷酸根离子和铝离子。
所述磷酸盐溶液可由磷酸水溶液和金属氧化物或金属氢氧化物反应生成。所述磷酸盐溶液中磷酸根离子和金属离子的摩尔比一般为25:10至35:10，优先为28:10至32:10。磷酸盐水溶液的固含量一般为10％至20％。优选的磷酸铝溶液可以由氧化铝或氢氧化铝与磷酸水溶液反应生成。磷酸铝溶液中磷酸根离子和铝离子的摩尔比一般为25:10至35:10，优先为28:10至32:10。
所述固化剂一般是一种或多种金属氧化物，如氧化镁、氧化铝、氧化铁、氧化锌等。本发明优选固化剂是工业级氧化镁。工业级氧化镁产品一般含有杂质，如CaO、SiO2、Fe2O3、Al2O3、SO3和其他痕量杂质。优选的工业级氧化镁的含量大于80％。
磷酸盐溶液和固化剂混合形成一种磷酸盐涂料。磷酸盐涂料相对于有机泡沫颗粒的用量通常为每立方米有机泡沫颗粒需要1至10千克，优选为3至7千克。
所述磷酸盐涂料可以通过搅拌、滚揉、喷涂或其他合适的方法与有机泡沫颗粒混合，在有机泡沫颗粒表面形成磷酸盐涂层，因而形成改性有机泡沫颗粒。通常，磷酸盐涂料与有机泡沫颗粒混合时间为0.5分钟至5分钟。
本发明的保温板包含一种波特兰水泥粘结剂。所述波特兰水泥粘结剂包括水泥和其它组分，如粉煤灰、矿渣、硅灰、和偏高岭土、等。波特兰水泥是一种由水泥熟料生产的水硬性水泥，主要由硅酸钙组成。粉煤灰是燃烧煤的副产品，含有氧化铝、二氧化硅、氧化钙和少量其他物质。矿渣是冶炼含有金属氧化物和二氧化硅的金属矿石的副产品。硅灰是由细的二氧化硅组成，是的生产硅所产生的副产品。偏高岭土是由粘土制成的具有分子式为Al2Si2O7的铝硅酸盐。
每立方米有机泡沫颗粒使用的所述波特兰水泥的量一般为50至150千克，更优选为70至100千克。
所述的波特兰水泥粘结剂可以含有减水剂。合适的减水剂包括，磺化萘甲醛缩合物(通常是钠盐)、磺化三聚氰胺甲醛缩合物、改性木质素磺酸盐和聚羧酸化合物如聚丙烯酸，等。聚丙烯酸是优选的减水剂。
所述的波特兰水泥粘结剂可以含有防水剂。优选的减水剂为硬脂酸钙。所述的波特兰水泥与硬脂酸钙的重量比为在50:1至100:1。
所述的改性有机泡沫颗粒分布于所述波特兰水泥粘结剂介质中。有机泡沫颗粒被波特兰水泥粘结剂包裹使得改性有机泡沫颗粒均匀地分布在波特兰水泥粘结剂中。同时，由于改性有机泡沫颗粒被一层波特兰水泥粘结剂包裹，导致了该保温板的不燃性能。
本发明保温板的一种制备方法描述如下。
所述磷酸盐涂料可以通过搅拌、滚揉、喷涂或其他合适的方法与有机泡沫颗粒混合，因而形成改性有机泡沫颗粒。有机泡沫颗粒与磷酸盐涂料混合一般在5℃至40℃的温度下完成。混合时间一般为1分钟至5分钟。
所述的波特兰水泥，以及其他成分可以与水混合形成粘合剂浆料。所述波特兰水泥与水的重量比一般为4:1至6:1。
改性有机泡沫颗粒与粘合剂浆料混合一般在5℃至40℃完成。改性有机泡沫颗粒与粘合剂浆料混合时间一般为1分钟至5分钟。
改性有机泡沫颗粒与粘合剂浆料充分混合后，将混合物加入到一种模具中成型、固化，以产生保温块。
所述模具可以是任何形状或尺寸。一般使用长方体模具。例如，可以使用长度为0.5至3米、宽度为0.5至3米、高度为0.5至3米的模具。模具可以由金属、塑料、复合材料或其他材料制成。模具的顶盖能够上下移动。上述混合物加入模具后，加上顶盖。压力可以施加到模具的顶盖，使得泡沫粘合剂混合物在压力下进一步在模具中压实。在模具中的混合物进一步固化一段时间，使混合物获得足够的机械强度。在模具中的固化时间可以从1小时到100小时。固化温度一般在5至90℃。固化温度优选为10℃至40℃。将所形成的保温块达到一定的机械强度后便可从模具取出。最优选的成型、固化步骤是在1至24小时内完成。保温块可通过本领域技术人员所熟知的技术方法，如切割，加工成其他尺寸和形状的保温板。
该发明的保温板干密度优选为0.10至0.25千克/升，更优选为0.14至0.20千克/升，最优选为0.15至0.18千克/升。保温板样品的干密度是在60至90℃的烘箱中干燥后测定。
该发明的保温板优选导热系数(在25℃下测量)小于0.065W/(m·K)，更优选小于0.060W/(m·K)，最优选小于0.055W/(m·K)。
该发明的保温板的抗压强度优选大于0.20MPa，更优选大于0.30MPa.
实施例1
将氢氧化铝(180克,2.3mole)与磷酸水溶液(68％，1000克,6.9mole)在室温下混合、搅拌10小时。在25℃，将上述产物加入5kg水。再加入100克氧化镁(800目,85％)。混合后，得涂料。将上述涂料与聚苯乙烯颗粒(1.2立方米，体积密度7g/L，平均粒径1.0-1.5毫米)充分混合，直到涂料在膨胀聚苯乙烯颗粒表面的均匀发布，得改性聚苯乙烯颗粒。
将波特兰52.5级水泥(85.5kg)、水(17kg)、聚羧酸减水剂(0.4kg)、硬脂酸钙(1kg)混和2分钟形成浆料。将上述波特兰水泥浆料与上述改性聚苯乙烯颗粒在25℃混合2分钟后，添加到模具中。模具长度为1.22米，宽度为0.92米，高度为1米。模具被顶盖覆盖，压力施加到顶盖，使得盖向下移动并锁定在离模具底部0.6米的位置。模具在25℃下保持24小时，然后打开。保温块从模具中取出，锯成厚度为4厘米的产品。其干密度为0.15kg/L，其抗压强度为0.40MPa。其导热系数(在25℃)为0.051W/(m·K)。产品符合A2防火等级。参见：中国国家标准GB 8624-2012(对建筑材料及制品燃烧性能分级)。
比较例1
在25℃，一种52.5级波特兰水泥(87.5kg)、水(27kg)、聚羧酸减水剂(0.4kg)、硬脂酸钙(1kg)混合2分钟，成为浆料。将上述浆料与膨胀聚苯乙烯颗粒(1.2立方米，密度7g/L，平均粒径1.0-1.5mm)在25℃混合2分钟，直到浆料粘结剂对聚苯乙烯珠粒达到均匀覆盖。将上述混合物添加到模具中，其长度为1.22米，宽度为0.92米，高度为1米。模具被顶板覆盖，压力添加到顶板上，使得盖向下移动，并锁定在离模具底部0.6米的位置。模具在25℃下保持24小时，然后再打开模具获得保温块。将保温块锯成厚度为4cm的产品。其干密度为0.15kg/L，抗压强度为0.20MPa。
实施例1得到的保温板的抗压强度显著高于比较例1。这是可能是由于磷酸盐涂料对聚苯乙烯泡沫颗粒的包裹，改进了与水泥粘合剂结合。
Claims (7)
1.一种波特兰水泥基复合保温板，包含：一种有机泡沫颗粒；磷酸盐涂层；和，一种波特兰水泥粘结剂,其特征是:
所述磷酸盐涂层分布于所述有机泡沫颗粒的表面形成改性有机泡沫颗粒；
所述改性有机泡沫颗粒分布于所述波特兰水泥粘结剂介质中。
2.根据权利要求1所述的复合保温板，其特征是所述的有机泡沫颗粒是聚苯乙烯泡沫颗粒。
3.根据权利要求1所述的复合保温板，其特征是所述的有机泡沫颗粒是石墨聚苯乙烯泡沫颗粒。
4.根据权利要求1所述的复合保温板，其特征是所述的磷酸盐涂层含铝离子。
5.根据权利要求1所述的复合保温板，其特征是所述的磷酸盐涂层含磷酸酸根离子与铝离子的摩尔比为28:10至32:10。
6.根据权利要求1所述的复合保温板，其特征是：
所述的有机泡沫颗粒是聚苯乙烯泡沫颗粒；
所述的有机泡沫颗粒的堆积密度为5至15kg/m3；
所述磷酸盐涂层是由一种磷酸盐水溶液和一种固化剂混合生成；
所述的磷酸盐水溶液是由氧化铝或氢氧化铝与磷酸水溶液反应生成；
所述的磷酸盐水溶液含磷酸酸根离子与铝离子的摩尔比为28:10至32:10；
所述的固化剂为氧化镁；
所述的波特兰水泥粘合剂包括波特兰水泥、矿渣、和聚丙烯酸减水剂；
所述的有机泡沫颗粒与波特兰水泥的量为70至100千克波特兰水泥/立方米有机泡沫颗粒。
7.根据权利要求6所述的复合保温板，其特征是：
所述复合保温板的干密度为0.15至0.18千克/升；
所述复合保温板导热系数(25℃)小于0.055W/(m·K)；
所述复合保温板的抗压强度大于0.30MPa。
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