CN110078468A - 一种隔音空心砖及其制备方法 - Google Patents
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Abstract
本发明公开了一种隔音空心砖，它包括下述重量份的各原料：矿棉纤维5‑8、炉渣30‑40、改性聚氨酯发泡材料6‑9、膨润土10‑20、石灰石20‑25、秸秆粉10‑14、醋酸纤维2‑5、煤矸石20‑27、蛭石粉10‑17、壳聚糖2‑4、脂肪醇聚氧乙烯醚1‑2，本发明的空心砖具有很好的强度，且隔音效果好，品质高。
Description
技术领域
本发明属于建筑材料领域，具体涉及一种隔音空心砖及其制备方法。
背景技术
煤矸石作为我国排放量最大的工业固体废弃物之一。而且每年煤矸石的排放量相当于当年煤炭产量的10％左右。年排放速度将大于1.6亿吨。堆放煤矸石不仅占用大量土地，而且污染环境，影响人们的生活和健康。另外，煤矸石自燃能释放多种有害气体等，同时还伴生大量的烟尘和有爆炸危险性。因此煤矸石山自燃给周围的大气环境、人体健康、动植物生长等造成不同程度的影响。粉煤灰是我国当前排量较大的工业废渣之一，随着电力工业的发展，燃煤电厂的粉煤灰排放量逐年增加。大量的粉煤灰不加处理，就会产生扬尘，污染大气；若排入水系会造成河流淤塞，而其中的有毒化学物质还会对人体和生物造成危害。
在国家墙改政策的推动下，我国北方大部分产煤区普遍采用煤矸石为主要原料制砖。利用煤矸石烧砖，它既可作原料，又可以作燃料，这是一个既处理废料，又节约耕地，且节约燃料的一举三得的综合利用项目。作为煤矸石本身，它也是一种沉积页岩，其化学成分基本接近页岩，因为它邻近煤层生成，故含有一定量的碳成分，可供烧砖使用；
然而，随着社会的进步，人们对于建筑材料的要求也不断提高，传统的空心砖只讲求重量、韧性，而对于其隔音效果研究的很少，因此，本发明的目的就是为了进一步提高成品空心砖的品质，增强隔音效果。
发明内容
本发明的目的就是为了进一步提高成品空心砖的品质，增强隔音效果，从而提供一种隔音空心砖及其制备方法。
为实现上述目的，本发明采用以下技术方案：
一种隔音空心砖，它包括下述重量份的各原料：
矿棉纤维5-8、炉渣30-40、改性聚氨酯发泡材料6-9、膨润土10-20、石灰石20-25、秸秆粉10-14、醋酸纤维2-5、煤矸石20-27、蛭石粉10-17、壳聚糖2-4、脂肪醇聚氧乙烯醚1-2。
所述改性聚氨酯发泡材料是由下述重量份的原料组成的：
三乙醇胺2-4、聚碳酸酯二醇80-100、异佛尔酮二异氰酸酯60-70、偶氮二甲酰胺2-3、油酸3-5、二甲基二巯基乙酸异辛酯锡0.1-0.14、正硅酸乙酯50-60、硬脂酸钙2-3。
所述改性聚氨酯发泡材料的制备方法，包括以下步骤：
(1)取油酸、正硅酸乙酯混合，加入到混合料重量60-70倍的去离子水中，搅拌3-5小时，送入到反应釜中，升高温度为240-255℃，加入硬脂酸钙，保温搅拌30-40分钟，出料冷却，得预处理溶胶；
(2)取偶氮二甲酰胺，加入到其重量10-15倍的丙酮中，搅拌均匀，得丙酮溶液；
(3)取预处理溶胶，与聚碳酸酯二醇、异佛尔酮二异氰酸酯混合，搅拌均匀，送入到反应釜中，通入氮气，加入二甲基二巯基乙酸异辛酯锡、丙酮溶液，在50-60℃下保温搅拌2-3小时，加入三乙醇胺，升高反应釜温度为130-135℃，保温搅拌2-3小时，冷却出料，旋蒸脱去丙酮，即得所述改性聚氨酯发泡材料。
一种隔音空心砖的制备方法，包括以下步骤：
(1)取秸秆粉、醋酸纤维混合，加入到混合料重量20-30倍的去离子水中，搅拌均匀，加入脂肪醇聚氧乙烯醚，搅拌均匀，得纤维水乳液；
(2)取炉渣、膨润土、石灰石、煤矸石、蛭石粉混合，搅拌均匀，送入到粉碎机中，粉碎成100-200目粒子；
(3)取上述粒子，与矿棉纤维、改性聚氨酯发泡材料混合，在60-70℃下保温搅拌1-2小时，加入上述纤维水乳液，搅拌均匀，静止2-3小时，送入到空心砖模具中，振动挤压成型，制成空心砖砖坯；
(4)将制成的砖坯在自然风干的情况下干燥至含水量为10-12％，然后置于蒸气氛围中进行养护，养护温度控制在50-55℃，养护时间20-26h，然后在760-800℃下焙烧3-4小时，冷却后即得所述空心砖。
本发明的优点：
本发明加入的改性聚氨酯发泡材料，不仅可以起到很好的隔音效果，而且能够提高各原料间的结合强度，本发明在制备聚氨酯发泡材料的过程中，采用正硅酸乙酯为前驱体，以油酸为水解促进剂，实现溶胶与聚氨酯胶的有效结合，进一步提高了结合强度和力学稳定性，本发明通过三乙醇胺与油酸的反应，还可以起到一定的发泡效果，从而避免了发泡剂的重复添加，降低了工序，节约了资源，本发明的空心砖具有很好的强度，且隔音效果好，品质高。
具体实施方式
实施例1
一种隔音空心砖，它包括下述重量份的各原料：
矿棉纤维5、炉渣30、改性聚氨酯发泡材料6、膨润土10、石灰石20、秸秆粉10、醋酸纤维2、煤矸石20、蛭石粉10、壳聚糖2、脂肪醇聚氧乙烯醚1。
所述改性聚氨酯发泡材料是由下述重量份的原料组成的：
三乙醇胺2、聚碳酸酯二醇80、异佛尔酮二异氰酸酯60、偶氮二甲酰胺2、油酸3、二甲基二巯基乙酸异辛酯锡0.1、正硅酸乙酯50、硬脂酸钙3。
所述改性聚氨酯发泡材料的制备方法，包括以下步骤：
(1)取油酸、正硅酸乙酯混合，加入到混合料重量60倍的去离子水中，搅拌3小时，送入到反应釜中，升高温度为240℃，加入硬脂酸钙，保温搅拌30分钟，出料冷却，得预处理溶胶；
(2)取偶氮二甲酰胺，加入到其重量10倍的丙酮中，搅拌均匀，得丙酮溶液；
(3)取预处理溶胶，与聚碳酸酯二醇、异佛尔酮二异氰酸酯混合，搅拌均匀，送入到反应釜中，通入氮气，加入二甲基二巯基乙酸异辛酯锡、丙酮溶液，在50℃下保温搅拌2小时，加入三乙醇胺，升高反应釜温度为130℃，保温搅拌2小时，冷却出料，旋蒸脱去丙酮，即得所述改性聚氨酯发泡材料。
一种隔音空心砖的制备方法，包括以下步骤：
(1)取秸秆粉、醋酸纤维混合，加入到混合料重量20倍的去离子水中，搅拌均匀，加入脂肪醇聚氧乙烯醚，搅拌均匀，得纤维水乳液；
(2)取炉渣、膨润土、石灰石、煤矸石、蛭石粉混合，搅拌均匀，送入到粉碎机中，粉碎成100目粒子；
(3)取上述粒子，与矿棉纤维、改性聚氨酯发泡材料混合，在60℃下保温搅拌1小时，加入上述纤维水乳液，搅拌均匀，静止2小时，送入到空心砖模具中，振动挤压成型，制成空心砖砖坯；
(4)将制成的砖坯在自然风干的情况下干燥至含水量为10％，然后置于蒸气氛围中进行养护，养护温度控制在50℃，养护时间20h，然后在760℃下焙烧3小时，冷却后即得所述空心砖。
实施例2
一种隔音空心砖，它包括下述重量份的各原料：
矿棉纤维8、炉渣40、改性聚氨酯发泡材料9、膨润土20、石灰石25、秸秆粉14、醋酸纤维5、煤矸石27、蛭石粉17、壳聚糖4、脂肪醇聚氧乙烯醚2。
所述改性聚氨酯发泡材料是由下述重量份的原料组成的：
三乙醇胺4、聚碳酸酯二醇100、异佛尔酮二异氰酸酯70、偶氮二甲酰胺3、油酸5、二甲基二巯基乙酸异辛酯锡0.14、正硅酸乙酯60、硬脂酸钙3。
所述改性聚氨酯发泡材料的制备方法，包括以下步骤：
(1)取油酸、正硅酸乙酯混合，加入到混合料重量70倍的去离子水中，搅拌5小时，送入到反应釜中，升高温度为255℃，加入硬脂酸钙，保温搅拌40分钟，出料冷却，得预处理溶胶；
(2)取偶氮二甲酰胺，加入到其重量15倍的丙酮中，搅拌均匀，得丙酮溶液；
(3)取预处理溶胶，与聚碳酸酯二醇、异佛尔酮二异氰酸酯混合，搅拌均匀，送入到反应釜中，通入氮气，加入二甲基二巯基乙酸异辛酯锡、丙酮溶液，在60℃下保温搅拌3小时，加入三乙醇胺，升高反应釜温度为135℃，保温搅拌3小时，冷却出料，旋蒸脱去丙酮，即得所述改性聚氨酯发泡材料。
一种隔音空心砖的制备方法，包括以下步骤：
(1)取秸秆粉、醋酸纤维混合，加入到混合料重量30倍的去离子水中，搅拌均匀，加入脂肪醇聚氧乙烯醚，搅拌均匀，得纤维水乳液；
(2)取炉渣、膨润土、石灰石、煤矸石、蛭石粉混合，搅拌均匀，送入到粉碎机中，粉碎成200目粒子；
(3)取上述粒子，与矿棉纤维、改性聚氨酯发泡材料混合，在70℃下保温搅拌2小时，加入上述纤维水乳液，搅拌均匀，静止3小时，送入到空心砖模具中，振动挤压成型，制成空心砖砖坯；
(4)将制成的砖坯在自然风干的情况下干燥至含水量为10-12％，然后置于蒸气氛围中进行养护，养护温度控制55℃，养护时间26h，然后在800℃下焙烧4小时，冷却后即得所述空心砖。
性能测试：
实施例1-2制得的空心砖成品的各项性能指标均符合GB25779-2010《承重混多孔砖》国家标淮；
实施例1中得到的空心砖成品表观密度为1088kg/m3；抗压强度为65.7Mpa、隔音量：41.5db。
实施例2中得到的空心砖成品表观密度为1030kg/m3；抗压强度为66.5Mpa、隔音量：42.0db。
Claims (4)
1.一种隔音空心砖，其特征在于，它包括下述重量份的各原料：
矿棉纤维5-8、炉渣30-40、改性聚氨酯发泡材料6-9、膨润土10-20、石灰石20-25、秸秆粉10-14、醋酸纤维2-5、煤矸石20-27、蛭石粉10-17、壳聚糖2-4、脂肪醇聚氧乙烯醚1-2。
2.根据权利要求1所述的一种隔音空心砖，其特征在于，所述改性聚氨酯发泡材料是由下述重量份的原料组成的：
三乙醇胺2-4、聚碳酸酯二醇80-100、异佛尔酮二异氰酸酯60-70、偶氮二甲酰胺2-3、油酸3-5、二甲基二巯基乙酸异辛酯锡0.1-0.14、正硅酸乙酯50-60、硬脂酸钙2-3。
3.根据权利要求2所述的种隔音空心砖，其特征在于，所述改性聚氨酯发泡材料的制备方法，包括以下步骤：
(1)取油酸、正硅酸乙酯混合，加入到混合料重量60-70倍的去离子水中，搅拌3-5小时，送入到反应釜中，升高温度为240-255℃，加入硬脂酸钙，保温搅拌30-40分钟，出料冷却，得预处理溶胶；
(2)取偶氮二甲酰胺，加入到其重量10-15倍的丙酮中，搅拌均匀，得丙酮溶液；
(3)取预处理溶胶，与聚碳酸酯二醇、异佛尔酮二异氰酸酯混合，搅拌均匀，送入到反应釜中，通入氮气，加入二甲基二巯基乙酸异辛酯锡、丙酮溶液，在50-60℃下保温搅拌2-3小时，加入三乙醇胺，升高反应釜温度为130-135℃，保温搅拌2-3小时，冷却出料，旋蒸脱去丙酮，即得所述改性聚氨酯发泡材料。
4.一种如权利要求1所述的隔音空心砖的制备方法，其特征在于，包括以下步骤：
(1)取秸秆粉、醋酸纤维混合，加入到混合料重量20-30倍的去离子水中，搅拌均匀，加入脂肪醇聚氧乙烯醚，搅拌均匀，得纤维水乳液；
(2)取炉渣、膨润土、石灰石、煤矸石、蛭石粉混合，搅拌均匀，送入到粉碎机中，粉碎成100-200目粒子；
(3)取上述粒子，与矿棉纤维、改性聚氨酯发泡材料混合，在60-70℃下保温搅拌1-2小时，加入上述纤维水乳液，搅拌均匀，静止2-3小时，送入到空心砖模具中，振动挤压成型，制成空心砖砖坯；
(4)将制成的砖坯在自然风干的情况下干燥至含水量为10-12％，然后置于蒸气氛围中进行养护，养护温度控制在50-55℃，养护时间20-26h，然后在760-800℃下焙烧3-4小时，冷却后即得所述空心砖。
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