CN108951987A - 一种蓄能天花吊顶板及其制造方法 - Google Patents
一种蓄能天花吊顶板及其制造方法 Download PDFInfo
- Publication number
- CN108951987A CN108951987A CN201810891435.8A CN201810891435A CN108951987A CN 108951987 A CN108951987 A CN 108951987A CN 201810891435 A CN201810891435 A CN 201810891435A CN 108951987 A CN108951987 A CN 108951987A
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Links
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Classifications
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- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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Abstract
本发明公开一种蓄能天花吊顶板，适用于家庭、办公、商场等室内场所，蓄能天花吊顶包括面板、面板上方为保温防火层，保温防火层中部与柔性相变材料层复合镶嵌为一体，相变材料层的其中一面与面板相接触。本相变材料蓄能保温吊顶利用相变材料蓄能包可大量储存和释放热能的特点，实现调解室内温度，节能降耗的功效；材料蓄能包内的相变材料中混合加入碧玺成分，碧玺具有发射远红外、释放负离子、净化空气的作用，对室内居住的人群具有保健功效。
Description
技术领域
本发明涉及一种室内天花吊顶，具体涉及一种蓄能天花吊顶板及其制造方法。
背景技术
能源是人类赖以生存的基础。随着现代工业的迅速发展，人们对能源的需求量越来越大，迫切需要全球各国不断开发和利用新能源。在此过程中，虽然新能源在不断被开发，但是我们对能源的利用在许多情况下都未达到合理化，致使大量能源被浪费。因此，提高能源的利用率很有必要。储热技术可用于解决热能供给和需求失配的矛盾，是提高能源利用效率和保护环境的重要技术。储热技术以相变材料（Phase Change Material，PCM）的固-固、固-液相变潜热来储存热量的潜热型热能储存方式最为普遍，也最为重要。其优点为：储热密度大、储放热过程近似等温和过程容易控制等。
近年来，相变材料储能技术也越来越受到建筑装饰行业的青睐，相变材料主要体现在建筑节能方面，应用相变材料制备建筑的围护结构、太阳能相变供暖储热系统和室内相变空调蓄冷系统。例如热电厂的能源转换效率，由于采暖与发电负荷的不一致，导致有过量的热能被浪费。因此，像蓄电池一样的介质，将热量储存起来，在需要时释放能量，以求达到能量的最大化利用-相变储热材料将会被广泛应用。相变材料建筑装饰材料的应用有着优异的节能降耗效果，符合我国节能减排，减少碳排放，高效利用资源的发展方向。
我们通过专利和文献检索，也发现了一些现有关于使用相变材料达到蓄能保温功能的天花板，例如：
1、具有调温调湿和空气净化功能的吊顶天花板及其制备方法，申请号：CN201410109582.7，申请人：烟台斯坦普精工建设有限公司；摘要：本发明公开了一种具有调温调湿和空气净化功能的吊顶天花板，从里至外依次包括固定在一起的隔热减噪层（1）、调温调湿层（2）和空气净化层（3），其中，所述隔热减噪层（1）为泡沫微晶陶瓷板，所述调温调湿层（2）为相变材料，所述空气净化层（3）为硅藻泥。本发明通过工厂化生产，将具有防火、保温隔热、隔声减噪的泡沫微晶陶瓷板与具有调温调湿功能的相变材料和具有空气净化功能的硅藻土相复合，制成环境功能性天花板，实现绿色建材的使用功能复合化、建筑安装部品化和建筑体系集成化。
2、建筑用相变蓄能板及其制造方法，申请号：CN201210543217.8，申请人：天津大学；
摘要：本发明公开了一种建筑用相变蓄能板，由上盖板、下底板和相变材料组成；所述相变材料为脂肪酸与高碳醇类的混合物，脂肪酸为正癸酸、月桂酸、肉豆蔻酸、棕榈酸和硬脂酸；醇类为十二醇、十四醇、十六醇和十八醇；脂肪酸与高碳醇类的质量百分比为46.4%：53.6%～97.5%：2.5%。本发明从根本上解决了诸如破坏力学性能以及环保、安全等问题，避免了实际应用中存在的风险，本发明结构稳定，相变材料不易泄露且无刺激性气体溢出，外表美观，除应用于建筑墙体之外还可用于室内装饰、吊顶及铺设地板。
3、一种相变蓄能吊顶空调采暖方法及装置，申请号：CN200410009094.5，申请权利人：清华大学；摘要：一种相变蓄能吊顶空调采暖方法及装置，属于采暖空调技术领域。本发明采用相变材料为蓄能介质进行吊顶空调和采暖。将相变材料放置于顶部楼板保温层和吊顶之间，在相变材料之中布置与热泵或冷机相连的热水或冷水管道；在电网低谷时段，使热泵或冷机工作产生热水或冷水使相变材料蓄能；在电网高峰时段，热泵或冷机停止工作，利用相变材料蓄存的热量或冷量向房间供热或供冷。
4、一种具有呼吸调湿与净化空气功能的天花材料，申请号：CN201410546679.4，申请权利人：深圳市宜丽家生态建材有限公司；摘要：本发明提供了一种具有呼吸调湿与净化空气功能的天花材料，它是采用硅藻土、β型石膏粉、纳米氧化锌、纳米二氧化钛、电气石粉、三氧化二铝、云母粉、玻璃纤维、钛白粉、腐植酸钠、磷酸锆载银粉、硼砂和α型石膏粉等原料复配而成。本发明天花材料除了装饰功能外，还具有呼吸调湿与净化空气的功能。
上述文献1-3通过相变材料的蓄能功效，应用于室内装饰材料，进行室内温度的控制，但没有净化空气和保健的功效；对比文件4是使用含有电气石（碧玺）粉成分的配方制成的天花材料，但没有蓄能，调解温度的功能；对比文件中的天花板有功能单一，厚度大，制造复杂成本高，集成化程度不高，不利于快捷施工等缺点。
发明内容
本发明的目的是旨在提供一种兼具有调解室内温度和有保健功效的吊顶天花，既能利用相变材料大量储存和释放热能，实现了室内环境温度恒定，降低室内制冷/制热设备运转功率，节约能源的功效；隔音隔热，安装便捷，制造成本低，整体结构稳固轻便，厚度小，占用空间少，具有较强的防火能力；同时具有净化空气，释放负离子、释放远红外线等保健功能。
本发明的技术方案是这样实现的：
蓄能天花吊顶板，蓄能天花吊顶板为多层结构，多层结构从下至上包括面板、相变材料层、保温防火层和贴覆于保温防火层表面的金属箔保护层；各层具有不同的功能，多层结构相互配合，相互支撑，形成多功能天花吊顶板。
所述相变材料层为相变材料包，相变材料包既能与保温防火层是两层不同材料的叠加，也可以是相变材料包复合镶嵌在保温防火层中部，相变材料包复合镶嵌的好处在于：可以进一步减小吊顶板的厚度，而防火保温的功能却不受影响，相比直接两者叠加，集成化程度更高，工人安装时更便捷；相变材料层的下表面与面板或金属箔保护层相接触，相变材料层可以很容易与室内空气环境进行热交换，相变材料包的外包材料为柔性PE或PVC，也可为硬质塑料外壳，柔性外包可以实现更多的装修造型和多样化，成本低，硬质塑料外壳可进一步加强吊顶板的刚度，结构更坚固，用户可根据自身需求进行选择。
所述相变材料层中的相变材料由50份-70份水合盐类、15份-20份膨胀石墨、5份-20份的铝铜混合粉末重量份数组成；其产生相变的温度为27-30℃，其相变材料的组分都是无机材料组合而成，成本低，相比市面现有的有机相变材料本发明无毒无污染，蓄能效果优秀。
所述相变材料层中的相变材料还进一步混合加入5-30份重量份数的碧玺粉末，粉末颗粒大小为200-4000目。
碧玺，又名“电气石”，“托玛琳”，碧玺作为装饰性宝石至少始于古罗马帝国，近年来因为其具有的显著静电场电极作用、负离子产生作用、发射远红外线作用，电磁屏蔽作用以及表面吸附性能等而被认为是优良的环境友好材料。碧玺纳米活粒子表面有许多永久性带电体的小晶粒，小晶粒周围的电场能电离空气中的水分子，产生大量负氧离子；负离子又称为空气的维他命,具有调节人体离子平衡作用，能使身心放松，活化细胞，提高自然治愈率等作用，负氧离子由于带有负电荷，能使通常带正电荷的室内尘埃、烟雾、病毒、细菌相互聚集，失去在空气中自由漂浮的能力迅速降落，从而净化空气。有研究表明，温度的变化能够促进碧玺产生负离子的能力。
所述保温防火层为酚醛泡沫板，酚醛泡沫版具有优异的防火性能，优良的绝热性能，抗腐蚀抗老化性能，吸声性能，且密度小、重量轻、环保无毒，是一种适合于有苛刻要求的环境条件下使用的高性能材料。
酚醛泡沫中含有防火材料，所述的防火材料为氢氧化铝、碱式碳酸铝镁、磷酸酯、卤代磷酸酯或三氧化二锑，或以上防火材料的组合物，加入的重量含量为1－3%，使吊顶板的防火能力进一步提高，可达到耐火A级。
所述金属箔保护层为铝箔、铜箔、锡箔或镁箔，因酚醛泡沫板的抗折、抗拉等力学性能较低，容易受到损坏，因此设置金属箔保护层的对酚醛泡沫板进行保护，将板受到的应力传递到金属箔保护层上，提高吊顶板整体的刚度。金属箔保护层还可以利用自身的反射能力，反射来自外界的热辐射能量，保持室内温度环境。
蓄能天花吊顶板的制作方法，包含以下生产步骤：
A．将相变材料包置于酚醛泡沫板成型模具中，并将模具和预先制造好的相变材料包一起加热至50-80℃，加热的作用是使下一步骤进入的酚醛泡沫原材料均匀受热，从而可以成型更均匀，组织性能更一致；
B．将加入了防火材料的酚醛泡沫原材料灌注成型模具中，经过发泡、固化后成型脱模，相变材料包就与酚醛泡沫板融为一体；
C．对成型的板材边部按照预定尺寸进行修边、切割；
D．对板材进行静置，熟化20-25天，将板材内多余的热量缓慢散发，防止其快速冷却而产生应力变形，也进一步释放酚醛板材中的有害气体；
E．在酚醛泡沫板上下表面分别放置金属箔，用辊压机将金属箔与酚醛泡沫板辊压进行压合；相变材料包位置表面可覆盖金属箔保护层或不覆盖金属箔保护层；
F．将压合好后的板材与面板进行拼接组合，即完成蓄能天花吊顶板的制造。
本发明提供的蓄能天花吊顶板的使用方式是：将蓄能天花吊顶板如普通天花吊顶的安装方式安装在龙骨上，龙骨通过吊杆与建筑相连。在用电低谷期，室内制冷/制热装置工作，室内温度通过空气将冷能/热能传递给本发明吊顶的面板，面板通过自身热传递将冷能/热能传递到相变材料蓄能包，使相变材料蓄能包中的相变储能材料发生相变，将冷能/热能储存起来，然后在用电高峰期时，可关闭或降低制冷/制热设备的功率，室内温度发生变化时，相变储能材料再次发生相反的相变，储存在相变材料中的冷能/热能又重新通过面板的热传递释放到室内空气中，从而达到在用电低谷时期，将冷能/热能储存在蓄能天花吊顶板的相变材料中，然后在用电高峰期时将储存在蓄能天花吊顶板中的冷能/热能释放出来，进而减小城市供电压力，以及有效利用用电低谷期的电力。
与现有技术相比，本发明的优点：
1、本发明既能起到调节室内温度，降低能耗，降低用户电费的功效，又能释放负离子净化室内空气；释放的远红外线和磁场能量，对人体具有保健功效。
2、酚醛泡沫材料保温防火层与相变材料层整体复合镶嵌为一体，结构稳固，保温隔音效果更好，进一步减小吊顶板的厚度，本发明吊顶板生产方法效率高，质量稳定工艺易于控制，工业流水线可大规模生产。
3、本发明厚度小，质量轻，对房间的顶部空间占用少，集成化程度高，施工便捷快速，节省人力和成本。
附图说明
图 1 是本发明分解结构示意图
图 2 是本发明剖视图
附图标号及名称如下 ：
1、面板；2、保温防火层；3、相变材料层；4、金属箔保护层。
具体实施方式
实施例1
蓄能天花吊顶板，蓄能天花吊顶板为多层结构，多层结构从下至上包括铝合金面板1、相变材料层3、保温防火层2和贴覆于保温防火层2表面的铝箔保护层4；相变材料由50份水合盐类、15份膨胀石墨、5份的铝铜混合粉末、5份的碧玺粉末重量份数组成；碧玺粉末颗粒大小为4000目；酚醛泡沫中含有防火材料，所述的防火材料为氢氧化铝，加入的重量含量为1%。
蓄能天花吊顶板的制作方法为以下生产步骤：
将相变材料包置于酚醛泡沫板成型模具中，并将模具和预先制造好的相变材料包一起加热至50-80℃；将加入了防火材料的酚醛泡沫原材料灌注成型模具中，经过发泡、固化后成型脱模；对成型的板材边部按照预定尺寸进行修边、切割；对板材进行静置，熟化20-25天；在酚醛泡沫板上下表面分别放置金属箔，用辊压机将金属箔与酚醛泡沫板辊压进行压合；相变材料包位置表面覆盖金属箔保护层；将压合好后的板材与面板进行拼接组合，即完成蓄能天花吊顶板的制造。
实施例2
蓄能天花吊顶板，蓄能天花吊顶板为多层结构，多层结构从下至上包括不锈钢面板1、相变材料层3、保温防火层2和贴覆于保温防火层2表面的铜箔保护层4；相变材料层3为相变材料包，相变材料包复合镶嵌在保温防火层2中部，相变材料包的外包材料为柔性PE，相变材料层3的下表面与面板相接触，相变材料由70份水合盐类、20份膨胀石墨、20份的铝铜混合粉末、30份的碧玺粉末重量份数组成；碧玺粉末颗粒大小为1000目；酚醛泡沫中含有防火材料，所述的防火材料为碱式碳酸铝镁，加入的重量含量为3%。
蓄能天花吊顶板的制作方法为以下生产步骤：
将相变材料包置于酚醛泡沫板成型模具中，并将模具和预先制造好的相变材料包一起加热至80℃；将加入了防火材料的酚醛泡沫原材料灌注成型模具中，经过发泡、固化后成型脱模；对成型的板材边部按照预定尺寸进行修边、切割；对板材进行静置，熟化25天；在酚醛泡沫板上下表面分别放置金属箔，用粘胶将铜箔与酚醛泡沫板辊压进行粘贴并压紧；相变材料包位置表面不覆盖铜箔保护层；将粘合好后的板与不锈钢面板进行拼接组合，不锈钢面板四周有卡边，可将卡边将酚醛泡沫板卡扣固定，即完成蓄能天花吊顶板的制造。
实施例3
蓄能天花吊顶板，蓄能天花吊顶板为多层结构，多层结构从下至上包括PVC面板1、相变材料层3、保温防火层2和贴覆于保温防火层2表面的锡箔保护层4；相变材料层3为相变材料包，相变材料包复合镶嵌在保温防火层2中部，相变材料包的外包材料为柔性PVC，相变材料层3的下表面与面板相接触，相变材料由60份水合盐类、17份膨胀石墨、17份的铝铜混合粉末、20份的碧玺粉末重量份数组成；碧玺粉末颗粒大小为500目；酚醛泡沫中含有防火材料，所述的防火材料为卤代磷酸酯，加入的重量含量为2%。
蓄能天花吊顶板的制作方法为以下生产步骤：
将相变材料包置于酚醛泡沫板成型模具中，并将模具和预先制造好的相变材料包一起加热至70℃；将加入了防火材料的酚醛泡沫原材料灌注成型模具中，经过发泡、固化后成型脱模；对成型的板材边部按照预定尺寸进行修边、切割；对板材进行静置，熟化21天；在酚醛泡沫板上下表面分别放置锡箔，用粘胶将锡箔与酚醛泡沫板进行粘贴后再辊压；相变材料包位置表面覆盖金属箔保护层；将粘合好后的板与PVC面板进行拼接组合，PVC面板四周有卡边，可将卡边将酚醛泡沫板卡扣固定，即完成蓄能天花吊顶板的制造。
实施例4
蓄能天花吊顶板，蓄能天花吊顶板为多层结构，多层结构从下至上包括钢化玻璃面板1、相变材料层3、保温防火层2和贴覆于保温防火层2表面的镁箔保护层4；相变材料层3为相变材料包，相变材料包复合镶嵌在保温防火层2中部，相变材料包的外包材料为硬质塑料，相变材料层3的下表面与面板相接触，相变材料由65份水合盐类、15份膨胀石墨、8份的铝铜混合粉末、10份的碧玺粉末重量份数组成，碧玺粉末颗粒大小为200目；酚醛泡沫中含有防火材料，所述的防火材料为氢氧化铝和碱式碳酸铝镁的混合物，加入的重量含量为1.5%,，两者的重量比例为1:2。
蓄能天花吊顶板的制作方法为以下生产步骤：
将相变材料包置于酚醛泡沫板成型模具中，并将模具和预先制造好的相变材料包一起加热至60℃；将加入了防火材料的酚醛泡沫原材料灌注成型模具中，经过发泡、固化后成型脱模；对成型的板材边部按照预定尺寸进行修边、切割；对板材进行静置，熟化23天；在酚醛泡沫板上下表面分别放置镁箔，用花纹辊轮将镁箔与酚醛泡沫板进行辊压；相变材料包位置表面不覆盖镁箔保护层；将粘合好后的板与钢化玻璃面板进行拼接组合，钢化玻璃面板四周有卡边，可将卡边将酚醛泡沫板卡扣固定，即完成蓄能天花吊顶板的制造。
应用实施例：
本发明蓄能天花吊顶板安装于申请人的办公室内，办公室面积约为30㎡，办公室长期开启空调进行室温调节，经过申请人的实际测试，可以达到良好的节能效果：保持室内温度27℃的温度条件不变，室外温度约为33℃，在没有安装本发明的的情况下，空调在早9点到晚19点的总耗能电量为8KW；安装了本发明天花吊顶板后，保持室内温度27℃的温度条件不变，室外温度约为33℃，使用同样的空调进行制冷，空调在早9点到晚19点的总耗能电量为3.5KW；计算约可节约用电量56%。
相变材料蓄能包中添加碧玺与相变材料相混合，通过本发明人多次实验，并不会影响相互的性能。本发明提供的蓄能天花吊顶板经过本发明人使用负离子测试仪IONTESTER（型号：COM-3010PRO）对本发明周围空气进行检测，证实本发明周围空气中负离子浓度可达1700-1900ions/cc，而在同样的地点之前未安装本发明的时候，环境中负离子浓度仅为100-200 ions/cc。特别在中国北方地区秋冬季节，室外的寒冷天气和雾霾导致许多办公室和家庭将门窗紧锁，且许多室内并没有安装新风系统，室内的有害气体和PM2.5污染物将损害人体健康，因此本发明对此环境下的室内环境有极大的改善作用，有极大的实用价值。
Claims (8)
1.一种蓄能天花吊顶板，蓄能天花吊顶板为多层结构，其特征在于：多层结构从下至上包括面板（1）、相变材料层（3）、保温防火层（2）和贴覆于保温防火层（2）表面的金属箔保护层（4）。
2.根据权利要求1所述的蓄能天花吊顶板，其特征在于：所述相变材料层（3）为相变材料包，相变材料包复合镶嵌在保温防火层（2）中部，相变材料层（3）的下表面与面板相接触。
3.根据权利要求2所述的蓄能天花吊顶板，其特征在于：所述相变材料包的外包材料为柔性PE或PVC，也可为硬质塑料外壳。
4.根据权利要求1所述的蓄能天花吊顶板，其特征在于：所述相变材料层（3）中的相变材料由50份-70份水合盐类、15份-20份膨胀石墨、5份-20份的铝铜混合粉末重量份数组成；其产生相变的温度为27-30℃。
5.根据权利要求1所述的蓄能天花吊顶板，其特征在于：所述相变材料层（3）中的相变材料还进一步混合加入5-30份重量份数的碧玺粉末，粉末颗粒大小为200-4000目。
6.根据权利要求1所述的蓄能天花吊顶板，其特征在于：所述保温防火层（2）为酚醛泡沫板，酚醛泡沫中含有防火材料，所述的防火材料为氢氧化铝、碱式碳酸铝镁、磷酸酯、卤代磷酸酯或三氧化二锑，加入的重量含量为1－3%。
7.根据权利要求1所述的蓄能天花吊顶板，其特征在于：所述金属箔保护层（4）为铝箔、铜箔、锡箔或镁箔。
8.蓄能天花吊顶板的制作方法，其特征在于：包含以下生产步骤：
将相变材料包置于酚醛泡沫板成型模具中，并将模具和预先制造好的相变材料包一起加热至50-80℃；
将加入了防火材料的酚醛泡沫原材料灌注成型模具中，经过发泡、固化后成型脱模；
对成型的板材边部按照预定尺寸进行修边、切割；
对板材进行静置，熟化20-25天；
在酚醛泡沫板上下表面分别放置金属箔，用辊压机将金属箔与酚醛泡沫板辊压进行压合；相变材料包位置表面可覆盖金属箔保护层或不覆盖金属箔保护层；
将压合好后的板材与面板进行拼接组合，即完成蓄能天花吊顶板的制造。
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