CN109605848B - 一种具有隔音减震保温防腐功能的复合板基材及制造方法 - Google Patents
一种具有隔音减震保温防腐功能的复合板基材及制造方法 Download PDFInfo
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Abstract
本发明涉及人造复合板领域,提供一种具有隔音减震保温防腐功能的复合板基材及制造方法,用于提高防火材料的防火防腐及隔音性能。本发明提供的一种具有隔音减震保温防腐功能的复合板基材及制造方法,包括芯板和隔音垫,所述的芯板同隔音垫通过防火胶连接。芯板有着良好的防火与防生物腐蚀功能,隔音垫可以有效的隔绝噪音,连接上述两种板材的防火胶有着良好的防火效果;将芯板和隔音垫通过防火胶连接,得到的基材有着优秀的隔音、减震、保温、防腐效果。
Description
技术领域
本发明涉及人造复合板领域,具体涉及一种具有隔音减震保温防腐功能的复合板基材及其制造方法。
背景技术
在以上这些领域中,均需要使用综合性能高的特种复合板材,这种特种复合板材最大的特点就是功能性的需求,既要解决车辆及船舶在行驶过程中震动大﹑温差大﹑噪音大﹑保温差的物理性能方面的问题,也要解决防火﹑防潮﹑防腐﹑防霉﹑防虫蚁等化学性能方面的问题。
根据实际调研,我国未来3年,交通制造业每年对这种功能性新材料~隔音﹑减震﹑保温﹑防腐复合板基材的需求量将达到RMB260亿元以上,其中,新能源客车车对该板材的需求就达到60万辆约3000万平方米,且每年平均增长率达到20~30%,而国际市场每年的需求量将超过RMB512亿元。在民用建筑装饰领域对这种功能性新材料~隔音﹑减震﹑保温﹑防腐复合板基材的需求量更大,每年需求量达我国计划在2030年,把中国集成式房屋的比例提升至30%以上,19000万平方米,且每年平均增长率达到10~15%。
发明内容
本发明解决的技术问题为提高人造复合板的防火防腐及隔音性能,提供一种具有隔音减震保温防腐功能的复合板基材及其制造方法。
为了解决上述技术问题,本发明提供的技术方案为:
一种具有隔音减震保温防腐功能的复合板基材及其制造方法,包括芯板和隔音垫,所述的芯板同隔音垫通过防火胶连接。
芯板有着良好的防火与防生物腐蚀功能,隔音垫可以有效的隔绝噪音,连接上述两种板材的防火胶有着良好的防火效果。
将芯板和隔音垫通过防火胶连接,得到的基材有着优秀的隔音、减震、保温、防腐效果。
优选地,所述的芯板的厚度为1~25mm,所述的芯板为多层实木旋切板通过防火胶粘合而成。芯板为多层实木旋切板通过防火胶粘合而成,其多层防火效果有了很大的提高。
优选地,所述的隔音垫的顶面和底面设置有高密度无纺布。隔音垫两侧设置的高密度无纺布可以有效的防止防火胶渗入,保证隔音垫的隔音效果。
优选地,所述的隔音垫的厚度为1~10mm,所述的隔音垫的密度为1300~1800Kg/m3。隔音垫的厚度和密度维持在上述范围内可以有效的保证隔音效果。
优选地,所述的隔音垫同高密度无纺布通过高密度发泡胶粘结,所述的高密度无纺布的单位面积质量为50~80g/m2。发泡胶可以保证隔音垫的有效厚度。
优选地,所述的隔音垫的制作方法为:天然橡胶粒20~40质量份、石英砂8~12质量份、聚异戊二烯30~50质量份、聚氨酯发泡胶15~30质量份,料柱冷压12~36小时成型后旋切成所需厚度。所述的料柱冷压为,将原料混合后加入圆柱形模具中,在常温下加压反应,得到圆柱形的橡胶胚体,将胚体旋切,即可得到所需厚度的隔音垫。
优选地,所述的防火胶包括阻燃剂50~65质量份、酚醛树脂80~100质量份、防霉剂0.5~2质量份、防腐剂10~20质量份及增稠剂20~30质量份;所述的阻燃剂为硅系列阻燃剂,所述的防腐剂为ACQ系列防腐剂,所述的防火胶通过以下方法制成:在50~70℃下,在酚醛树脂中慢慢加入阻燃剂、防霉剂、防腐剂及增稠剂,搅拌均匀,反应2~3h。
一种具有隔音减震保温防腐功能的复合板基材的制造方法,包括以下步骤:
将隔音垫同芯板通过防火胶粘结,得到复合板坯;
将两个以上的板坯通过防火胶粘结,所述的任意两个板坯之间通过隔音垫同芯板连接;
对复合板坯进行热压处理后,进行养生处理;
进行双面砂光处理后裁边得到复合基材。
复合板坯的芯板和隔音垫交叉布置,可以有效的发挥防火与隔音的效果。
优选地,所述的隔音垫的占地面积同芯板相同,所述的隔音垫一体成型。隔音垫需一体成型,务必避免拼接,从而充分的隔音;可以通过旋切调整厚度。
优选地,所述的热压处理的压力为1~1.2MPa,所述热压温度为120~180℃,所述的热压速率为0.8~1.5mm/min,所述的养生处理不少于30天。热压可以使得胶水快速固化,控制相应的参数可以使得各板坯之间充分粘结。
与现有技术相比,本发明具有的有益效果为:芯板有着良好的防火与防生物腐蚀功能,隔音垫可以有效的隔绝噪音,连接上述两种板材的防火胶有着良好的防火效果;将芯板和隔音垫通过防火胶连接,得到的基材有着优秀的隔音、减震、保温、防腐效果。
复合板基材的负载强度方面提高30%;保温性能提升250%;计权隔音量最高可达36~48dB;耐温范围可达到耐高温120℃,耐低温零下50℃;板材表面平整度提升4%。
具体实施方式
以下实施列是对本发明的进一步说明,不是对本发明的限制。
实施例1
一种具有隔音减震保温防腐功能的复合板基材及其制造方法,包括芯板和隔音垫,所述的芯板同隔音垫通过防火胶连接。所述的芯板的厚度为25mm,所述的芯板为多层实木旋切板通过防火胶粘合而成。所述的隔音垫包括石英砂、发泡剂和聚异戊二烯,所述的隔音垫的顶面和底面设置有高密度无纺布。所述的隔音垫的厚度为10mm,所述的隔音垫的密度为1800Kg/m3。所述的隔音垫同高密度无纺布通过高密度发泡胶粘结,所述的高密度无纺布的单位面积质量为50g/m2。所述的隔音垫的制作方法为:天然橡胶粒30质量份、石英砂10质量份、聚异戊二烯40质量份、聚氨酯发泡胶20质量份,料柱冷压24小时成型后旋切成所需厚度。所述的防火胶包括阻燃剂59质量份、酚醛树脂80~100质量份、防霉剂1质量份、防腐剂15质量份及增稠剂25质量份;所述的阻燃剂为硅系列阻燃剂,所述的防腐剂为ACQ系列防腐剂,所述的防火胶通过以下方法制成:在60℃下,在酚醛树脂中慢慢加入阻燃剂、防霉剂、防腐剂及增稠剂,搅拌均匀,反应2.5h。
芯板有着良好的防火与防生物腐蚀功能,隔音垫可以有效的隔绝噪音,连接上述两种板材的防火胶有着良好的防火效果。
将芯板和隔音垫通过防火胶连接,得到的基材有着优秀的隔音、减震、保温、防腐效果。芯板为多层实木旋切板通过防火胶粘合而成,其多层防火效果有了很大的提高。隔音垫两侧设置的高密度无纺布可以有效的防止防火胶渗入,保证隔音垫的隔音效果。隔音垫的厚度和密度维持在上述范围内可以有效的保证隔音效果。发泡胶可以保证隔音垫的有效厚度。
一种隔音、减震、保温、防腐复合基材制造方法,包括以下步骤:
将隔音垫同芯板通过防火胶粘结,得到复合板坯;
将两个以上的板坯通过防火胶粘结,所述的任意两个板坯之间通过隔音垫同芯板连接;
对复合板坯进行热压处理后,进行养生处理;
进行双面砂光处理后裁边得到复合基材。所述的隔音垫的占地面积同芯板相同,所述的隔音垫一体成型。所述的热压处理的压力为1.2MPa,所述热压温度为180℃,所述的热压速率为1.5mm/min,所述的养生处理为45天。
复合板坯的芯板和隔音垫交叉布置,可以有效的发挥防火与隔音的效果。隔音垫需一体成型,务必避免拼接,从而充分的隔音。热压可以使得胶水快速固化,控制相应的参数可以使得各板坯之间充分粘结。
实施例2
实施例2同实施例1不同之处在于,所述的芯板的厚度为1mm,所述的芯板为多层实木旋切板通过防火胶粘合而成。所述的隔音垫的厚度为1mm,所述的隔音垫的密度为1300Kg/m3。所述的热压处理的压力为1MPa,所述热压温度为120℃,所述的热压速率为0.8mm/min,所述的养生处理为30天。所述的隔音垫的制作方法为:天然橡胶粒20质量份、石英砂8质量份、聚异戊二烯30质量份、聚氨酯发泡胶15质量份,料柱冷压12小时成型后旋切成所需厚度。所述的防火胶包括阻燃剂50质量份、酚醛树脂80质量份、防霉剂0.5质量份、防腐剂10质量份及增稠剂20质量份;所述的阻燃剂为硅系列阻燃剂,所述的防腐剂为ACQ系列防腐剂,所述的防火胶通过以下方法制成:在50℃下,在酚醛树脂中慢慢加入阻燃剂、防霉剂、防腐剂及增稠剂,搅拌均匀,反应2h。
实施例3
实施例3同实施例1不同之处在于,所述的芯板的厚度为15mm,所述的芯板为多层实木旋切板通过防火胶粘合而成。所述的隔音垫的厚度为8mm,所述的隔音垫的密度为1500Kg/m3。所述的无纺布的单位面积质量为80g/m2。所述的热压处理的压力为1.1MPa,所述热压温度为150℃,所述的热压速率为1.2mm/min,所述的养生处理为40天。所述的隔音垫的制作方法为:天然橡胶粒40质量份、石英砂12质量份、聚异戊二烯50质量份、聚氨酯发泡胶30质量份,料柱冷压36小时成型后旋切成所需厚度。所述的防火胶包括阻燃剂65质量份、酚醛树脂100质量份、防霉剂2质量份、防腐剂20质量份及增稠剂30质量份;所述的阻燃剂为硅系列阻燃剂,所述的防腐剂为ACQ系列防腐剂,所述的防火胶通过以下方法制成:在70℃下,在酚醛树脂中慢慢加入阻燃剂、防霉剂、防腐剂及增稠剂,搅拌均匀,反应3h。
对比例1
对比例1同实施例1不同之处在于,所述的芯板的厚度为30mm,所述的芯板为多层实木旋切板通过防火胶粘合而成。所述的隔音垫的厚度为15mm,所述的隔音垫的密度为2000Kg/m3。所述的热压处理的压力为1.5MPa,所述热压温度为200℃,所述的热压速率为2.0mm/min。
对比例2
对比例2同实施例1不同之处在于,所述的两个以上的板坯通过防火胶粘结,所述的任意两个板坯的芯板同芯板连接。
对比例3
对比例3同实施例1不同之处在于,所述的两个以上的板坯通过防火胶粘结,所述的任意两个板坯的隔音垫同隔音垫连接。
对比例4
对比例4同实施例1不同之处在于,所述的复合基材中包括多层芯板和市售橡胶垫。
对比例5
对比例5同实施例1不同之处在于,所述的复合基材中包括隔音垫和实木板。
实验例1
通过模拟大板燃烧法测试实施例1~3和对比例1~5中生产出的多层芯板的阻燃性能,每个产品进行6次实验,取耐火时间的平均值。
参照木材天然耐腐性实验室方法测试实施例1~3和对比例1~5中生产出的多层芯板的耐腐蚀性能,以重量损失率来表征耐腐蚀性能。具体结果见表1。
表1板材防火防腐隔音性能
从表1可知,实施例1~3对应的复合基材,其耐火时间和重量损失率均高于对比例和未经处理的轻质柳桉木板,可以看出经过旋切、阻燃防腐处理和组胚处理的木材同,其防火和防腐效果得到了显著的提高。
实施例1~3中,实施例3的防火防腐效果优于实施例1和2,表明在本申请公开的工艺参数范围中可以针对柳桉木优选出较优的工艺参数,进而实现了柳桉木防火防腐效果的进一步提高。
对比例1的,芯板的厚度、隔音垫的厚度均超出了本申请优选的工艺参数,可看出,本申请公开的各层的厚度范围对芯板的防火防腐性能的影响较大,在厚度过小可能导致木材无法充分的负载阻燃剂或防腐剂,导致防火防腐性能下降;厚度过大,可能导致木材无法充分的吸收阻燃剂或防腐剂,也可能导致防火防腐蚀性能的下降。
对比例2和对比例3中,芯板同隔音板并不是交叉式式的堆叠在一起,进而导致了芯板或者隔音垫过厚的现象发生。
对比例4和5中复合板含有隔音垫与实木板或者市售橡胶垫与芯板,同实施例1相比,表明将芯板同隔音板组合在一起,可以发生协同效果,提高复合板基材的防火防腐效果。
实施例1~3的计权隔音量明显优于对比例1~5,表明芯板和隔音垫对提高隔音效果有着重要的作用,通过对比例4和5可以看出,只有本申请中提及的芯片和隔音垫的结合才能显著的提高隔音效果。同时从对比例1和2中可以看出,若芯板或者隔音垫的制作方法不在本申请优选的方法范围内,则隔音效果也会显著的下降。
实验例2
参照GB/T19889.3-2005,对单元面积指令为12.55kg/m2的复合基材的隔音效果进行测试,得到复合基材的隔音效果如表2所示。
表2隔音效果
上列详细说明是针对本发明可行实施例的具体说明,以上实施例并非用以限制本发明的专利范围,凡未脱离本发明所为的等效实施或变更,均应包含于本案的专利范围中。
Claims (6)
1.一种具有隔音减震保温防腐功能的复合板基材,其特征在于,包括芯板和隔音垫,所述的芯板同隔音垫通过防火胶连接;
所述的隔音垫的制作方法为:天然橡胶粒20~40质量份、石英砂8~12质量份、聚异戊二烯30~50质量份、聚氨酯发泡胶15~30质量份,料柱冷压12~36小时成型后旋切成所需厚度;所述的料柱冷压在8~15MPa下进行;
所述的防火胶包括阻燃剂50~65质量份、酚醛树脂80~100质量份、防霉剂0.5~2质量份、防腐剂10~20质量份及增稠剂20~30质量份;所述的阻燃剂为硅系列阻燃剂,所述的防腐剂为ACQ系列防腐剂,所述的防火胶通过以下方法制成:在50~70℃下,在酚醛树脂中慢慢加入阻燃剂、防霉剂、防腐剂及增稠剂,搅拌均匀,反应2~3h;
所述复合板基材的制备方法包括以下步骤:
将隔音垫同芯板通过防火胶粘结,得到复合板坯;
将两个以上的板坯通过防火胶粘结,所述的任意两个板坯之间的隔音垫、芯板交叉布置;
对复合板坯进行热压处理后,进行养生处理;
进行双面砂光处理后裁边得到复合板基材;
所述的热压处理的压力为1.1~1.2MPa,所述热压温度为120~150℃,所述的热压速率为0.8~1.2mm/min,所述的养生处理不少于30天。
2.根据权利要求1所述的具有隔音减震保温防腐功能的复合板基材,其特征在于,所述的芯板的厚度为1~25mm,所述的芯板为多层实木旋切板通过防火胶粘合而成。
3.根据权利要求1所述的具有隔音减震保温防腐功能的复合板基材,其特征在于,所述的隔音垫的顶面和底面设置有高密度无纺布。
4.根据权利要求2所述的具有隔音减震保温防腐功能的复合板基材,其特征在于,所述的隔音垫的厚度为1~10mm,所述的隔音垫的密度为1300~1800Kg/m³。
5.根据权利要求3所述的具有隔音减震保温防腐功能的复合板基材,其特征在于,所述的隔音垫同高密度无纺布通过高密度发泡胶粘结,所述的高密度无纺布的单位面积质量为50~80g/m 2 。
6.根据权利要求1所述的具有隔音减震保温防腐功能的复合板基材,其特征在于,所述的隔音垫的占地面积同芯板相同,所述的隔音垫一体成型。
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