CN111231484B - 一种聚氨酯复合深冷保温板及其制备方法 - Google Patents
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Abstract
本发明公开了一种聚氨酯复合深冷保温板的制备方法,应用于LNG的存储和运输领域,它由玻纤增强型聚氨酯泡沫板,胶合板,增强型环氧树脂和双组分聚氨酯胶粘剂复合而成。本发明在复合工艺中使用了高密度的胶合板作为上下面板,复合后的板材的表面强度得到大幅提高,可以确保板材在运输和安装过程不易损坏,且可以承受LNG在运输过程中的冲击晃荡。同时,本发明在复合工艺中使用了玻纤增强型环氧树脂,该树脂可以有效防止因聚氨酯泡沫板在低温下开裂导致的LNG的泄漏,确保LNG的运输及存贮安全。
Description
技术领域
本发明涉及一种深冷保温板,特别是一种LNG的存储和运输领域用聚氨酯复合深冷保温板的制备方法。
背景技术
液化天然气是公认的最清洁能源,随着我国对环境保护的日益重视,对液化天然气的需求正日益剧增。液化天然气的存贮和运输需要用到在超低温环境下保持高绝热性、高强度及高稳定性的保温材料。
普通的聚氨酯材料具有绝佳的保温性能,然而它在超低温下会发生严重收缩无法保持其在常温下的力学强度。通常可以采用与廉价的玻纤进行复合来增强聚氨酯材料在低温下的力学性能和尺寸稳定性,并通过加入一定的阻燃剂来提高聚氨酯的阻燃等级。
专利2016100894643(公开号CN107090074A)公开了一种以连续玻纤毡为增强材料的高阻燃型玻纤增强硬质聚氨酯超低温保温材料及其制法;专利2016100963709(公开号CN107099018A)公开了一种环保型发泡剂生产的耐超低温无卤阻燃玻纤增强型硬质聚氨酯保温材料及其制备方法,两篇专利仅描述了增强型聚氨酯材料的制备方法,而并未考虑到实际应用过程中聚氨酯泡沫本身存在强度不高,易破损,安装不便捷,且无法承受LNG在海上运输过程中的急剧晃荡冲击等问题。此外,没有任何相关专利考虑到在超低温环境下聚氨酯泡沫开裂可能导致运输的液化天然气泄漏的风险。
发明内容
发明目的:本发明的目的在于解决现有增强型聚氨酯泡沫存在的强度不高,运输及安装过程易破损,易受潮受污染,无法承受LNG在海上运输过程中的急剧晃荡冲击,且未考虑到在超低温环境下聚氨酯泡沫开裂可能导致运输的液化天然气泄漏的风险问题。
技术方案:为实现上述目的,本发明采用的技术方案为:
一种聚氨酯复合深冷保温板的制备方法,包括以下步骤:
1)利用自动淋胶机将双组分聚氨酯胶粘剂均匀淋洒在已经放置在不锈钢模具底部的第一层胶合板的上表面并通过辊道输送至装配区;
2)将双组分聚氨酯胶粘剂均匀淋洒在第一层玻纤增强型聚氨酯泡沫板的上表面,并将其码垛至第一层胶合板上表面;
3)将双组分聚氨酯胶粘剂均匀淋洒在增强型环氧树脂的上表面,并将其码垛在第一层玻纤增强型聚氨酯泡沫板上表面;
4)将双组分聚氨酯胶粘剂均匀淋洒在第二层玻纤增强型聚氨酯泡沫板的上表面,并将其码垛在增强型环氧树脂上;
5)将第二层胶合板覆盖在上部玻纤增强型聚氨酯泡沫板上,而后将板材输送入压机进行压合;
6)将压合完毕的聚氨酯复合深冷保温板送入数控机床根据图纸进行机加工,最后经除尘后打包。
进一步地,聚氨酯复合深冷保温板从下至上依次由第一层胶合板,第一层玻纤增强型聚氨酯泡沫板,增强型环氧树脂,第二层玻纤增强型聚氨酯泡沫板,第二层胶合板这五层材料通过双组分聚氨酯胶粘剂复合而成。
进一步地,所述胶合板的密度在500~1000kg/m3,长度在1m~4m,宽度在0.5~1.5m,厚度在5mm~20mm。
进一步地,所述玻纤增强型聚氨酯硬泡的密度在50~250kg/m3,长度在1m~4m,宽度在0.5~1.5m,厚度在50mm~400mm。
进一步地,所述增强型环氧树脂的表观密度为0.5~2kg/m2,长度在1m~4m,宽度在 0.5~1.5m,厚度在0.5mm~2mm。
进一步地,所述双组分聚氨酯胶粘剂中的树脂组分的粘度在10000~30000mPa·S,密度在1.2~1.7g/cm3;固化剂组分的粘度在150~300mPa·S,异氰酸酯含量在25~35%,胶粘剂开放时间在1~3小时。
进一步地,双组分聚氨酯胶粘剂的树脂与固化剂组分的比例为3.5~4.5:1,胶粘剂的涂胶量在250~600g/m2,出胶温度在20~30℃,每道胶水的间隙控制在2~6mm。
进一步地,压合压力为0.5~2bar,压合温度控制在15~35℃,压合时间为4~10小时。
有益效果:本发明与现有技术相比:
本发明提供的聚氨酯复合深冷保温板,极大改善了聚氨酯保温材料的表面强度,确保保温材料在运输安装过程中不易破损,并可以极大提高保温材料的抗冲击性能,同时在复合板材中增加了玻纤增强型环氧树脂,该树脂可以有效防止因聚氨酯泡沫板在低温下开裂导致的LNG的泄漏,确保LNG在运输过程中的安全性。
另,本发明采用的制备工艺中,增加了双组分聚氨酯胶粘剂作为粘连剂,相对于现有的通过发泡的方式使得组分间结合,时间更短,但是如果仅采用粘连剂,可能结合不紧密,故需要压合的配合,而如果仅采用一次压合,会由于过多层数导致输送过程中可能存在倾倒的情况,故先将第一层胶合板、第一层玻纤增强型聚氨酯泡沫板和增强型环氧树脂进行一次压合成为组合体,再将第二层胶合板、第二层玻纤增强型聚氨酯泡沫板和组合体进行二次压合成为成品,通过两次压合使得在结合紧密的同时,省却了发泡所消耗的大量时间,提高了生产效率。
附图说明
图1为本发明进行压合的制备工艺流程图。
具体实施方式
下面结合实施例和附图对本发明进行进一步地描述。
实施例1
本实施例中的聚氨酯复合深冷保温板由以下材料制备而成:两块1000kg/m3密度的胶合板,长度为4m,宽度为1.5m,厚度为20mm;两块250kg/m3密度的增强型聚氨酯泡沫板,长度为4m,宽度为1.5m,厚度为400mm;脂表观密度为2kg/m2的增强型环氧树脂的,长度在4m,宽度在1.5m,厚度在2mm。
本实施例中的聚氨酯复合深冷保温板采用以下复合工艺:
1)利用自动淋胶机将双组分聚氨酯胶粘剂均匀淋洒在已经放置在不锈钢模具底部的第一层胶合板的上表面并通过辊道输送至装配区;
2)将双组分聚氨酯胶粘剂均匀淋洒在第一层玻纤增强型聚氨酯泡沫板的上表面,并将其码垛至第一层胶合板上表面;
3)将双组分聚氨酯胶粘剂均匀淋洒在增强型环氧树脂的上表面,并将其码垛在第一层玻纤增强型聚氨酯泡沫板上表面;
4)将双组分聚氨酯胶粘剂均匀淋洒在第二层玻纤增强型聚氨酯泡沫板的上表面,并将其码垛在增强型环氧树脂上;
5)将第二层胶合板覆盖在上部玻纤增强型聚氨酯泡沫板上,而后将板材输送入压机进行压合;
6)将压合完毕的聚氨酯复合深冷保温板送入数控机床根据图纸进行机加工,最后经除尘后打包。
双组分聚氨酯胶粘剂中的树脂组分的粘度在30000mPa·S,密度在1.7g/cm3;固化剂组分的粘度在300mPa·S,异氰酸酯含量在35%,胶粘剂开放时间在3小时。
胶粘剂树脂与固化剂组分的比例为4.5:1,胶粘剂的涂胶量在600g/m2,出胶温度在 30℃,每道胶水的间隙控制在6mm。压合压力为2bar,压合温度控制在35℃,压合时间为4小时。
实施例2
本实施例中的聚氨酯复合深冷保温板由以下材料制备而成:1块500kg/m3密度的胶合板,长度为1m,宽度为0.5m,厚度为5mm;1块900kg/m3密度的胶合板,长度为1m,宽度为0.5m,厚度为15mm;两块50kg/m3密度的增强型聚氨酯泡沫板,长度为1m,宽度为0.5m,厚度为50mm;表观密度为0.5kg/m2的增强型环氧树脂的,长度为1m,宽度为0.5m,厚度在0.5mm。
本实施例中的聚氨酯复合深冷保温板采用以下复合工艺:
1)利用自动淋胶机将双组分聚氨酯胶粘剂均匀淋洒在已经放置在不锈钢模具底部的第一层胶合板的上表面并通过辊道输送至装配区;
2)将双组分聚氨酯胶粘剂均匀淋洒在第一层玻纤增强型聚氨酯泡沫板的上表面,并将其码垛至第一层胶合板上表面;
3)将双组分聚氨酯胶粘剂均匀淋洒在增强型环氧树脂的上表面,并将其码垛在第一层玻纤增强型聚氨酯泡沫板上表面;
4)将双组分聚氨酯胶粘剂均匀淋洒在第二层玻纤增强型聚氨酯泡沫板的上表面,并将其码垛在增强型环氧树脂上;
5)将第二层胶合板覆盖在上部玻纤增强型聚氨酯泡沫板上,而后将板材输送入压机进行压合;
6)将压合完毕的聚氨酯复合深冷保温板送入数控机床根据图纸进行机加工,最后经除尘后打包。
胶粘剂树脂与固化剂组分的比例为3.5:1,胶粘剂的涂胶量在250g/m2,出胶温度在 20℃,每道胶水的间隙控制在2mm。压合压力为0.5bar,压合温度控制在15℃,压合时间为10小时。
实施例3
本实施例中的聚氨酯复合深冷保温板由以下材料制备而成:1块800密度的胶合板,长度为2.5m,宽度为1.3m,厚度为10mm;1块700密度的胶合板,长度为2.5m,宽度为1.3m,厚度为14mm;两块170密度的增强型聚氨酯泡沫板,长度为2.5m,宽度为1.3m,厚度为350mm;表观密度为1kg/m2的增强型环氧树脂的,长度为2.5m,宽度为1.3m,厚度在0.7mm。
本实施例中的聚氨酯复合深冷保温板采用以下复合工艺:
1)利用自动淋胶机将双组分聚氨酯胶粘剂均匀淋洒在已经放置在不锈钢模具底部的第一层胶合板的上表面并通过辊道输送至装配区;
2)将双组分聚氨酯胶粘剂均匀淋洒在第一层玻纤增强型聚氨酯泡沫板的上表面,并将其码垛至第一层胶合板上表面;
3)将双组分聚氨酯胶粘剂均匀淋洒在增强型环氧树脂的上表面,并将其码垛在第一层玻纤增强型聚氨酯泡沫板上表面;
4)将双组分聚氨酯胶粘剂均匀淋洒在第二层玻纤增强型聚氨酯泡沫板的上表面,并将其码垛在增强型环氧树脂上;
5)将第二层胶合板覆盖在上部玻纤增强型聚氨酯泡沫板上,而后将板材输送入压机进行压合;
6)将压合完毕的聚氨酯复合深冷保温板送入数控机床根据图纸进行机加工,最后经除尘后打包。
胶粘剂树脂与固化剂组分的比例为4.1:1,胶粘剂的涂胶量在480g/m2,出胶温度在 28℃,每道胶水的间隙控制在4mm。压合压力为1.2bar,压合温度控制在28℃,压合时间为6小时。
实施例4
本实施例中的聚氨酯复合深冷保温板由以下材料制备而成:1块750密度的胶合板,长度为3m,宽度为1m,厚度为9mm;1块850密度的胶合板,长度为3m,宽度为1m,厚度为12mm;1块70密度的增强型聚氨酯泡沫板,长度为3m,宽度为1m,厚度为100mm; 1块130密度的增强型聚氨酯泡沫板,长度为3m,宽度为1m,厚度为300mm;表观密度为1.1kg/m2的增强型环氧树脂的,长度为3m,宽度为1m,厚度在0.8mm。
本实施例中的聚氨酯复合深冷保温板采用以下复合工艺:
1)利用自动淋胶机将双组分聚氨酯胶粘剂均匀淋洒在已经放置在不锈钢模具底部的第一层胶合板的上表面并通过辊道输送至装配区;
2)将双组分聚氨酯胶粘剂均匀淋洒在第一层玻纤增强型聚氨酯泡沫板的上表面,并将其码垛至第一层胶合板上表面;
3)将双组分聚氨酯胶粘剂均匀淋洒在增强型环氧树脂的上表面,并将其码垛在第一层玻纤增强型聚氨酯泡沫板上表面;
4)将双组分聚氨酯胶粘剂均匀淋洒在第二层玻纤增强型聚氨酯泡沫板的上表面,并将其码垛在增强型环氧树脂上;
5)将第二层胶合板覆盖在上部玻纤增强型聚氨酯泡沫板上,而后将板材输送入压机进行压合;
6)将压合完毕的聚氨酯复合深冷保温板送入数控机床根据图纸进行机加工,最后经除尘后打包。
胶粘剂树脂与固化剂组分的比例为4.2:1,胶粘剂的涂胶量在500g/m2,出胶温度在 25℃,每道胶水的间隙控制在5mm。压合压力为1.0bar,压合温度控制在25℃,压合时间为5小时。
实施例5
本实施例中的聚氨酯复合深冷保温板由以下材料制备而成:1块700密度的胶合板,长度为3m,宽度为1m,厚度为9mm;1块800密度的胶合板,长度为2.5m,宽度为0.8m,厚度为15mm;1块90密度的增强型聚氨酯泡沫板,长度为3m,宽度为1m,厚度为300mm; 1块130密度的增强型聚氨酯泡沫板,长度为2.5m,宽度为0.8m,厚度为100mm;表观密度为1kg/m2的增强型环氧树脂的,长度为3m,宽度为1m,厚度在0.6mm。
本实施例中的聚氨酯复合深冷保温板采用以下复合工艺:
1)利用自动淋胶机将双组分聚氨酯胶粘剂均匀淋洒在已经放置在不锈钢模具底部的第一层胶合板的上表面并通过辊道输送至装配区;
2)将双组分聚氨酯胶粘剂均匀淋洒在第一层玻纤增强型聚氨酯泡沫板的上表面,并将其码垛至第一层胶合板上表面;
3)将双组分聚氨酯胶粘剂均匀淋洒在增强型环氧树脂的上表面,并将其码垛在第一层玻纤增强型聚氨酯泡沫板上表面;
4)将双组分聚氨酯胶粘剂均匀淋洒在第二层玻纤增强型聚氨酯泡沫板的上表面,并将其码垛在增强型环氧树脂上;
5)将第二层胶合板覆盖在上部玻纤增强型聚氨酯泡沫板上,而后将板材输送入压机进行压合;
6)将压合完毕的聚氨酯复合深冷保温板送入数控机床根据图纸进行机加工,最后经除尘后打包。
压合分两次进行,先将长度为3m,宽度为1m,厚度为9mm的密度700的胶合板与长度为3m,宽度为1m,厚度为300mm的90密度的增强型聚氨酯泡沫板及长度为3m,宽度为1m,厚度在0.6mm的1kg/m2的增强型环氧树脂进行一次压合做成组合体,而后将长度为2.5m,宽度为0.8m,厚度为15mm的800密度的胶合板及长度为2.5m,宽度为0.8m,厚度为100mm的130密度的增强型聚氨酯泡沫板与组合体再次进行压合。其中胶粘剂树脂与固化剂组分的比例为4.0:1,胶粘剂的涂胶量在4200g/m2,出胶温度在25℃,每道胶水的间隙控制在4mm。压合压力为1.0bar,压合温度控制在25℃,压合时间为8 小时。
Claims (1)
1.一种聚氨酯复合深冷保温板的制备方法,其特征在于,包括以下步骤:
1)利用自动淋胶机将双组分聚氨酯胶粘剂均匀淋洒在已经放置在不锈钢模具底部的第一层胶合板的上表面并通过辊道输送至装配区;
2)将双组分聚氨酯胶粘剂均匀淋洒在第一层玻纤增强型聚氨酯泡沫板的上表面,并将其码垛至第一层胶合板上表面;
3)将双组分聚氨酯胶粘剂均匀淋洒在增强型环氧树脂的上表面,并将其码垛在第一层玻纤增强型聚氨酯泡沫板上表面;
4)将双组分聚氨酯胶粘剂均匀淋洒在第二层玻纤增强型聚氨酯泡沫板的上表面,并将其码垛在增强型环氧树脂上;
5)将第二层胶合板覆盖在上部玻纤增强型聚氨酯泡沫板上,而后将板材输送入压机进行压合;
6)将压合完毕的聚氨酯复合深冷保温板送入数控机床根据图纸进行机加工,最后经除尘后打包;
双组分聚氨酯胶粘剂中,胶粘剂树脂与固化剂组分的比例为4.0:1,胶粘剂的出胶温度在25℃,每道胶水的间隙控制在4mm;
压合分两次进行,先将长度为3m,宽度为1m,厚度为9mm的密度700kg/m3的胶合板与长度为3m,宽度为1m,厚度为300mm的90kg/m3密度的增强型聚氨酯泡沫板及长度为3m,宽度为1m,厚度在0.6mm的表观密度1kg/m2的增强型环氧树脂进行一次压合做成组合体,而后将长度为2.5m,宽度为0.8m,厚度为15mm的800kg/m3密度的胶合板及长度为2.5m,宽度为0.8m,厚度为100mm的130kg/m3密度的增强型聚氨酯泡沫板与组合体再次进行压合;压合压力为1.0bar,压合温度控制在25℃,压合时间为8小时。
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