CN110002895A - 一种无机改性聚苯保温板的生产方法 - Google Patents
一种无机改性聚苯保温板的生产方法 Download PDFInfo
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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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
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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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/40—Porous or lightweight materials
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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
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- C—CHEMISTRY; METALLURGY
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- 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
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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
- C04B2201/50—Mortars, concrete or artificial stone characterised by specific physical values for the mechanical strength
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Abstract
本发明涉及一种无机改性聚苯保温板的生产方法。本发明方法能够生产具有优越的绝热性能、防火性能、和机械性能的复合保温板。该生产方法包括:将一种聚合物乳液与一种有机泡沫颗粒混合以产生改性有机泡沫颗粒;将所述改性有机泡沫颗粒与一种波特兰水泥粘结剂浆料混合以形成泡沫粘合剂混合物;将所述泡沫粘合剂混合物加到一种模具中成型、固化,以产生保温块;将所述保温块加工成保温板。
Description
技术领域
本发明公开了一种无机改性聚苯保温板的生产方法,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的生产方法。
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性能。CN104529374A,CN103964807A,CN103601995A,CN103524106A,CN108612211A,CN109049288A,CN108912521A描述了该类保温板的制备方法。但这些方法所生产的保温板有导热系数高、机械强度低、成本昂贵等缺点。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要进一步提高。
发明内容
本发明是一种轻质、不燃、导热系数低、机械强度高的无机改性聚苯保温板的生产方法。该保温板主要是由有机泡沫颗粒、聚合物乳液、和水泥粘结剂组成。本发明方法包括:(a)将一种聚合物乳液与一种有机泡沫颗粒混合以产生改性有机泡沫颗粒;(b)将所述改性有机泡沫颗粒与一种波特兰水泥粘结剂浆料混合以形成泡沫粘合剂混合物;(c)将所述泡沫粘合剂混合物加入到一种模具中成型、固化,以产生保温块;(d)将所述保温块加工成保温板。
所述的有机泡沫颗粒包括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。通过上述至少一种乙烯基芳族单体与一种或多种其它单体的共聚,如二乙烯苯、共轭二烯(非限制性实例是丁二烯、异戊二烯、1,3-和2,4-己二烯)、甲基丙烯酸烷基酯、丙烯酸烷基酯、丙烯腈。所述有机泡沫颗粒优选为苯乙烯聚合物,特别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以是球状、不规则形状、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。
所述的聚合物乳液溶剂是水。所述的聚合物优选包括氯乙烯、乙酸乙烯酯、乙烯醇、丙烯酸、丙烯酸酯、和丙烯酰胺的共聚物。聚合物乳液优选包括聚醋酸乙烯酯,或乙烯和乙酸乙烯酯共聚物。最优选的聚合物乳液包括乙烯和乙酸乙烯酯的共聚物。见美国专利US8,586,686。乙烯和乙酸乙烯酯的共聚物通常包括乙酸乙酯成分为50~80%,更为优选的是按重量计的乙酸乙烯酯成分为60%~80%。乙烯和乙酸乙烯酯共聚物可以含有其它单体,例如具有3至18个碳原子的羧酸乙烯基酯,比如丙酸乙烯酯、丁酸乙烯酯、2-乙基己酸乙烯酯、月桂酸乙烯酯和1-甲基醋酸乙烯酯。
所述的聚合物乳液一般重量浓度为1%至10%。聚合物乳液中所含聚合物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(散装体积)需要0.5~10千克,优选为1~5千克聚合物。
所述聚合物乳液可以通过搅拌、滚揉、喷涂或其他合适的方法与有机泡沫颗粒混合以产生处理的泡沫颗粒。通常,聚合物乳液与有机泡沫颗粒混合时间为0.5分钟至5分钟。
有机泡沫颗粒与聚合物乳液混合一般在5℃至40℃完成。
本发明包括将所述改性有机泡沫颗粒与一种波特兰水泥粘结剂混合以形成泡沫粘合剂混合物。改性有机泡沫颗粒与波特兰水泥粘合剂浆料混合一般在5℃至40℃完成。改性有机泡沫颗粒与波特兰水泥粘合剂浆料混合时间一般为0.5分钟至5分钟。
所述波特兰水泥粘结剂浆料包含水泥、水和其它组分。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。
所述波特兰水泥粘合剂浆料可以含有其他材料来改善波特兰水泥的性能,包括粉煤灰、矿渣、和偏高岭土,等。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。偏高岭土是由粘土制成的具有分子式为Al2Si2O7的铝硅酸盐。
在一个优选的例子中,波特兰水泥粘合剂浆料包括波特兰水泥和矿渣。波特兰水泥与矿渣的重量比可以在50:1至1:1的范围内,最优选在20:1至10:1的范围内。
所述波特兰水泥与水的重量比一般为4:1至6:1。
每立方米有机泡沫颗粒使用的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浆料可以含有减水剂。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合剂浆料可以含有防水剂。优选的减水剂为硬脂酸钙和有机硅防水剂。如选用硬脂酸钙作为防水剂,所述的波特兰水泥与硬脂酸钙的重量比为在50:1至100:1。
该发明包括将所述泡沫粘合剂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。泡沫粘结剂混合物加入模具后,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。
该发明包括将所述保温块加工成保温板。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。
保温板的干密度优选为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。
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)。
保温板的抗压强度优选大于0.20MPa。
使用该发明方法制备所得的无机改性聚苯保温板结构如图1所示。有机泡沫颗粒1被聚合物2包裹后形成改性有机泡沫颗粒。改性有机泡沫颗粒与波特兰水泥粘结剂3结合形成保温板。
附图说明
图1为改性有机泡沫颗粒与波特兰水泥粘结剂浆料混合以形成无机改性聚苯保温板结构示意图。
实施例1
将10公斤乙烯-乙酸乙烯酯共聚物乳液(固含量63%;粘度200-800mPa·S;pH6.0-7.5;密度1.07克/毫升;颗粒直径0.5-1.0微米)在室温下与聚苯乙烯颗粒(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,直到乳液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0.050W/(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)。
Claims (8)
1.一种无机改性聚苯保温板的生产方法,该方法包含:(a)将一种聚合物乳液与一种有机泡沫颗粒混合以产生改性有机泡沫颗粒;(b)将所述改性有机泡沫颗粒与一种波特兰水泥粘结剂浆料混合以形成泡沫粘合剂混合物;(c)将所述泡沫粘合剂混合物加入到一种模具中成型、固化,以产生保温块;(d)将所述保温块加工成保温板。
2.根据权利要求1所述的生产方法,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所述的生产方法,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所述的生产方法,其特征是所述聚合物乳液溶剂是水。
5.根据权利要求4所述的生产方法,其特征是所述聚合物乳液包括聚醋酸乙烯酯或乙烯和乙酸乙烯酯共聚物。最优选的聚合物乳液包括乙烯和乙酸乙烯酯的共聚物。
6.根据权利要求4所述的生产方法,其特征是所述聚合物乳液包括乙烯和乙酸乙烯酯的共聚物。
7.根据权利要求1所述的生产方法,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;
所述聚合物乳液包括乙烯和乙酸乙烯酯的共聚物;
所述的波特兰水泥粘合剂包括波特兰水泥、水、矿渣、聚丙烯酸减水剂;
所述的波特兰水泥与水的重量比为4:1至6:1;
所述的有机泡沫颗粒与波特兰水泥的用量为70至100千克波特兰水泥/立方米有机泡沫颗粒;
所述成型、固化步骤是在温度为10至40℃,时间为1至24小时完成。
8.根据权利要求7所述的生产方法,其特征是:
所述保温板的干密度为0.15至0.18千克/升;
所述保温板导热系数(25℃)小于0.055W/(m·K);
所述保温板的抗压强度大于0.30MPa。
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