CN109107062B - 一种环保阻火包的制备方法 - Google Patents
一种环保阻火包的制备方法 Download PDFInfo
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Abstract
本发明涉及一种环保阻火包的制备方法，包括以下步骤：（1）、制备编织外层；（2）、制备内部填充料；（3）、将步骤（2）制备好的内部填充料填充至步骤（1）制备的编织外层中，封装，得到阻火包。相对于传统的阻火包，可以显著降低蛭石等膨胀剂的使用量，这样可以更多地加入阻燃料的使用量，提升阻火的效果，本申请阻火包的成本相对于大量使用氧化锆及氧化铝纤维成本降低15%以上。
Description
技术领域
本申请属于耐火材料领域，具体涉及一种环保阻火包的制备方法。
背景技术
阻火包外层采用由编织紧密，经特殊处理耐用的玻璃纤维布制成袋状，内部填充特种耐火、隔热材料和膨胀材料，阻火包具有不燃性，耐火极限可达4小时以上，在较高温度下膨胀和凝固。形成一种隔热、隔烟的密封，且防火抗潮性好，不含石棉等有毒物成份。主要技术性能已达到国外同类产品的先进水平，阻火包可有效地用于发电厂、工矿企业、高层建筑、石化等电缆贯穿孔洞处作防火封堵，特别适用于需经常更换或增减电缆的场合或施工工程中暂时性的防火措施。
现在很多阻火包材料往往以氧化锆或者氧化铝作为阻燃基体来提升高温下阻火包的阻燃效果，这样就会造成阻火包的成本显著提升。
发明内容
本发明的目的是提升一种环保阻火包的制备方法，通过改变添加的成分及成分的配方并对原料进行处理，使其在高温下具有良好的阻火效果。
本发明通过以下技术方案实现：
一种环保阻火包的制备方法，包括以下步骤：
（1）、制备编织外层
利用氧化锆纤维和玄武岩纤维编织成阻火包外层包裹袋；
（2）、制备内部填充料
按重量计取蒙脱石15-22份、氧化锆纤维6-8份、玻璃纤维22-25份、硅酸铝40-50份、生蛭石3-5份、硅橡胶20-25份，将上述原料按比例混合后，使用高速搅拌机在1500-1800r/min的转速下搅拌45-50min，然后造粒；
（3）、将步骤（2）制备好的内部填充料填充至步骤（1）制备的编织外层中，封装，得到阻火包。
优选地，所述蒙脱石经过改性处理，具体步骤如下：
（1）、制备水性聚氨酯悬浮液，
a、将聚丁二醇100份加热至120℃，减压至-0.05MPa处理60min，降温至40℃；
b、向a处理好的聚丁二醇中加入1,4丁二醇15份、2,4-甲苯二异氰酸酯42份、丙酮10份，保持温度在60℃，通入干燥氮气，以560r/min的速度搅拌处理30min，然后加入水1.2份、二羟甲基丙酸18份、凹凸棒土8.5份，在90℃下反应100min，降温至30℃；
c、向步骤b处理好的体系中加入12份三乙胺，搅拌15min，加入400份去离子水在2000r/min 的转速下搅拌处理12-20min，得到水性聚氨酯悬浮液；
（2）、对蒙脱石进行处理，
A、将蒙脱石破碎，过80目筛，然后使用质量分数为5%的碳酸氢钠溶液浸泡50-60min，过滤，烘干；
B、将步骤A处理好的蒙脱石与步骤（1）制备的水性聚氨酯乳液按重量比1:5-8的比例混合，在2000r/min的转速下搅拌处理5-8min，然后使用25kHz的超声波震荡处理15-20min；
C、将步骤B处理好的蒙脱石在60-65℃下烘干，得到改性蒙脱石。
优选地，所述氧化锆纤维使用以下方法处理：
（1）、将氧化锆纤维使用固含量30%的苯丙乳液60份、偶联剂KH550 5份、羟基聚二甲基硅烷2份制成的悬浮液浸泡处理15-20min；
（2）、将步骤（1）处理好的氧化锆纤维在60-70℃烘干。
进一步地，所述硅酸铝经过以下方式进行处理：
（1）、将硅酸铝使用质量分数为5%的硅烷偶联剂KH550醇溶液浸泡处理30min，浸泡过程中不断搅拌，抽滤，烘干；
（2）、按重量计取硝酸镁22份、硬脂酸钠8份、乙醇9份、水100份混合分散制成混合液，将步骤（1）处理好的硅酸铝加入混合液中以1500r/min搅拌30min，升温至45℃，然后超声波震荡20min，超声波频率为25kHz，然后过滤，在60℃下烘干，得到处理后的硅酸铝。
优选地，造粒后颗粒的粒径为1.2-3mm。
进一步地，所述凹凸棒土经过改性处理，具体改性方式如下：
（1）、将凹凸棒土使用质量分数5%的双氧水溶液浸泡，浸泡过程中以1000r/min的速度进行搅拌处理；
（2）、对步骤（1）处理好的凹凸棒土进行水洗，烘干，按重量计取凹凸棒土20份加入100份的无水乙醇、5份硅烷偶联剂、2份碳化硅纳米晶须、1份壳聚糖，以2000r/min的转速搅拌60min，然后使用微波处理10-15min，抽滤，然后将凹凸棒土烘干，得到改性凹凸棒土。
所述微波功率为700W。
所述外层中氧化锆纤维与玄武岩纤维比例为10:1。
本发明方法制备的阻火包中对蒙脱石进行处理，蒙脱石表面经过处理能形成一定的孔洞，使得水性聚氨酯与蒙脱石能形成良好的修饰和结合作用，使得在正常状态下能保持很好的稳定性，在高温下能够产生气体膨胀，起到填充及隔离火源的效果，同时，本申请在水性聚氨酯制备时加入经过改性的凹凸棒土，能增强聚氨酯的强度，避免高温下强度下降造成塌陷。硅酸铝经过处理过后，负载着镁离子等成分的硅酸铝具有更高的活性，易于其他成分结合，增强连接强度，也增加了耐温性能；与其他成分的分散效果更好，而且与蒙脱石等成分结合后，能在高温下保持良好的强度。
本发明的有益效果：本发明制备的阻火包蒙脱石、氧化锆纤维、玻璃纤维、硅酸铝、生蛭石、硅橡胶为主要原料，其中改变了传统阻火包中的组成结构，以超耐高温的氧化锆纤维作为基体，以硅酸铝、蒙脱石、玻璃纤维等作为主要材料，通过对各成分的改性处理，一方面提升了阻火性能，使其与活化后的氧化锆纤维具有良好的结合能力，形成交联的网状物质，使阻火包耐温性能达到2000℃以上，而且在高温下不会产生有毒物质，使用安全性高。本申请中经过对原料的组合及处理，相对于传统的阻火包，可以显著降低蛭石等膨胀剂的使用量，这样可以更多地加入阻燃料的使用量，提升阻火的效果，本申请阻火包的成本相对于大量使用氧化锆及氧化铝纤维成本降低15%以上。
具体实施方式
实施例1
一种环保阻火包的制备方法，包括以下步骤：
（1）、制备编织外层
利用氧化锆纤维和玄武岩纤维编织成阻火包外层包裹袋；
（2）、制备内部填充料
按重量计取蒙脱石20份、氧化锆纤维7份、玻璃纤维24份、硅酸铝48份、生蛭石4.2份、硅橡胶22份，将上述原料按比例混合后，使用高速搅拌机在1500r/min的转速下搅拌50min，然后造粒；
（3）、将步骤（2）制备好的内部填充料填充至步骤（1）制备的编织外层中，封装，得到阻火包。
优选地，所述蒙脱石经过改性处理，具体步骤如下：
（1）、制备水性聚氨酯悬浮液，
a、将聚丁二醇100份加热至120℃，减压至-0.05MPa处理60min，降温至40℃；
b、向a处理好的聚丁二醇中加入1,4丁二醇15份、2,4-甲苯二异氰酸酯42份、丙酮10份，保持温度在60℃，通入干燥氮气，以560r/min的速度搅拌处理30min，然后加入水1.2份、二羟甲基丙酸18份、凹凸棒土8.5份，在90℃下反应100min，降温至30℃；
c、向步骤b处理好的体系中加入12份三乙胺，搅拌15min，加入400份去离子水在2000r/min 的转速下搅拌处理12-20min，得到水性聚氨酯悬浮液；
（2）、对蒙脱石进行处理，
A、将蒙脱石破碎，过80目筛，然后使用质量分数为5%的碳酸氢钠溶液浸泡50-60min，过滤，烘干；
B、将步骤A处理好的蒙脱石与步骤（1）制备的水性聚氨酯乳液按重量比1:5-8的比例混合，在2000r/min的转速下搅拌处理5-8min，然后使用25kHz的超声波震荡处理15-20min；
C、将步骤B处理好的蒙脱石在60-65℃下烘干，得到改性蒙脱石。
优选地，所述氧化锆纤维使用以下方法处理：
（1）、将氧化锆纤维使用固含量30%的苯丙乳液60份、偶联剂KH550 5份、羟基聚二甲基硅烷2份制成的悬浮液浸泡处理15-20min；
（2）、将步骤（1）处理好的氧化锆纤维在60-70℃烘干。
进一步地，所述硅酸铝经过以下方式进行处理：
（1）、将硅酸铝使用质量分数为5%的硅烷偶联剂KH550醇溶液浸泡处理30min，浸泡过程中不断搅拌，抽滤，烘干；
（2）、按重量计取硝酸镁22份、硬脂酸钠8份、乙醇9份、水100份混合分散制成混合液，将步骤（1）处理好的硅酸铝加入混合液中以1500r/min搅拌30min，升温至45℃，然后超声波震荡20min，超声波频率为25kHz，然后过滤，在60℃下烘干，得到处理后的硅酸铝。
优选地，造粒后颗粒的粒径为1.2-3mm。
进一步地，所述凹凸棒土经过改性处理，具体改性方式如下：
（1）、将凹凸棒土使用质量分数5%的双氧水溶液浸泡，浸泡过程中以1000r/min的速度进行搅拌处理；
（2）、对步骤（1）处理好的凹凸棒土进行水洗，烘干，按重量计取凹凸棒土20份加入100份的无水乙醇、5份硅烷偶联剂、2份碳化硅纳米晶须、1份壳聚糖，以2000r/min的转速搅拌60min，然后使用微波处理10-15min，抽滤，然后将凹凸棒土烘干，得到改性凹凸棒土。
所述微波功率为700W。
实施例2
与实施例1相比，所述内部填充料按重量计由以下原料制成：蒙脱石20份、氧化锆纤维8份、玻璃纤维24份、硅酸铝48份、生蛭石5份、硅橡胶23份。
实施例3
与实施例1相比，本申请中的各原料配比一致，蒙脱石不经过改性处理。
实施例4
与实施例1相比，本申请中的各原料配比一致，氧化锆纤维不经过改性处理。
实施例5
与实施例1相比，本申请中的各原料配比一致，硅酸铝纤维不经过改性处理。
实施例6
与实施例1相比，本申请中的各原料配比一致，蒙脱石改性过程中不使用凹凸棒土。
对比例1
与实施例相比，不使用氧化锆纤维。
对比例2
与实施例1相比，不使用硅橡胶。
对比例3
与实施例1相比，不使用硅酸铝。
本发明各实施例中制备的阻火包的技术性能如表1所示：
| 膨胀性能（%） | 耐火性能 | 耐湿热性（h） | 耐水性（h） | |
| 实施例1 | 285 | 15h包装完整，背温上升不超过160℃ | 符合要求 | 符合要求 |
| 实施例2 | 282 | 15h包装完整，背温上升不超过160℃ | 符合要求 | 符合要求 |
| 实施例3 | 185 | 12h包装完整，背温上升约220℃ | 符合要求 | 符合要求 |
| 实施例4 | 267 | 9h包装完整，背温上升不超过165℃ | 符合要求 | 符合要求 |
| 实施例5 | 235 | 8h包装完整，背温上升不超过180℃ | 符合要求 | 符合要求 |
| 实施例6 | 242 | 8h包装完整，背温上升不超过180℃ | 不符合要求 | 符合要求 |
| 对比例1 | 280 | 不符合要求 | 不符合要求 | 不符合要求 |
| 对比例2 | 208 | 不符合要求 | 不符合要求 | 不符合要求 |
| 对比例3 | 205 | 不符合要求 | 不符合要求 | 不符合要求 |
由表1可见，上述检测使用GB 23864-2009标准测试，本申请各实施例中的阻火包的综合性能符合甚至超越国家标准。
本申请还验证了各组阻火包的最高耐火温度，结果如表2所示：
表2
| 实施例1 | 实施例2 | 实施例3 | 实施例4 | 实施例5 | |
| 最高耐火温度（℃） | 2058 | 2046 | 2001 | 1985 | 1925 |
| 实施例6 | 对比例1 | 对比例2 | 对比例3 | ||
| 最高耐火温度（℃） | 1996 | 1654 | 1875 | 1824 |
以上最高温度为在此温度下阻火包易燃能够保持性能时间至少3h。
由表2可知，本申请中的阻火包能在2000℃以上正常使用，可见，本申请中虽然使用了较少的氧化锆纤维，依然可以保持良好的性能。
Claims (6)
1.一种环保阻火包的制备方法，其特征在于，包括以下步骤：
（1）、制备编织外层
利用氧化锆纤维和玄武岩纤维编织成阻火包外层包裹袋；
（2）、制备内部填充料
按重量计取蒙脱石15-22份、氧化锆纤维6-8份、玻璃纤维22-25份、硅酸铝40-50份、生蛭石3-5份、硅橡胶20-25份，将上述原料按比例混合后，使用高速搅拌机在1500-1800r/min的转速下搅拌45-50min，然后造粒；
（3）、将步骤（2）制备好的内部填充料填充至步骤（1）制备的编织外层中，封装，得到阻火包；
所述蒙脱石经过改性处理，具体步骤如下：
（1）、制备水性聚氨酯悬浮液，
a、将聚丁二醇100份加热至120℃，减压至-0.05MPa处理60min，降温至40℃；
b、向a处理好的聚丁二醇中加入1,4丁二醇15份、2,4-甲苯二异氰酸酯42份、丙酮10份，保持温度在60℃，通入干燥氮气，以560r/min的速度搅拌处理30min，然后加入水1.2份、二羟甲基丙酸18份、凹凸棒土8.5份，在90℃下反应100min，降温至30℃；
c、向步骤b处理好的体系中加入12份三乙胺，搅拌15min，加入400份去离子水在2000r/min 的转速下搅拌处理12-20min，得到水性聚氨酯悬浮液；
（2）、对蒙脱石进行处理，
A、将蒙脱石破碎，过80目筛，然后使用质量分数为5%的碳酸氢钠溶液浸泡50-60min，过滤，烘干；
B、将步骤A处理好的蒙脱石与步骤（1）制备的水性聚氨酯乳液按重量比1:5-8的比例混合，在2000r/min的转速下搅拌处理5-8min，然后使用25kHz的超声波震荡处理15-20min；
C、将步骤B处理好的蒙脱石在60-65℃下烘干，得到改性蒙脱石。
2.根据权利要求1所述的一种环保阻火包的制备方法，其特征在于，所述氧化锆纤维使用以下方法处理：
（1）、将氧化锆纤维使用固含量30%的苯丙乳液60份、偶联剂KH550 5份、羟基聚二甲基硅烷2份制成的悬浮液浸泡处理15-20min；
（2）、将步骤（1）处理好的氧化锆纤维在60-70℃烘干。
3.根据权利要求1所述的一种环保阻火包的制备方法，其特征在于：所述硅酸铝经过以下方式进行处理：
（1）、将硅酸铝使用质量分数为5%的硅烷偶联剂KH550醇溶液浸泡处理30min，浸泡过程中不断搅拌，抽滤，烘干；
（2）、按重量计取硝酸镁22份、硬脂酸钠8份、乙醇9份、水100份混合分散制成混合液，将步骤（1）处理好的硅酸铝加入混合液中以1500r/min搅拌30min，升温至45℃，然后超声波震荡20min，超声波频率为25kHz，然后过滤，在60℃下烘干，得到处理后的硅酸铝。
4.根据权利要求1所述的一种环保阻火包的制备方法，其特征在于：造粒后颗粒的粒径为1.2-3mm。
5.根据权利要求1所述的一种环保阻火包的制备方法，其特征在于：所述凹凸棒土经过改性处理，具体改性方式如下：
（1）、将凹凸棒土使用质量分数5%的双氧水溶液浸泡，浸泡过程中以1000r/min的速度进行搅拌处理；
（2）、对步骤（1）处理好的凹凸棒土进行水洗，烘干，按重量计取凹凸棒土20份加入100份的无水乙醇、5份硅烷偶联剂、2份碳化硅纳米晶须、1份壳聚糖，以2000r/min的转速搅拌60min，然后使用微波处理10-15min，抽滤，然后将凹凸棒土烘干，得到改性凹凸棒土。
6.根据权利要求5所述的一种环保阻火包的制备方法，其特征在于：所述微波功率为700W。
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| CN104178182A (zh) * | 2014-08-07 | 2014-12-03 | 镇江洋溢汽车部件有限公司 | 一种阻火包的制备方法 |
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