CN110466230A - 一种轻质耐高压聚氨酯泡沫复合板及其制备方法 - Google Patents
一种轻质耐高压聚氨酯泡沫复合板及其制备方法 Download PDFInfo
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- CN110466230A CN110466230A CN201910805244.XA CN201910805244A CN110466230A CN 110466230 A CN110466230 A CN 110466230A CN 201910805244 A CN201910805244 A CN 201910805244A CN 110466230 A CN110466230 A CN 110466230A
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- polyurethane foam
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- top panel
- layer
- fiber
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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Abstract
本发明公开了一种轻质耐高压聚氨酯泡沫复合板及其制备方法，由上面板、下面板，上下面板间径向勾连的纤维束与填充的聚氨酯泡沫构成，上面板外侧依次胶黏装饰层和耐磨层，下面板外侧固定防潮平衡底层，上面板与下面板由纤维整体编织而成，本发明采用复合板作为整体复合板的承载结构，并在复合板空隙中高压注入聚氨酯泡沫，具有极强的抗压强度，并采用多层结构，实现承载、隔热、隔音板材一体化，可用于汽车、高铁、船舶、飞机等对轻质高强有要求领域。
Description
技术领域
本发明涉及一种复合板及其制备方法，特别是涉及一种轻质耐高压聚氨酯泡沫复合板及其制备方法。
背景技术
2009年9月，《民用建筑外墙保温系统及外墙装饰防火暂行规定》颁布实施，对建筑保温材料的防火等级做了明确要求。我国普遍使用的墙体保温材料极易燃烧，如何将保温材料的高效节能与优异的防火于一身，成为一个行业性难题。聚氨酯外墙保温防火系统，具有突出的防火性能，达到国家A级标准，耐火耐热，高温下不融化、无滴落物、低烟雾，尺寸稳定性好，并且具有良好的保温节能效果，将优异的防火性能和良好的节能效果于一身，适用于外墙保温等诸多领域。
聚氨酯硬质泡沫是以异氰酸酯和聚醚为主要原料，在发泡剂、催化剂、阻燃剂等多种助剂的作用下，通过专用设备混合，经高压喷涂现场发泡而成的高分子聚合物。聚氨酯泡有软泡和硬泡两种。软泡为开孔结构，硬泡为闭孔结构；软泡又分为结皮和不结皮两种。硬质聚氨酯泡沫塑料主要应用在建筑物外墙保温，屋面防水保温一体化、冷库保温隔热、管道保温材料、建筑板材、冷藏车及冷库隔热材等。
申请号为CN201410173906.3的中国发明专利公开了一种不饱和聚酯树脂泡沫保温复合材料及其制备方法，涉及泡沫保温复合材料配方及制备技术领域，特别是一种不饱和聚酯树脂泡沫保温复合材料及其制备方法，按重量份计，该复合材料具有如下组分：不饱和聚酯树脂100份、苯乙烯10~40份、发泡剂0.5~5份、固化剂0.5~5份、表面活性剂1~5份、阻燃剂15~40份、改性废PCB粉1~10份、改性填料5~30份。与现有技术相比，该发明的技术方案采用不饱和聚酯树脂作为基体、与无机绝热材料进行复合制作泡沫保温复合材料，所得复合材料具有容重轻、保温隔热性能优良、吸水性小、无甲醛气体挥发的特点，且韧性、强度比发泡聚苯乙烯好，成本比聚氨酯泡沫和酚醛泡沫低，加工操作工艺简单，适宜规模化推广应用。
申请号为CN201210482524.X的中国发明专利公开了一种复合聚氨酯泡沫板材，涉及聚合物复合材料，更具体地说是涉及一种高分子隔热消音材料。用连续性的生产工艺，制备以铝箔为面层材料、以聚氨酯半硬质泡沫为芯材的复合型聚氨酯泡沫板材。该板材具有隔热和消音性能优良，吸水率较低的特性，适于建筑隔热和运输工具的隔热消音。。
申请号为CN201520404749.2的中国实用新型专利公开了复合聚氨酯泡沫板，涉及一种起到吸音降噪的作用的泡沫板，具体的说是一种复合聚氨酯泡沫板，该复合聚氨酯泡沫板为上下对称结构，其中间层是阻燃型聚氨酯泡沫层，阻燃型聚氨酯泡沫层的两侧是第一胶层，第一胶层的外侧是无纺布层、无纺布层的外侧是第二胶层，第二胶层的外侧是铝箔玻纤布层。该实用新型应用于车辆钢板、铝板内侧能够起到吸音降噪的作用及具有保温功能，结构简单合理，使用方便，同时还能够解决内饰件之间摩擦产生的声音。
申请号为CN201420065553.0的中国实用新型专利公开了一种用于建筑保温的超低密度硬质聚氨酯泡沫板材，板材密度介于12~35Kg/m3。该泡沫芯材利用环氧改性聚氨酯作为发泡基体，同时加入微米或者纳米级碳纤维进行结构增强。在阻燃方面，该实用新型使用高倍率可膨胀石墨代替大部分液体阻燃剂。因此，该板材具有优良力学性能同时，兼具优异的阻燃防火性能。该实用新型主要应用于建筑节能保温，也可用于冰箱冷库及其它保温隔热用途。
如上述几个专利，均公开了本领域相关的技术产品，但是强度和隔热性能达不到要求，不能应用于建筑外墙等领域。因此，急需研制一种结构强度更高、隔热效果更好的轻质耐高压聚氨酯泡沫复合板。
发明内容
本发明的目的旨在克服现有技术的不足，提供一种轻质耐高压聚氨酯泡沫复合板及其制备方法。
为实现本发明的目的所采用的技术方案是：一种轻质耐高压聚氨酯泡沫复合板，密度0.2~0.6g/cm3，常温导热系数0.020~0.035W/m·K，抗压强度10~30MPa，由上面板、下面板，上下面板间径向勾连的纤维束与填充的聚氨酯泡沫构成，上面板外侧依次胶黏装饰层和耐磨层，下面板外侧固定防潮平衡底层，上面板与下面板由纤维整体编织而成，上面板与下面板厚度分别为2~5mm，上面板与下面板间距为10~30mm，纤维束直径为1~5mm，纤维束水平间距为15~40mm。
进一步的，所述的上面板编织纤维为陶瓷纤维、玻璃纤维、碳纤维中的一种，下面板为碳纤维、高硅氧纤维、玻璃纤维中的一种，所述的装饰层为塑料装饰板、铝塑装饰板、金属装饰板中的一种，厚度为0.5~2.5mm；所述的耐磨层为添加三氧化二铝颗粒的表层纸浸渍三聚氰胺树脂制成，耐磨系数为25000-30000转，厚度为0.1~1.0mm，所述的聚氨酯泡沫中添加炭黑颗粒、陶瓷微珠颗粒或玻璃微珠颗粒，颗粒占比2~5%，所述的防潮平衡底层有牛皮纸浸润树脂后固化形成，厚度为0.5~2.5mm。
一种轻质耐高压聚氨酯泡沫复合板的制备方法，其特征在于包括下述顺序的步骤：
（1）在平面钢制模具表面涂覆脱模剂，然后在模具表面铺覆耐磨层，采用胶黏剂固定装饰层，然后在装饰层表面编织上面板纤维布，内层纤维布紧贴装饰层表面，按照一定间距将编织的纱线从纤维布中穿出一定长度，编织外层纤维布，编织致密后，再穿进内层纤维布中，反复穿进穿出，构造上面板、下面板以及其间径向勾连的纤维束；
（2）在下面板纤维布表面涂覆防潮平衡底层，然后在底层外套更大尺寸的表面涂覆脱模剂的定型模具，采用螺栓固定整个构件，按照设计要求实现定型；
（3）调配聚氨酯发泡原料，并添加发泡剂、催化剂、阻燃剂、红外反射颗粒，通过专用设备混合后用高压喷枪均匀喷入复合板内部，通电加热模具，使复合板内部温度达到30~45℃；
（4）待复合板内部聚氨酯泡沫固化后停止加热，对模具周边的多余泡沫进行精加工，得到固定尺寸，然后去除内外模具，得到聚氨酯泡沫复合板。
本发明的有益效果是：（1）本发明采用复合板作为整体复合板的承载结构，具有极强的抗压强度，并采用多层结构，轻质高强，实现承载、隔音、隔热结构板材一体化。（2）本发明在复合板空隙中高压注入聚氨酯泡沫，在降低整体复合板密度的同时，提高了复合板的抗压强度，另外聚氨酯泡沫的注入显著降低了整体复合板的导热系数，实现高效隔热和隔音，可应用于建筑外墙以及汽车、高铁、船舶、飞机等交通运输领域。
具体实施方式
下面结合具体实施例，进一步阐明本发明，应理解这些实施例仅用于说明本发明而不用于限制本发明的范围，在阅读了本发明之后，本领域技术人员对本发明的各种等价形式的修改均落于本申请所附权利要求所限定。
实施例
一种轻质耐高压聚氨酯泡沫复合板，密度0.3g/cm3，常温导热系数0.028W/m·K，抗压强度20MPa，由上面板、下面板，上下面板间径向勾连的纤维束与填充的聚氨酯泡沫构成，上面板外侧依次胶黏装饰层和耐磨层，下面板外侧固定防潮平衡底层，上面板与下面板由纤维整体编织而成，上面板与下面板厚度分别为3mm，上面板与下面板间距为20mm，纤维束直径为3mm，纤维束水平间距为25mm。
进一步的，所述的上面板编织纤维为玻璃纤维，下面板为高硅氧纤维，所述的装饰层为铝塑装饰板，厚度为2.0mm；所述的耐磨层为添加三氧化二铝颗粒的表层纸浸渍三聚氰胺树脂，耐磨系数为28000转，厚度为0.5mm，所述的聚氨酯泡沫中添加炭黑颗粒、陶瓷微珠颗粒或玻璃微珠颗粒，颗粒占比3%，所述的防潮平衡底层有牛皮纸浸润树脂后固化形成，厚度为1.5mm。
制备上述一种轻质耐高压聚氨酯泡沫复合板，采用了下述顺序方法的步骤：
（1）在平面钢制模具表面涂覆脱模剂，然后在模具表面铺覆耐磨层，采用胶黏剂固定装饰层，然后在装饰层表面编织上面板纤维布，内层纤维布紧贴装饰层表面，按照一定间距将编织的纱线从纤维布中穿出一定长度，编织外层纤维布，编织致密后，再穿进内层纤维布中，反复穿进穿出，构造上面板、下面板以及其间径向勾连的纤维束；
（2）在下面板纤维布表面涂覆防潮平衡底层，然后在底层外套更大尺寸的表面涂覆脱模剂的定型模具，采用螺栓固定整个构件，按照设计要求实现定型；
（3）调配聚氨酯发泡原料，并添加发泡剂、催化剂、阻燃剂、红外反射颗粒，通过专用设备混合后用高压喷枪均匀喷入复合板内部，通电加热模具，使复合板内部温度达到40℃；
（4）待复合板内部聚氨酯泡沫固化后停止加热，对模具周边的多余泡沫进行精加工，得到固定尺寸，然后去除内外模具，得到聚氨酯泡沫复合板。
该实施例所制备的复合板可大面积用于外墙保温一体板，不仅外形美观，而且阻燃，无火焰蔓延，可整体化安装，减少了施工成本。
上述仅为本发明的一个具体实施方式，但本发明的设计构思并不局限于此，凡利用此构思对本发明进行非实质性的改动，均应属于侵犯本发明保护的范围的行为。但凡是未脱离本发明技术方案的内容，依据本发明的技术实质对以上实施例所作的任何形式的简单修改、等同变化与改型，仍属于本发明技术方案的保护范围。
Claims (3)
1.一种轻质耐高压聚氨酯泡沫复合板，密度0.2~0.6g/cm3，常温导热系数0.020~0.035W/m·K，抗压强度10~30MPa，由上面板、下面板，上下面板间径向勾连的纤维束与填充的聚氨酯泡沫构成，上面板外侧依次胶黏装饰层和耐磨层，下面板外侧固定防潮平衡底层，上面板与下面板由纤维整体编织而成，上面板与下面板厚度分别为2~5mm，上面板与下面板间距为10~30mm，纤维束直径为1~5mm，纤维束水平间距为15~40mm。
2.根据权利要求1所述的复合板，其特征在于所述的上面板编织纤维为陶瓷纤维、玻璃纤维、碳纤维中的一种，下面板为碳纤维、高硅氧纤维、玻璃纤维中的一种，所述的装饰层为塑料装饰板、铝塑装饰板、金属装饰板中的一种，厚度为0.5~2.5mm；所述的耐磨层为添加三氧化二铝颗粒的表层纸浸渍三聚氰胺树脂制成，耐磨系数为25000-30000转，厚度为0.1~1.0mm，所述的聚氨酯泡沫中添加炭黑颗粒、陶瓷微珠颗粒或玻璃微珠颗粒，颗粒占比2~5%，所述的防潮平衡底层有牛皮纸浸润树脂后固化形成，厚度为0.5~2.5mm。
3.一种轻质耐高压聚氨酯泡沫复合板的制备方法，其特征在于包括下述顺序的步骤：
（1）在平面钢制模具表面涂覆脱模剂，然后在模具表面铺覆耐磨层，采用胶黏剂固定装饰层，然后在装饰层表面编织上面板纤维布，内层纤维布紧贴装饰层表面，按照一定间距将编织的纱线从纤维布中穿出一定长度，编织外层纤维布，编织致密后，再穿进内层纤维布中，反复穿进穿出，构造上面板、下面板以及其间径向勾连的纤维束；
（2）在下面板纤维布表面涂覆防潮平衡底层，然后在底层外套更大尺寸的表面涂覆脱模剂的定型模具，采用螺栓固定整个构件，按照设计要求实现定型；
（3）调配聚氨酯发泡原料，并添加发泡剂、催化剂、阻燃剂、红外反射颗粒，通过专用设备混合后用高压喷枪均匀喷入复合板内部，通电加热模具，使复合板内部温度达到30~45℃；
（4）待复合板内部聚氨酯泡沫固化后停止加热，对模具周边的多余泡沫进行精加工，得到固定尺寸，然后去除内外模具，得到聚氨酯泡沫复合板。
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| CN201371609Y (zh) * | 2009-04-02 | 2009-12-30 | 北京中铁长龙新型复合材料有限公司 | 高阻燃双芯材承力复合板 |
| CN103874575A (zh) * | 2011-10-12 | 2014-06-18 | 陶氏环球技术有限责任公司 | 具有阻火层的板件 |
| CN103831923A (zh) * | 2012-11-23 | 2014-06-04 | 上海昊海化工有限公司 | 一种复合聚氨酯泡沫板材 |
| CN209211835U (zh) * | 2018-11-28 | 2019-08-06 | 浙江永裕竹业股份有限公司 | 一种防水复合地板 |
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| WO2021227145A1 (zh) * | 2019-10-15 | 2021-11-18 | 龙钟江 | 一种聚氨酯复合地板及其制作工艺 |
| GB2609377A (en) * | 2019-10-15 | 2023-02-01 | Long Zhongjiang | Polyurethane composite floor and fabrication process therefor |
| CN114311862A (zh) * | 2021-12-30 | 2022-04-12 | 重庆再升科技股份有限公司 | 一种低密度泡沫类隔声介质及其制备方法 |
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