CN110655674A - 一种复合泡沫保温板的施工工艺 - Google Patents
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Abstract
本发明涉及复合保温板技术领域，具体涉及一种复合泡沫保温板的施工工艺，包括以下步骤：预处理施工、生产施工和现场施工，预处理施工对EPS珠粒进行预发泡和二次发泡，生产施工将各成分混合均匀并通过模具固化养护，其中各成分酚醛树脂、脂肪酸聚氧乙烯酯、聚乙二醇、阻燃剂、正戊烷、二次发泡EPS颗粒料、固化剂的质量比为35‑38:4‑6:5:10:10‑16:40‑45:20‑22；本发明得到的保温板孔径分布均匀细腻，降低复合泡沫保温板表观密度，从而提高复合泡沫保温板的保温性能。与市售酚醛保温板相比，本发明的复合泡沫保温板的导热系数大幅度降低，力学性能和阻燃性能显著提高，降低生产成本和施工难度。
Description
技术领域
本发明涉及复合保温板技术领域，具体涉及一种复合泡沫保温板的施工工艺。
背景技术
目前常规的泡沫材料如聚苯乙烯板，由于其抗冻效果好、强度高、吸水率低、质轻、施工方便等优点，已成为目前国内外建筑外墙保温系统的主流材料；但这类保温材料也存在缺点：板材结构疏松、内部颗粒间存在较多空隙、导热系数较高、易燃。聚苯乙烯泡沫易燃的缺陷，使得其燃烧时放出有毒的烟雾，纵然经过阻燃处理其燃烧性也仅能达到B级，耐久性差，这严重限制了建筑安全生产中聚苯板的应用，聚苯乙烯泡沫保温板在我国市场上已经不再被欢迎，而是处于即将被淘汰的境地。酚醛、脲醛类泡沫材料虽然具有较高的耐热、阻燃性能等优点，但其存在结构不规整、吸水率高的缺点，特别是泡沫延伸率低、抗压强度低、脆性大、易掉粉等问题，限制了酚醛泡沫的应用。
发明内容
针对现有技术的不足，本发明提供了一种复合泡沫保温板的施工工艺，导热系数大幅度降低，力学性能和阻燃性能显著提高，降低生产成本和施工难度。
为实现以上目的，本发明通过以下技术方案予以实现：
一种复合泡沫保温板的施工工艺，包括以下步骤：
a)预处理施工：通过蒸汽锅炉对EPS珠粒进行预发泡，吹干后得到预发泡EPS颗粒料，25℃敞口熟化8-9h，将预发泡EPS颗粒料进行二次发泡，得到二次发泡EPS颗粒料；
b)生产施工：将酚醛树脂、脂肪酸聚氧乙烯酯、聚乙二醇和阻燃剂加入到容器中，25℃、200r/min搅拌3min，再加入正戊烷，搅拌均匀后继续加入固化剂搅拌均匀，再加入二次发泡EPS颗粒料，通过捏合机使混合物充分混合均匀，将捏合好的混合物倒入预热过的模具中，并快速转移至真空干燥箱中，75-85℃固化养护5-8h得到复合泡沫保温板，所述模具设有顶出柱，复合泡沫保温板具有与顶出柱相配合的辅助孔，向辅助孔中填充胶粘剂，并通过撕裂条连接胶粘剂；
c)现场施工：除去撕裂条，将填充胶粘剂的一面粘贴于外墙墙面上。
进一步的，所述预发泡蒸汽锅炉的蒸汽压强为0.5-0.6MPa，所述预发泡的温度为100-105℃。
进一步的，所述二次发泡的蒸汽压强和温度与预发泡一致。
进一步的，所述酚醛树脂、脂肪酸聚氧乙烯酯、聚乙二醇、阻燃剂、正戊烷、二次发泡EPS颗粒料、固化剂的质量比为35-38:4-6:5:10:10-16:40-45:20-22。
进一步的，所述酚醛树脂、脂肪酸聚氧乙烯酯、聚乙二醇、阻燃剂、正戊烷、二次发泡EPS颗粒料的质量比为35:5:5:10:16:40:22。
进一步的，所述阻燃剂选自氢氧化镁、氢氧化铝、磷酸三丁酯的一种，优选为氢氧化铝。
进一步的，所述固化剂选自对甲苯磺酸、盐酸、磷酸的一种或两种，优选为对甲苯磺酸和盐酸按照1:2的质量比混合。
由于采用上述的技术方案，本发明的有益效果如下：
本发明通过控制酚醛树脂、脂肪酸聚氧乙烯酯、聚乙二醇和阻燃剂的混合搅拌速度和搅拌时间从而控制酚醛树脂的粘度，获得良好的流动性，使酚醛树脂在发泡的过程中各成分混合均匀，泡孔结构均匀，降低发泡的难度。脂肪酸聚氧乙烯酯起到乳化剂和稳泡剂的作用，维持混合物的稳定性和均匀性，酚醛树脂发泡过程中，在大量反应热作用下正戊烷液滴气化，泡沫产生，已经形成的气泡在脂肪酸聚氧乙烯酯的促进作用下继续稳定长大，降低破碎、合并或者塌陷的频次；同时，脂肪酸聚氧乙烯酯还加快发泡反应的进程，缩短复合泡沫保温板固化成型的时间。
聚乙二醇分子中含有羟基，酚醛树脂中含有羟甲基，羟甲基与羟基产生化学反应，既生成接枝共聚物，也生成部分氢键，将部分柔性醚链导入树脂中，从而起到增韧的效果，同时加入阻燃剂，降低聚乙二醇对复合泡沫保温板阻燃性能的负面影响，发挥聚乙二醇的增韧优点，补偿、限制其负面作用。
本发明固化养护的温度控制混合物的粘度，更易于发泡剂的挥发和成型固化，酚醛树脂在固化交联过程会放出热量，与真空干燥箱中的热量共同作用于正戊烷，催进了正戊烷的挥发；并且固化反应的速度远远低于正戊烷的挥发速度，得到的保温板孔径分布均匀细腻，降低复合泡沫保温板表观密度，从而提高复合泡沫保温板的保温性能。与市售酚醛保温板相比，本发明的复合泡沫保温板的导热系数大幅度降低，力学性能和阻燃性能显著提高，降低生产成本和施工难度。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本发明实施例，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例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作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
一种复合泡沫保温板的施工工艺，包括以下步骤：
a)预处理施工：通过蒸汽锅炉对EPS珠粒进行预发泡，吹干后得到预发泡EPS颗粒料，25℃敞口熟化8h，将预发泡EPS颗粒料进行二次发泡，得到二次发泡EPS颗粒料，预发泡与二次发泡的蒸汽压强均为0.5MPa，温度均为105℃；
b)生产施工：将35份酚醛树脂、5份脂肪酸聚氧乙烯酯、5份聚乙二醇和10份氢氧化铝加入到容器中，25℃、200r/min搅拌3min，再加入16份正戊烷，搅拌均匀后继续加入22份固化剂搅拌均匀，固化剂由对甲苯磺酸和盐酸按照1:2的质量比混合而成，再加入40份二次发泡EPS颗粒料，通过捏合机使混合物充分混合均匀，将捏合好的混合物倒入预热过的模具中，并快速转移至真空干燥箱中，80℃固化养护8h得到复合泡沫保温板，模具设有顶出柱，复合泡沫保温板具有与顶出柱相配合的辅助孔，向辅助孔中填充聚氨酯胶粘剂，并通过撕裂条连接聚氨酯胶粘剂；
c)现场施工：除去撕裂条，将填充胶粘剂的一面粘贴于外墙墙面上。
实施例2
一种复合泡沫保温板的施工工艺，包括以下步骤：
a)预处理施工：通过蒸汽锅炉对EPS珠粒进行预发泡，吹干后得到预发泡EPS颗粒料，25℃敞口熟化8h，将预发泡EPS颗粒料进行二次发泡，得到二次发泡EPS颗粒料，预发泡与二次发泡的蒸汽压强均为0.6MPa，温度均为100℃；
b)生产施工：将35份酚醛树脂、4份脂肪酸聚氧乙烯酯、5份聚乙二醇和10份氢氧化铝加入到容器中，25℃、200r/min搅拌3min，再加入10份正戊烷，搅拌均匀后继续加入20份对甲苯磺酸搅拌均匀，再加入40份二次发泡EPS颗粒料，通过捏合机使混合物充分混合均匀，将捏合好的混合物倒入预热过的模具中，并快速转移至真空干燥箱中，85℃固化养护8h得到复合泡沫保温板，模具设有顶出柱，复合泡沫保温板具有与顶出柱相配合的辅助孔，向辅助孔中填充聚氨酯胶粘剂，并通过撕裂条连接聚氨酯胶粘剂；
c)现场施工：除去撕裂条，将填充胶粘剂的一面粘贴于外墙墙面上。
实施例3
一种复合泡沫保温板的施工工艺，包括以下步骤：
a)预处理施工：通过蒸汽锅炉对EPS珠粒进行预发泡，吹干后得到预发泡EPS颗粒料，25℃敞口熟化9h，将预发泡EPS颗粒料进行二次发泡，得到二次发泡EPS颗粒料，预发泡与二次发泡的蒸汽压强均为0.6MPa，温度均为105℃；
b)生产施工：将38份酚醛树脂、6份脂肪酸聚氧乙烯酯、5份聚乙二醇和10份氢氧化铝加入到容器中，25℃、200r/min搅拌3min，再加入16份正戊烷，搅拌均匀后继续加入22固化剂搅拌均匀，固化剂由对甲苯磺酸和盐酸按照1:2的质量比混合而成，再加入45份二次发泡EPS颗粒料，通过捏合机使混合物充分混合均匀，将捏合好的混合物倒入预热过的模具中，并快速转移至真空干燥箱中，75℃固化养护6h得到复合泡沫保温板，模具设有顶出柱，复合泡沫保温板具有与顶出柱相配合的辅助孔，向辅助孔中填充聚氨酯胶粘剂，并通过撕裂条连接聚氨酯胶粘剂；
c)现场施工：除去撕裂条，将填充胶粘剂的一面粘贴于外墙墙面上。
选取2种市售酚醛树脂保温板作为对照，对照保温板与实施例1-3的复合泡沫保温板制成相同的尺寸，进行性能测试，结果如表1所示：
表1 各保温板的性能参数
以上实施例仅用以说明本发明的技术方案，而非对其限制；尽管参照前述实施例对本发明进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本发明各实施例技术方案的精神和范围。
Claims (7)
1.一种复合泡沫保温板的施工工艺，其特征在于，包括以下步骤：
a)预处理施工：通过蒸汽锅炉对EPS珠粒进行预发泡，吹干后得到预发泡EPS颗粒料，25℃敞口熟化8-9h，将预发泡EPS颗粒料进行二次发泡，得到二次发泡EPS颗粒料；
b)生产施工：将酚醛树脂、脂肪酸聚氧乙烯酯、聚乙二醇和阻燃剂加入到容器中，25℃、200r/min搅拌3min，再加入正戊烷，搅拌均匀后继续加入固化剂搅拌均匀，再加入二次发泡EPS颗粒料，通过捏合机使混合物充分混合均匀，将捏合好的混合物倒入预热过的模具中，并快速转移至真空干燥箱中，75-85℃固化养护5-8h得到复合泡沫保温板，所述模具设有顶出柱，复合泡沫保温板具有与顶出柱相配合的辅助孔，向辅助孔中填充胶粘剂，并通过撕裂条连接胶粘剂；
c)现场施工：除去撕裂条，将填充胶粘剂的一面粘贴于外墙墙面上。
2.根据权利要求1所述的复合泡沫保温板的施工工艺，其特征在于，所述预发泡蒸汽锅炉的蒸汽压强为0.5-0.6MPa，所述预发泡的温度为100-105℃。
3.根据权利要求1所述的复合泡沫保温板的施工工艺，其特征在于，所述二次发泡的蒸汽压强和温度与预发泡一致。
4.根据权利要求1所述的复合泡沫保温板的施工工艺，其特征在于，所述酚醛树脂、脂肪酸聚氧乙烯酯、聚乙二醇、阻燃剂、正戊烷、二次发泡EPS颗粒料、固化剂的质量比为35-38:4-6:5:10:10-16:40-45：20-22。
5.根据权利要求4所述的复合泡沫保温板的施工工艺，其特征在于，所述酚醛树脂、脂肪酸聚氧乙烯酯、聚乙二醇、阻燃剂、正戊烷、二次发泡EPS颗粒料、固化剂的质量比为35:5:5:10:16:40:22。
6.根据权利要求1所述的复合泡沫保温板的施工工艺，其特征在于，所述阻燃剂选自氢氧化镁、氢氧化铝、磷酸三丁酯的一种，优选为氢氧化铝。
7.根据权利要求1所述的复合泡沫保温板的施工工艺，其特征在于，所述固化剂选自对甲苯磺酸、盐酸、磷酸的一种或两种，优选为对甲苯磺酸和盐酸按照1:2的质量比混合。
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