CN109294206A - 一种酚醛泡沫夹心复合板的制备方法 - Google Patents
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Abstract
本发明涉及一种酚醛泡沫夹心复合板的制备方法,属于复合板材料技术领域。本发明由马来酸酐单体接枝聚氨酯丙烯酸酯单体作为增容剂,通过机械共混法对酚醛树脂进行改性,使得聚氨酯改性酚醛树脂具有高耐磨性、粘附力、柔韧性和优良的耐低温性能;本发明通过轧制和热压起泡固化制备出酚醛泡沫夹心复合板,轧制复合过程实现面板/芯层粉末有效的初结合,轧后粉末层的致密度高,轧制复合板通过热压起泡固化工艺可以获得良好的芯层泡沫结构,而依靠界面上发生的一系列物理冶金行为可以使金属面板/芯层形成理想的冶金结合,从而得到粘结强度高的的酚醛泡沫夹心复合板。
Description
技术领域
本发明涉及一种酚醛泡沫夹心复合板的制备方法,属于复合板材料技术领域。
背景技术
酚醛(PF)泡沫材料作为第三代泡沫保温材料,具有轻质、阻燃、保温、低烟、低毒特性和耐热性强等诸多优点,通过与金属面板(主要是镀锌钢板、冷轧钢板、不锈钢板、铝板)、塑料面板和木质面板复合制备泡沫夹心复合板,大大增加其强度,可作为轻质墙体广泛应用于工业厂房、船舶、体育场馆、民用住宅、医院、活动板房等建筑,具有良好的应用前景。酚醛泡沫夹心复合板是一种新型的阻燃型人造板,具有绝热、隔声等作用,是应用于墙体、外墙内和外墙外的节能保温的理想轻质建材。现阶段市场上PF泡沫夹芯复合板材上下表面起承载作用的面板主要是彩钢板、不锈钢板、铝板等金属薄板,种类相对单一,限制了其在建筑领域的应用范围,因此,亟需开发新型轻质保温夹芯板。将阻燃纤维板等人造板与酚醛泡沫复合制备保温夹芯板,以其作为节能保温的轻质建材,具有很大的发展潜力。
酚醛泡沫塑料以可发性酚醛树脂为原料,加入表面活性剂、固化剂及发泡剂等组分,重复搅拌混合均与后,将混合物倒入模具中,酚醛树脂在固化剂的促进下经过交联固化成网状结构,同时放出热量,促使发泡剂汽化且在混合物中形成微孔,历经气泡核生成-气泡核增长-气泡核的固化成型三个阶段最终得到酚醛泡沫。经研究表明,酚醛泡沫的性能与原料的配比,酚醛树脂固含量、发泡温度,固化剂种类及用量、表面活性剂及填料等因素有关。
目前,国内泡沫类保温材料和轻质墙体材料仍以聚苯乙烯泡沫和聚氨酯为主,其夹芯板主要用于建造大楼、厂房、仓库、体育馆、活动房屋等轻质墙体材料,特点是快装组合、施工方便、工期缩短。相对于其它大多数泡沫而言,聚氨酯泡沫具有中等强度,易于加工成型。
酚醛泡沫具有优异的保温性能和防火特性,但由于其自身强度较低,限制了其应用领域。以酚醛泡沫为芯层材料,阻燃纤维板作为增强材料制备酚醛泡沫夹心复合板,开发轻质阻燃隔墙体材料,具有广阔的市场应用前景。
发明内容
本发明所要解决的技术问题:针对现有材料中酚醛泡沫芯板与金属面板粘接强度低的问题,提供了一种酚醛泡沫夹心复合板的制备方法。
为解决上述技术问题,本发明采用的技术方案是:
(1)按重量份数计,分别称取10~20份聚氨酯丙烯酸酯单体、10~15份马来酸酐单体、1~6份苯乙烯单体、0.2~0.6份引发剂、0.1~0.3份聚乙烯蜡、0.2~0.5份二甲基甲酰胺,将聚氨酯丙烯酸酯单体、马来酸酐单体、苯乙烯单体、引发剂、聚乙烯蜡和二甲基甲酰胺混合,保温搅拌处理,得共混物,通过双螺杆挤出机熔融挤出,得共聚物;按质量比1∶5∶5将共聚物、聚氨酯和酚醛树脂混合,球磨并过筛处理,即得改性酚醛树脂;
(2)按重量份数计,分别称取改性30~40份酚醛树脂、10~15份Tween-80、5~10份固化剂、1~5份石油醚,将改性酚醛树脂、Tween-80和固化剂混合均匀,得基体,加入石油醚后搅拌均匀,得前驱体,将前驱体均匀涂覆与两层金属面板之间,得坯料,将坯料进行轧制复合,并热压起泡固化,冷却至室温,即得酚醛泡沫夹心复合板。
步骤(1)所述的引发剂为过氧化苯甲酰。
步骤(1)所述的保温搅拌处理为在温度为180~200℃,搅拌速度为100~150r/min下搅拌均匀。
步骤(1)所述的熔融挤出条件为加工温度为第一段180℃、第二段185℃、第三段195℃、第四段195℃,第五段180℃,机头温控195℃,熔体温度控制在195℃。
步骤(1)所述的球磨并过筛处理为在球料比为20∶1,磨球采用钢球,钢球的直径为8~10mm,在转速为500~600r/min下球磨1~2h,并过16~20目筛。
步骤(2)所述的轧制工艺条件为轧制压下率为40%~80%,轧制速度为0.1~0.2m/s。
步骤(2)所述的热压起泡固化为在压力为0.3~0.6MPa,温度为70~80℃,热压起泡固化15~20min。
步骤(2)所述的固化剂为盐酸、硫酸、对甲苯磺酸和苯磺酸按质量比1∶2∶5∶6。
本发明与其他方法相比,有益技术效果是:
(1)本发明由马来酸酐单体接枝聚氨酯丙烯酸酯单体作为增容剂,通过机械共混法对酚醛树脂进行改性,聚氨酯丙烯酸酯的分子中含有丙烯酸官能团和氨基甲酸酯键,固化后的胶黏剂具有聚氨酯的高耐磨性、粘附力、柔韧性、高剥离强度和优良的耐低温性能以及聚丙烯酸酯卓越的光学性能和耐候性,通过反应挤出法由马来酸酐单体接枝聚氨酯丙烯酸酯单体作为增容剂,使得聚氨酯改性酚醛树脂具有高耐磨性、粘附力、柔韧性和优良的耐低温性能;
(2)本发明通过轧制和热压起泡固化制备出酚醛泡沫夹心复合板,轧制复合过程实现面板/芯层粉末有效的初结合,轧后粉末层的致密度高,轧制复合板通过热压起泡固化工艺可以获得良好的芯层泡沫结构,而依靠界面上发生的一系列物理冶金行为可以使金属面板/芯层形成理想的冶金结合,从而得到粘结强度高的的酚醛泡沫夹心复合板。
具体实施方式
按重量份数计,分别称取10~20份聚氨酯丙烯酸酯单体、10~15份马来酸酐单体、1~6份苯乙烯单体、0.2~0.6份引发剂、0.1~0.3份聚乙烯蜡、0.2~0.5份二甲基甲酰胺,将聚氨酯丙烯酸酯单体、马来酸酐单体、苯乙烯单体、引发剂、聚乙烯蜡和二甲基甲酰胺混合,在温度为180~200℃,搅拌速度为100~150r/min下搅拌均匀,得共混物,通过双螺杆挤出机熔融挤出,加工温度为第一段180℃、第二段185℃、第三段195℃、第四段195℃,第五段180℃,机头温控195℃,熔体温度控制在195℃,得共聚物;按质量比1∶5∶5将共聚物、聚氨酯和酚醛树脂混合,在球料比为20∶1,磨球采用钢球,钢球的直径为8~10mm,在转速为500~600r/min下球磨1~2h,并过16~20目筛,即得改性酚醛树脂;按重量份数计,分别称取改性30~40份酚醛树脂、10~15份Tween-80、5~10份固化剂、1~5份石油醚,将改性酚醛树脂、Tween-80和固化剂混合均匀,得基体,加入石油醚后搅拌均匀,得前驱体,将前驱体均匀涂覆与两层金属面板之间,得坯料,将坯料进行轧制复合,并在压力为0.3~0.6MPa,温度为70~80℃,热压起泡固化15~20min,冷却至室温,即得酚醛泡沫夹心复合板;所述的轧制压下率为40%~80%,轧制速度为0.1~0.2m/s。
按重量份数计,分别称取10份聚氨酯丙烯酸酯单体、10份马来酸酐单体、1份苯乙烯单体、0.2份引发剂、0.1份聚乙烯蜡、0.2份二甲基甲酰胺,将聚氨酯丙烯酸酯单体、马来酸酐单体、苯乙烯单体、引发剂、聚乙烯蜡和二甲基甲酰胺混合,在温度为180℃,搅拌速度为100r/min下搅拌均匀,得共混物,通过双螺杆挤出机熔融挤出,加工温度为第一段180℃、第二段185℃、第三段195℃、第四段195℃,第五段180℃,机头温控195℃,熔体温度控制在195℃,得共聚物;按质量比1∶5∶5将共聚物、聚氨酯和酚醛树脂混合,在球料比为20∶1,磨球采用钢球,钢球的直径为8mm,在转速为500r/min下球磨1h,并过16目筛,即得改性酚醛树脂;按重量份数计,分别称取改性30份酚醛树脂、10份Tween-80、5份固化剂、1份石油醚,将改性酚醛树脂、Tween-80和固化剂混合均匀,得基体,加入石油醚后搅拌均匀,得前驱体,将前驱体均匀涂覆与两层金属面板之间,得坯料,将坯料进行轧制复合,并在压力为0.3MPa,温度为70℃,热压起泡固化15min,冷却至室温,即得酚醛泡沫夹心复合板;所述的轧制压下率为40%,轧制速度为0.1m/s。
按重量份数计,分别称取15份聚氨酯丙烯酸酯单体、12份马来酸酐单体、3份苯乙烯单体、0.4份引发剂、0.2份聚乙烯蜡、0.3份二甲基甲酰胺,将聚氨酯丙烯酸酯单体、马来酸酐单体、苯乙烯单体、引发剂、聚乙烯蜡和二甲基甲酰胺混合,在温度为190℃,搅拌速度为125r/min下搅拌均匀,得共混物,通过双螺杆挤出机熔融挤出,加工温度为第一段180℃、第二段185℃、第三段195℃、第四段195℃,第五段180℃,机头温控195℃,熔体温度控制在195℃,得共聚物;按质量比1∶5∶5将共聚物、聚氨酯和酚醛树脂混合,在球料比为20∶1,磨球采用钢球,钢球的直径为9mm,在转速为550r/min下球磨1h,并过18目筛,即得改性酚醛树脂;按重量份数计,分别称取改性35份酚醛树脂、12份Tween-80、8份固化剂、2份石油醚,将改性酚醛树脂、Tween-80和固化剂混合均匀,得基体,加入石油醚后搅拌均匀,得前驱体,将前驱体均匀涂覆与两层金属面板之间,得坯料,将坯料进行轧制复合,并在压力为0.5MPa,温度为75℃,热压起泡固化18min,冷却至室温,即得酚醛泡沫夹心复合板;所述的轧制压下率为60%,轧制速度为0.1m/s。
按重量份数计,分别称取20份聚氨酯丙烯酸酯单体、15份马来酸酐单体、6份苯乙烯单体、0.6份引发剂、0.3份聚乙烯蜡、0.5份二甲基甲酰胺,将聚氨酯丙烯酸酯单体、马来酸酐单体、苯乙烯单体、引发剂、聚乙烯蜡和二甲基甲酰胺混合,在温度为200℃,搅拌速度为150r/min下搅拌均匀,得共混物,通过双螺杆挤出机熔融挤出,加工温度为第一段180℃、第二段185℃、第三段195℃、第四段195℃,第五段180℃,机头温控195℃,熔体温度控制在195℃,得共聚物;按质量比1∶5∶5将共聚物、聚氨酯和酚醛树脂混合,在球料比为20∶1,磨球采用钢球,钢球的直径为10mm,在转速为600r/min下球磨2h,并过20目筛,即得改性酚醛树脂;按重量份数计,分别称取改性40份酚醛树脂、15份Tween-80、10份固化剂、5份石油醚,将改性酚醛树脂、Tween-80和固化剂混合均匀,得基体,加入石油醚后搅拌均匀,得前驱体,将前驱体均匀涂覆与两层金属面板之间,得坯料,将坯料进行轧制复合,并在压力为0.6MPa,温度为80℃,热压起泡固化20min,冷却至室温,即得酚醛泡沫夹心复合板;所述的轧制压下率为80%,轧制速度为0.2m/s。
对照例:东莞某公司生产的酚醛泡沫夹心复合板。
将实例及对照例制备得到的酚醛泡沫夹心复合板进行检测,具体检测如下:
密度:按照GB/T6343-2009泡沫塑料和橡胶-表观密度测定的方法进行。
弯曲性能:弯曲强度按照GB/T8812-2008和JC/T1051-2007的方法进行测定。
压缩性能:压缩强度按照GB/T8813-2008和JC/T1501-2007的方法进行测定,试件尺寸为50×50×60mm。
24h吸水厚度膨胀率及吸水率:参照GB/T17657-2013的规定进行测试。
具体测试结果如表1。
表1性能表征对比表
检测项目 | 实例1 | 实例2 | 实例3 | 对照例 |
密度/g/cm<sup>3</sup> | 0.35 | 0.33 | 0.34 | 0.5 |
弯曲强度/MPa | 3.62 | 6.55 | 6.53 | 2.16 |
压缩强度/MPa | 0.71 | 0.70 | 0.69 | 0.21 |
24h吸水厚度膨胀率/% | 8.5 | 8.6 | 9.1 | 15.6 |
吸水率/% | 65.9 | 63.2 | 62.0 | 70.1 |
由表1可知,本发明制备的酚醛泡沫夹心复合板具有良好的物理性能、力学性能和较高的闭孔率。
Claims (8)
1.一种酚醛泡沫夹心复合板的制备方法,其特征在于具体制备步骤为:
(1)按重量份数计,分别称取10~20份聚氨酯丙烯酸酯单体、10~15份马来酸酐单体、1~6份苯乙烯单体、0.2~0.6份引发剂、0.1~0.3份聚乙烯蜡、0.2~0.5份二甲基甲酰胺,将聚氨酯丙烯酸酯单体、马来酸酐单体、苯乙烯单体、引发剂、聚乙烯蜡和二甲基甲酰胺混合,保温搅拌处理,得共混物,通过双螺杆挤出机熔融挤出,得共聚物;按质量比1∶5∶5将共聚物、聚氨酯和酚醛树脂混合,球磨并过筛处理,即得改性酚醛树脂;
(2)按重量份数计,分别称取改性30~40份酚醛树脂、10~15份Tween-80、5~10份固化剂、1~5份石油醚,将改性酚醛树脂、Tween-80和固化剂混合均匀,得基体,加入石油醚后搅拌均匀,得前驱体,将前驱体均匀涂覆与两层金属面板之间,得坯料,将坯料进行轧制复合,并热压起泡固化,冷却至室温,即得酚醛泡沫夹心复合板。
2.根据权利要求1所述的一种酚醛泡沫夹心复合板的制备方法,其特征在于:步骤(1)所述的引发剂为过氧化苯甲酰。
3.根据权利要求1所述的一种酚醛泡沫夹心复合板的制备方法,其特征在于:步骤(1)所述的保温搅拌处理为在温度为180~200℃,搅拌速度为100~150r/min下搅拌均匀。
4.根据权利要求1所述的一种酚醛泡沫夹心复合板的制备方法,其特征在于:步骤(1)所述的熔融挤出条件为加工温度为第一段180℃、第二段185℃、第三段195℃、第四段195℃,第五段180℃,机头温控195℃,熔体温度控制在195℃。
5.根据权利要求1所述的一种酚醛泡沫夹心复合板的制备方法,其特征在于:步骤(1)所述的球磨并过筛处理为在球料比为20∶1,磨球采用钢球,钢球的直径为8~10mm,在转速为500~600r/min下球磨1~2h,并过16~20目筛。
6.根据权利要求1所述的一种酚醛泡沫夹心复合板的制备方法,其特征在于:步骤(2)所述的轧制工艺条件为轧制压下率为40%~80%,轧制速度为0.1~0.2m/s。
7.根据权利要求1所述的一种酚醛泡沫夹心复合板的制备方法,其特征在于:步骤(2)所述的热压起泡固化为在压力为0.3~0.6MPa,温度为70~80℃,热压起泡固化15~20min。
8.根据权利要求1所述的一种酚醛泡沫夹心复合板的制备方法,其特征在于:步骤(2)所述的固化剂为盐酸、硫酸、对甲苯磺酸和苯磺酸按质量比1∶2∶5∶6。
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