CN110626012B - 一种玄武岩纤维不燃板及其制备方法 - Google Patents

一种玄武岩纤维不燃板及其制备方法 Download PDF

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CN110626012B
CN110626012B CN201910906690.XA CN201910906690A CN110626012B CN 110626012 B CN110626012 B CN 110626012B CN 201910906690 A CN201910906690 A CN 201910906690A CN 110626012 B CN110626012 B CN 110626012B
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邵军
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Qingdao Jiamei United Construction Equipment Co ltd
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Abstract

本发明公开一种玄武岩纤维不燃板及其制备方法，属于装饰板技术领域，包括玄武岩多层组合纤维层，所述玄武岩多层组合纤维层由玄武纤维网、玄武纤维布和玄武纤维毡构成，所述玄武纤维网的正反两面分别设有多层玄武纤维布，所述玄武纤维布外设有玄武纤维毡。本实新型的玄武岩纤维不燃板，防火等级为A级，符合GB50222‑2017《建筑内部装修设计防火规范》。具有耐磨、耐烟灼、耐染污、耐冲击、洁菌、隔音、防水的特点。

Description

一种玄武岩纤维不燃板及其制备方法
技术领域
本发明涉及装饰板技术领域，特别涉及一种玄武岩纤维不燃板及其制备方法。
背景技术
装饰材料是建筑装饰工程的物质基础，是装饰工程的实际效果与装饰材料的色彩、质感和纹理的具体展现。
传统的建材与传统的施工方法都无法避免装修所需打底板、木条、龙骨、胶水、油漆等辅料的配合，防火等级差，施工复杂，耗时，成本过高(材料及人工即为装修成本)，且材料损耗比例比较大，装修板材接缝明显，而胶水、油漆还会挥发影响健康的有害气体，因此亟需研发一种质量可靠、安装便捷、且无需胶水、具有一定功能性的新型装饰板材。
本发明所涉及的玄武岩连续纤维及其复合材料是2002年9月科技部列入国家863计划项目。
发明内容
本发明提供一种玄武岩纤维不燃板及其制备方法，该玄武岩纤维不燃板防火等级为A级，具有耐磨、耐烟灼、耐污染的优点。
为达到上述发明目的，本发明的技术方案为：
一种玄武岩纤维不燃板，包括玄武岩多层组合纤维层，所述玄武岩多层组合纤维层由玄武纤维网、玄武纤维布和玄武纤维毡构成，所述玄武纤维网的正反两面分别设有多层玄武纤维布，所述玄武纤维布外设有多层玄武纤维毡。
其中，优选地，所述玄武岩多层组合纤维层的正反两面分别设有阻隔层，所述阻隔层外设有表面装饰层。
其中，优选地，所述玄武纤维网为1-4层，所述玄武纤维布为1-4层，所述玄武纤维毡为1-4层。
其中，优选地，所述玄武岩多层组合纤维层为含浸改性三聚氰胺树脂或者改性酚醛树脂的纤维层。
其中，优选地，所述阻隔层为白色的含浸三聚氰胺树脂的玻纤毡。
其中，优选地，所述表面装饰层为含浸三聚氰胺树脂的色纸或木皮。
其中，优选地，所述木皮为天然木皮或科技木皮。
一种玄武岩纤维不燃板的制备方法，包括下述步骤：
(1)玄武岩连续纤维湿式制毡：取玄武岩连续纤维，短切至8-18mm短丝，浸入丙烯酸树脂混合水溶液中，取出，施胶的纤维置网带上，烘干，得到密度为75-85g/m2玄武岩纤维毡；；所述丙烯酸树脂混合水溶液中，其中玄武岩纤维83％，增稠剂3％，分散剂3％，消泡剂2％，丙烯酸乳液16％；
(2)玄武岩多层组合纤维层含浸液的制备：玄武岩多层组合纤维层的含浸液是由以下重量比的组分组成：改性三聚氰胺树脂或者改性酚醛树脂40-60份、氢氧化铝40-70份、发散剂1-3份、浸润剂0.4-0.7份、阻燃剂5-6份、偶联剂0.4-0.6份；取上述各组分，混合均匀，制得玄武岩多层组合纤维层含浸液；
(3)含浸、烘干：将玄武岩多层组合纤维层含浸液置入玄武岩纤维含浸机中，再将玄武岩多层组合纤维层置玄武岩纤维含浸机含浸，含浸后玄武岩多层组合纤维层的密度每层为750-850g/m2；再将三聚氰胺树脂置面层含浸机中，分别将表面装饰层和阻隔层置面层含浸机中含浸；将含浸后的玄武岩多层组合纤维层、表面装饰层和阻隔层分别烘干处理；
(4)排叠：将烘干后的多层组合纤维层、阻隔层和表面装饰层排叠后，置于恒温、恒湿的排叠室内；
(5)铺膜、热压：在钢板上按顺序铺膜，采用150-180℃热压，每平方英寸1430磅压力；热压50-70min；
(6)裁切、检验、入库。
其中，优选地，所述步骤(1)中玄武岩连续纤维的管径为13μm；玄武岩纤维密度为2.5-2.8g/cm3，制成的玄武岩纤维毡中玄武岩纤维与丙烯酸树脂混合溶液的重量比为83：17。
其中，优选地，所述发散剂是脂肪酸聚乙醇二脂，所述浸润剂为固含量为20％的石墨乳液或固含量为60％的硅油乳液，所述阻燃剂为聚磷酸铵，所述偶联剂为硅烷偶联剂KH-550或KH-560；其中，优选地，所述排叠室的储存环境温度低于35度，湿度保持50-60％之间；保存期为90天。
本发明的有益效果：
本发明的玄武岩纤维不燃板应用于室内有A级防火要求的水平面或墙面垂直面的装饰，如墙面、家具、桌面、门等；加抗紫外线UV处理后也可应用于室外，如户外家具、户外幕墙装饰面板等。防火等级为A级，符合GB50222-2017《建筑内部装修设计防火规范》。具有耐磨、耐烟灼、耐染污、耐冲击、洁菌、隔音、防水的特点。
施工容易：一般木工即可操作，无需特殊的工具和技术，不用上油漆，色泽均匀。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为发明中玄武岩纤维不燃板的结构示意图；
图中，1.玄武纤维网，2.玄武纤维布，3.玄武纤维毡，4.阻隔层，5.表面装饰层
具体实施方式
下面将结合本发明具体实施例，对本发明的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例1
如图1所示，本实施例提供一种玄武岩纤维不燃板，包括玄武岩多层组合纤维层，所述玄武岩多层组合纤维层的正反两面分别设有阻隔层，所述阻隔层外设有表面装饰层；所述玄武岩多层组合纤维层由玄武纤维网、玄武纤维布和玄武纤维毡构成，所述玄武纤维网的正反两面分别设有多层玄武纤维布，所述玄武纤维布外设有多层玄武纤维毡。
其中，所述玄武纤维网为2层，所述玄武纤维布为2层，所述玄武纤维毡为2层；所述玄武纤维网、所述玄武纤维布和所述玄武纤维毡的重量比为15：15：50。
其中，玄武纤维毡3为60-80％玄武岩纤维毡，使纤维毡光滑、平整，树脂吸收能力强形成含树脂量80％以上的富树脂层，使制品表面有一个色泽光亮平整的表面，同时提高制品的防渗漏、防腐蚀能力以及吸音、隔热性能。玄武岩纤维表面毡的粘结剂与树脂的相容性很好，能提高异型复合材料的成型性；玄武纤维网15-10％长而粗的纤维网格：增加复合材料的弹性模量和强度，抗撕裂强度、抗强张度和挺度；同时具有经、纬双向有很高的抗拉强度和较低的延伸率；玄武岩纤维布为5-15％玄武岩纤维布，具有较好的坚韧性和弹性、不燃、耐腐蚀、耐高温、高强、绝缘、防水，防火，耐高温、吸温性小、耐酸抗腐蚀，不变形等特殊的优异性能。
其中，玄武岩多层组合纤维层为含改性三聚氰胺树脂或者改性酚醛树脂的纤维层。具有以下作用：(1)增加厚度；(2)增强抗冲击效果；(3)增加防火性能；(4)提供树脂吸收附着能力。
其中，阻隔层4为白色的含浸三聚氰胺树脂的玻纤毡，防止透底，提高色彩饱和度。
其中，表面装饰层5为含浸三聚氰胺树脂的色纸，在本发明中也可为木皮或皮革。并且，木皮可为天然木皮或科技木皮。具有以下作用：(1)增加耐磨度、耐刮、防水；(2)增加新的花纹纹路；(3)调节表层颜色，引起色泽的变化。
本实施例玄武岩纤维不燃板的制备方法，包括下述步骤：
(1)取玄武岩连续纤维，短切至12mm短丝，浸入丙烯酸树脂混合水溶液中，取出，施胶的纤维置网带上，烘干，得到密度为80g/m2玄武岩纤维毡；；所述丙烯酸树脂混合水溶液中，其中玄武岩纤维83％，增稠剂3％，分散剂3％，消泡剂2％，丙烯酸乳液16％；制成的玄武岩纤维毡中玄武岩纤维与丙烯酸树脂混合溶液的重量比为83：17。
(2)玄武岩多层组合纤维层含浸液的制备：玄武岩多层组合纤维层的含浸液是由以下重量比的组分组成：改性三聚氰胺树脂或者改性酚醛树脂50份、氢氧化铝55份、发散剂2份、浸润剂0.6份、阻燃剂5.5份、偶联剂0.5份；取上述各组分，混合均匀，制得玄武岩多层组合纤维层含浸液；
(3)含浸、烘干：将玄武岩多层组合纤维层含浸液置入玄武岩纤维含浸机中，再将玄武岩多层组合纤维层置玄武岩纤维含浸机含浸，含浸后玄武岩多层组合纤维层的密度每层为800g/m2；再将三聚氰胺树脂置面层含浸机中，分别将表面装饰层和阻隔层置面层含浸机中含浸，表面装饰层含浸后密度为550/m2；阻隔层含浸后密度为800g/m2；将含浸后的玄武岩多层组合纤维层、表面装饰层和阻隔层分别烘干处理；
(4)排叠：将烘干后的多层组合纤维层、阻隔层和表面装饰层排叠后，置于恒温、恒湿的排叠室内；排叠室的储存环境温度低于35度，湿度保持50-60％之间；保存期为90天；
(5)铺膜、热压：在钢板上按顺序铺膜，采用150-180℃热压，每平方英寸1430磅压力；热压60min；
(6)裁切、检验、入库。
其中，所述发散剂是脂肪酸聚乙醇二脂，所述浸润剂为固含量为20％的石墨乳液，所述阻燃剂为聚磷酸铵，所述偶联剂为硅烷偶联剂KH-550。
实施例2
本实施例提供一种玄武岩纤维不燃板，包括玄武岩多层组合纤维层，所述玄武岩多层组合纤维层的正反两面分别设有阻隔层，所述阻隔层外设有表面装饰层；所述玄武岩多层组合纤维层由玄武纤维网、玄武纤维布和玄武纤维毡构成，所述玄武纤维网的正反两面分别设有多层玄武纤维布，所述玄武纤维布外设有多层玄武纤维毡。
其中，所述玄武纤维网为1层，所述玄武纤维布为4层，所述玄武纤维毡为1层；所述玄武纤维网、所述玄武纤维布和所述玄武纤维毡的重量比为10：20：40。
其中，所述玄武岩多层组合纤维层为含浸改性三聚氰胺树脂或者改性酚醛树脂的纤维层。
其中，所述阻隔层为白色的含浸三聚氰胺树脂的玻纤毡。
其中，所述表面装饰层为含浸三聚氰胺树脂的木皮。
本实施例玄武岩纤维不燃板的制备方法，包括下述步骤：
(1)玄武岩连续纤维湿式制毡：取玄武岩连续纤维，短切至8mm短丝，浸入丙烯酸树脂混合水溶液中，取出，施胶的纤维置网带上，烘干，得到密度为75g/m2玄武岩纤维毡；；所述丙烯酸树脂混合水溶液中，其中玄武岩纤维83％，增稠剂3％，分散剂3％，消泡剂2％，丙烯酸乳液16％；制成的玄武岩纤维毡中玄武岩纤维与丙烯酸树脂混合溶液的重量比为83：17。
(2)玄武岩多层组合纤维层含浸液的制备：玄武岩多层组合纤维层的含浸液是由以下重量比的组分组成：改性三聚氰胺树脂或者改性酚醛树脂40份、氢氧化铝70份、发散剂1份、浸润剂0.7份、阻燃剂5份、偶联剂0.6份；取上述各组分，混合均匀，制得玄武岩多层组合纤维层含浸液；
(3)含浸、烘干：将玄武岩多层组合纤维层含浸液置入玄武岩纤维含浸机中，再将玄武岩多层组合纤维层置玄武岩纤维含浸机含浸，含浸后玄武岩多层组合纤维层的密度每层为750g/m2；再将三聚氰胺树脂置面层含浸机中，分别将表面装饰层和阻隔层置面层含浸机中含浸，表面装饰层含浸后密度为820g/m2；阻隔层含浸后密度为750g/m2；将含浸后的玄武岩多层组合纤维层、表面装饰层和阻隔层分别烘干处理；
(4)排叠：将烘干后的多层组合纤维层、阻隔层和表面装饰层排叠后，置于恒温、恒湿的排叠室内；排叠室的储存环境温度低于35度，湿度保持50-60％之间；保存期为90天；
(5)铺膜、热压：在钢板上按顺序铺膜，采用150-180℃热压，每平方英寸1430磅压力；热压50min；
(6)裁切、检验、入库。
其中，所述发散剂是脂肪酸聚乙醇二脂，所述浸润剂为固含量为60％的硅油乳液，所述阻燃剂为聚磷酸铵，所述偶联剂为硅烷偶联剂KH-560。
实施例3
本实施例提供一种玄武岩纤维不燃板，包括玄武岩多层组合纤维层，所述玄武岩多层组合纤维层的正反两面分别设有阻隔层，所述阻隔层外设有表面装饰层；所述玄武岩多层组合纤维层由玄武纤维网、玄武纤维布和玄武纤维毡构成，所述玄武纤维网的正反两面分别设有多层玄武纤维布，所述玄武纤维布外设有多层玄武纤维毡。
其中，所述玄武纤维网为4层，所述玄武纤维布为1层，所述玄武纤维毡为4层；所述玄武纤维网、所述玄武纤维布和所述玄武纤维毡的重量比为20：10：40。
其中，所述玄武岩多层组合纤维层为含浸改性三聚氰胺树脂或者改性酚醛树脂的纤维层。
其中，所述阻隔层为白色的含浸三聚氰胺树脂的玻纤毡。
其中，所述表面装饰层为含浸三聚氰胺树脂的皮革。
本实施例玄武岩纤维不燃板的制备方法，包括下述步骤：
(1)玄武岩连续纤维湿式制毡：取玄武岩连续纤维，短切至18mm短丝，浸入丙烯酸树脂混合水溶液中，取出，施胶的纤维置网带上，烘干，得到密度为85g/m2玄武岩纤维毡；；所述丙烯酸树脂混合水溶液中，其中玄武岩纤维83％，增稠剂3％，分散剂3％，消泡剂2％，丙烯酸乳液16％；制成的玄武岩纤维毡中玄武岩纤维与丙烯酸树脂混合溶液的重量比为83：17；
(2)玄武岩多层组合纤维层含浸液的制备：玄武岩多层组合纤维层的含浸液是由以下重量比的组分组成：改性三聚氰胺树脂或者改性酚醛树脂60份、氢氧化铝40份、发散剂3份、浸润剂0.4份、阻燃剂6份、偶联剂0.4份；取上述各组分，混合均匀，制得玄武岩多层组合纤维层含浸液；
(3)含浸、烘干：将玄武岩多层组合纤维层含浸液置入玄武岩纤维含浸机中，再将玄武岩多层组合纤维层置玄武岩纤维含浸机含浸，含浸后玄武岩多层组合纤维层的密度每层为850g/m2；再将三聚氰胺树脂置面层含浸机中，分别将表面装饰层和阻隔层置面层含浸机中含浸，表面装饰层含浸后密度为380g/m2；阻隔层含浸后密度为850g/m2；将含浸后的玄武岩多层组合纤维层、表面装饰层和阻隔层分别烘干处理；
(4)排叠：将烘干后的多层组合纤维层、阻隔层和表面装饰层排叠后，置于恒温、恒湿的排叠室内；排叠室的储存环境温度低于35度，湿度保持50-60％之间；保存期为90天；
(5)铺膜、热压：在钢板上按顺序铺膜，采用150-180℃热压，每平方英寸1430磅压力；热压70min；
(6)裁切、检验、入库。
其中，所述发散剂是脂肪酸聚乙醇二脂，所述浸润剂为固含量为20％的石墨乳液，所述阻燃剂为聚磷酸铵，所述偶联剂为硅烷偶联剂KH-550
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (6)

1.一种玄武岩纤维不燃板的制备方法，所述玄武岩纤维不燃板包括玄武岩多层组合纤维层，所述玄武岩多层组合纤维层由玄武纤维网、玄武纤维布和玄武纤维毡构成，所述玄武纤维网的正反两面分别设有多层玄武纤维布，所述玄武纤维布外设有多层玄武纤维毡；所述玄武岩多层组合纤维层的正反两面分别设有阻隔层，所述阻隔层外设有表面装饰层；所述玄武岩多层组合纤维层为含浸改性三聚氰胺树脂或者改性酚醛树脂的纤维层；所述阻隔层为白色的含浸三聚氰胺树脂的玻纤毡；
其特征在于包括下述步骤：
(1)玄武岩连续纤维湿式制毡：取玄武岩连续纤维，短切至8-18mm短丝，浸入丙烯酸树脂混合水溶液中，取出，施胶的纤维置网带上，烘干，得到密度为75-85g/m2玄武岩纤维毡；所述丙烯酸树脂混合水溶液中，其中玄武岩纤维83％，增稠剂3％，分散剂3％，消泡剂2％，丙烯酸乳液16％；
(2)玄武岩多层组合纤维层含浸液的制备：玄武岩多层组合纤维层的含浸液是由以下重量比的组分组成：改性三聚氰胺树脂或者改性酚醛树脂40-60份、氢氧化铝40-70份、发散剂1-3份、浸润剂0.4-0.7份、阻燃剂5-6份、偶联剂0.4-0.6份；取上述各组分，混合均匀，制得玄武岩多层组合纤维层含浸液；
(3)含浸、烘干：将玄武岩多层组合纤维层含浸液置入玄武岩纤维含浸机中，再将玄武岩多层组合纤维层置玄武岩纤维含浸机含浸，含浸后玄武岩多层组合纤维层的密度每层为750-850g/m2；再将三聚氰胺树脂置面层含浸机中，分别将表面装饰层和阻隔层置面层含浸机中含浸；将含浸后的玄武岩多层组合纤维层、表面装饰层和阻隔层分别烘干处理；
(4)排叠：将烘干后的多层组合纤维层、阻隔层和表面装饰层排叠后，置于恒温、恒湿的排叠室内；
(5)铺膜、热压：在钢板上按顺序铺膜，采用150-180℃热压，每平方英寸1430磅压力；热压50-70min；
(6)裁切、检验、入库。
2.根据权利要求1所述的一种玄武岩纤维不燃板的制备方法，其特征在于：所述步骤(1)中玄武岩连续纤维的管径为13μm；玄武岩纤维密度为2.5-2.8g/cm3，制成的玄武岩纤维毡中玄武岩纤维与丙烯酸树脂混合溶液的重量比为83：17。
3.根据权利要求1所述的一种玄武岩纤维不燃板的制备方法，其特征在于：所述发散剂是脂肪酸聚乙醇二脂，所述浸润剂为固含量为20％的石墨乳液或固含量为60％的硅油乳液，所述阻燃剂为聚磷酸铵，所述偶联剂为硅烷偶联剂KH-550或KH-560；所述排叠室的储存环境温度低于35度，湿度保持50-60％之间；保存期为90天。
4.根据权利要求1所述的一种玄武岩纤维不燃板的制备方法，其特征在于：所述玄武纤维网为1-4层，所述玄武纤维布为1-4层，所述玄武纤维毡为1-4层。
5.根据权利要求1所述的一种玄武岩纤维不燃板的制备方法，其特征在于：所述表面装饰层为含浸三聚氰胺树脂的色纸或木皮。
6.根据权利要求5所述的一种玄武岩纤维不燃板的制备方法，其特征在于：所述木皮为天然木皮或科技木皮。
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