CN111269522A - 一种轻质玻璃钢墙板预浸料及其制造方法 - Google Patents
一种轻质玻璃钢墙板预浸料及其制造方法 Download PDFInfo
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Abstract
本发明公开了一种轻质玻璃钢墙板预浸料,由包括复合麻纤维毡、发泡树脂糊的原料制成,复合麻纤维毡、发泡树脂糊的质量比为(15~30)∶(70~85),发泡树脂糊由包括不饱和聚酯树脂、饱和树脂、低收缩剂、固化剂、脱膜剂、发泡剂、填充剂、阻燃剂、增稠剂、稀释剂的原料制成;通过称量、发泡树脂糊混合、设定浸渍参数、恒温浸渍、验证浸渍料克重、牵伸薄膜包腹、裁切、集包装、增稠烘房、入库等步骤制造而成。本发明的优点是:通过发泡技术制造的预渍料,可制得轻质、增强、阻燃、环保的玻璃钢墙板;也适用于制造轨道交通、汽车、舰船、建筑墙板等内饰;制造方法可行,成本低。
Description
技术领域
本发明涉及一种高分子复合发泡材料,特别是一种轻质玻璃钢墙板预浸料及其制造方法。
背景技术
目前,国内市场房屋内墙板没有规定的标准板材,都是采用下列板材,如石膏板、三聚氰胺装饰板、PVC板、玻镁板、铝板等,其中:石膏板密度大(密度3.1~4.3g/cm3),配方单一,易变色、脆性易碎、安装复杂,因此目前很少采用;三聚氰胺装饰板比较薄(厚度1~1.5mm),贴在木板后可用作墙板,这样密度大、成本又高,一般都用来贴合家俱;PVC板密度大(1.2g/cm3),加热易分解出有毒氯化氢气体,不环保、易变色、抗氧化性能差、不防潮、不防水等;玻镁板密度大(密度1.8g/cm3),存在易碎等缺点;铝板存在着不抗菌、导热系数高、不节能、凝结水露等一系列缺陷。这些墙板都存在密度大,不是轻质的缺点。
高分子复合材料装饰板及制作工艺(国别:中国,公开号:103146167A,公开日期:2013-06-12)公开了用玻璃纤维、不饱和聚酯树脂为基料,采用预浸工艺制成团料,但该工艺只能制得密度大(1.8g/cm3左右)的板材。
发明内容
发明目的:针对上述问题,本发明的目的是提供一种轻质玻璃钢墙板预浸料,以制得轻质玻璃钢墙板产品,同时提供这种预浸料的制造方法。
技术方案:一种轻质玻璃钢墙板预浸料,由包括复合麻纤维毡、发泡树脂糊的原料制成,所述复合麻纤维毡、发泡树脂糊的质量比为(15~30)∶(70~85),所述发泡树脂糊由包括不饱和聚酯树脂、饱和树脂、低收缩剂、固化剂、脱膜剂、发泡剂、填充剂、阻燃剂、增稠剂、稀释剂的原料制成,以所述不饱和聚酯树脂质量为100%计,所述饱和树脂为30~50%、所述低收缩剂为20~60%、所述固化剂为1~2.5%、所述脱膜剂为1~5%、所述发泡剂为3~9%、所述填充剂为150~200%、所述阻燃剂为10~100%、所述增稠剂为0.8~1.3%、所述稀释剂为5~20%。
进一步的,所述复合麻纤维毡包含按质量比(70~80)∶(20~30)配比的麻纤维和丙纶纤维。
最佳的,所述复合麻纤维毡的规格为200~600g/m2。
进一步的,所述不饱和聚酯树脂的粘度为1300~1600Pa·s;所述饱和树脂的粘度为200~500Pa·s;所述低收缩剂为聚丙烯粉、聚乙烯醇粉、质量浓度40%的苯乙烯糊的其中一种或至少两种混合;所述固化剂为过氧化苯甲酸叔丁酯、过氧化甲乙酮、过氧化苯甲酰、异丁酸叔丁酯的其中一种或至少两种混合;所述脱膜剂为硬酯酸锌;所述发泡剂为具有壳体结构的热塑性膨胀微珠发泡剂、柠檬酸、碳酸氢钠的其中一种或至少两种混合;所述填充剂为碳酸钙、硅铝微珠、滑石粉的其中一种或至少两种混合;所述阻燃剂为氢氧化铝、甲基膦酸二甲酯、聚磷酸铵、三聚氰胺、氰尿酸盐的其中一种或至少两种混合;所述增稠剂为氧化镁、氢氧化钙、二异氰酸酯的其中一种或至少两种混合;所述稀释剂为苯乙烯。
最佳的,所述微珠发泡剂选用开始温度100~110℃,最高温度150~160℃。
一种上述的轻质玻璃钢墙板预浸料的制造方法,包括以下步骤:
步骤一,称量:按照配方称取各原料;
步骤二,发泡树脂糊混合:将除增稠剂外的发泡树脂糊原料,全部倒入高剪切型分散机中搅拌混合10~15min,然后加入增稠剂再搅拌混合5~10min,制得发泡树脂糊;
步骤三,设定浸渍参数、恒温浸渍:设定浸渍槽的浸渍液温度20~30℃、牵伸速度1~9m/min;将制得的发泡树脂糊倒入浸渍槽中,将复合麻纤维毡引入浸渍槽,沉降在前后两旋转辊压辊下进行浸渍;
步骤四,验证浸渍料克重:将浸渍后的复合麻纤维毡引向浸渍槽后,一边通过浸渍槽后的第一对旋转辊筒将浸渍料往前推进与完成粗调克重,并通过浸渍槽后的第二对旋转辊筒调节辊距,完成细调克重,再裁剪样品验证预浸料片材是否为符合设定克重;
步骤五,牵伸薄膜包腹:将验证合格的预浸料片材一边推进一边由上下开卷薄膜包装;
步骤六,裁切:将经过薄膜包腹的预浸料片材,进入裁切机根据产品规格尺寸裁切成预浸料片,裁切速度与浸渍牵伸速度同步相匹配;
步骤七,集包装、增稠烘房、入库:将裁切后的预浸料片,送到平台若干片叠合后,用镀铝塑料薄膜集包装密封后,送烘房增稠,然后进仓入库,待热压固化。
最佳的,步骤七中,增稠温度为30~60℃,增稠时间为20~30h。
本发明的原理:一是利用发泡技术制造预浸料,进而实现玻璃钢墙板轻量化;二是采用复合麻纤维毡浸渍含不饱和聚酯的发泡树脂糊的技术进行发泡,实现复合麻纤维毡增强环保轻质玻璃钢墙板;三是阻燃剂可选择加入氢氧化铝,既能达到阻燃目的,同时也可以作为填料降低成本。
有益效果:与现有技术相比,本发明的优点是:通过发泡技术制造的预渍料,可制得轻质、增强、阻燃、环保的玻璃钢墙板;也适用于制造轨道交通、汽车、舰船、建筑墙板等内饰;制造方法可行,成本低。
附图说明
图1为预浸料制造设备结构示意图。
具体实施方式
下面结合附图和具体实施例,进一步阐明本发明。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。
实施例1
一种轻质玻璃钢墙板预浸料,所需制得的规格为2500g/m2。该预浸料由原料复合麻纤维毡、发泡树脂糊按质量比20∶80制成。
复合麻纤维毡的规格为420g/m2,包含按质量比(70~80)∶(20~30)配比的麻纤维和丙纶纤维。
发泡树脂糊由原料不饱和聚酯树脂、饱和树脂、低收缩剂、固化剂、脱膜剂、发泡剂、填充剂、阻燃剂、增稠剂、稀释剂制成。不饱和聚酯树脂的粘度为1500Pa·s,以不饱和聚酯树脂质量为100%计:饱和树脂为45%,粘度为300Pa·s;低收缩剂为40%,选用聚丙烯粉;固化剂为1%,选用过氧化苯甲酸叔丁酯;脱膜剂为5%,选用硬酯酸锌;发泡剂为4%,选用具有壳体结构的热塑性膨胀微珠发泡剂,壳体为甲基丙烯酸甲酯、丙烯腈的均聚物或共聚物,微珠发泡剂可以选用日本松本、韩国东进、瑞典阿克苏、国产上海西能、福建浩博锦浪等生产的,选用开始温度100~110℃,最高温度150~160℃;填充剂为150%,选用碳酸钙70%和硅铝微珠80%;阻燃剂为83%,选用氢氧化铝70%、聚磷酸铵8%、三聚氰胺5%;增稠剂为1.0%,选用氧化镁;稀释剂为20%,选用苯乙烯。
上述的轻质玻璃钢墙板预浸料的制造方法,结合附图1所示,具体包括以下步骤:
步骤一,称量:按照配方称取各原料;
步骤二,发泡树脂糊混合:将除增稠剂外的发泡树脂糊原料,全部倒入高剪切型分散机中搅拌混合10min,然后加入增稠剂再搅拌混合5min,制得发泡树脂糊;
步骤三,设定浸渍参数、恒温浸渍:设定浸渍槽2的浸渍液温度30℃、牵伸速度4m/min;将制得的发泡树脂糊倒入浸渍槽中,将复合麻纤维毡1引入浸渍槽,沉降在前后两旋转辊压辊3、4下进行浸渍;
步骤四,验证浸渍料克重:将浸渍后的复合麻纤维毡引向浸渍槽后,一边通过浸渍槽后的第一对旋转辊筒5将浸渍料往前推进与完成粗调克重,并通过浸渍槽后的第二对旋转辊筒6调节辊距,完成细调克重,再裁剪样品验证预浸料片材是否为符合设定克重;
步骤五,牵伸薄膜包腹:将验证合格的预浸料片材一边推进一边由上下开卷聚乙烯薄膜7、8包装;
步骤六,裁切:将经过薄膜包腹的预浸料片材,进入裁切机9根据产品规格尺寸通过光电定长控制10后裁切成预浸料片,裁切速度与浸渍牵伸速度同步相匹配;
步骤七,集包装、增稠烘房、入库:将裁切后的预浸料片,送到平台11若干片叠合后,用镀铝塑料薄膜集包装密封后,送烘房增稠,增稠温度为30~60℃,增稠时间为20~30h,然后进仓入库,待热压固化。
将本实施例制得的规格为2500g/m2的预浸料,再从储存到热压成轻质玻璃钢墙板,合计损耗10%,用来制成5mm厚玻璃钢墙板,密度为0.45g/cm3。
实施例2-6与实施例1基本相同,仅对其中相关制造参数进行调节,制得不同规格预浸料,在所制墙板厚度5mm不变情况下,比较制得的墙板密度,列为下表:
可见本申请预浸料可制得轻质玻璃钢墙板。
实施例7
一种轻质玻璃钢墙板预浸料,所需制得的规格为3100g/m2。该预浸料由原料复合麻纤维毡、发泡树脂糊按质量比30∶70制成。
复合麻纤维毡的规格为600g/m2,包含按质量比(70~80)∶(20~30)配比的麻纤维和丙纶纤维。
发泡树脂糊由原料不饱和聚酯树脂、饱和树脂、低收缩剂、固化剂、脱膜剂、发泡剂、填充剂、阻燃剂、增稠剂、稀释剂制成。不饱和聚酯树脂的粘度为1300Pa·s,以不饱和聚酯树脂质量为100%计:饱和树脂为40%,粘度为220Pa·s;低收缩剂为25%,选用聚丙烯粉15%和聚乙烯醇粉10%;固化剂为2.5%,选用过氧化苯甲酰;脱膜剂为1%,选用硬酯酸锌;发泡剂为6%,选用具有壳体结构的热塑性膨胀微珠发泡剂3%、碳酸氢钠3%,微珠发泡剂选用开始温度100~110℃,最高温度150~160℃;填充剂为200%,选用碳酸钙80%和滑石粉120%;阻燃剂为20%,选用甲基膦酸二甲酯;增稠剂为0.8%,选用氢氧化钙;稀释剂为10%,选用苯乙烯。
制造方法与实施例1相同。将本实施例制得的规格为3100g/m2的预浸料,再从储存到热压成轻质玻璃钢墙板,合计损耗10%,用来制成5mm厚玻璃钢墙板,密度为0.56g/cm3。
实施例8
一种轻质玻璃钢墙板预浸料,所需制得的规格为3200g/m2。该预浸料由原料复合麻纤维毡、发泡树脂糊按质量比15∶85制成。
复合麻纤维毡的规格为220g/m2,包含按质量比(70~80)∶(20~30)配比的麻纤维和丙纶纤维。
发泡树脂糊由原料不饱和聚酯树脂、饱和树脂、低收缩剂、固化剂、脱膜剂、发泡剂、填充剂、阻燃剂、增稠剂、稀释剂制成。不饱和聚酯树脂的粘度为1600Pa·s,以不饱和聚酯树脂质量为100%计:饱和树脂为30%,粘度为500Pa·s;低收缩剂为60%,选用质量浓度40%的苯乙烯糊(即苯乙烯糊中含质量浓度40%的聚苯乙烯);固化剂为1.2%,选用过氧化苯甲酸叔丁酯0.4%和过氧化苯甲酰0.8%;脱膜剂为3%,选用硬酯酸锌;发泡剂为9%,选用具有壳体结构的热塑性膨胀微珠发泡剂3%、柠檬酸3%、碳酸氢钠3%,微珠发泡剂选用开始温度100~110℃,最高温度150~160℃;填充剂为160%,选用碳酸钙50%、硅铝微珠80%、滑石粉30%;阻燃剂为20%,选用氢氧化铝10%和聚磷酸铵10%;增稠剂为1.3%,选用氧化镁0.5%、二异氰酸酯0.8%;稀释剂为5%,选用苯乙烯。
制造方法与实施例1相同。将本实施例制得的规格为3200g/m2的预浸料,再从储存到热压成轻质玻璃钢墙板,合计损耗10%,用来制成5mm厚玻璃钢墙板,密度为0.58g/cm3。
Claims (7)
1.一种轻质玻璃钢墙板预浸料,其特征在于:由包括复合麻纤维毡、发泡树脂糊的原料制成,所述复合麻纤维毡、发泡树脂糊的质量比为(15~30)∶(70~85),所述发泡树脂糊由包括不饱和聚酯树脂、饱和树脂、低收缩剂、固化剂、脱膜剂、发泡剂、填充剂、阻燃剂、增稠剂、稀释剂的原料制成,以所述不饱和聚酯树脂质量为100%计,所述饱和树脂为30~50%、所述低收缩剂为20~60%、所述固化剂为1~2.5%、所述脱膜剂为1~5%、所述发泡剂为3~9%、所述填充剂为150~200%、所述阻燃剂为10~100%、所述增稠剂为0.8~1.3%、所述稀释剂为5~20%。
2.根据权利要求1所述的一种轻质玻璃钢墙板预浸料,其特征在于:所述复合麻纤维毡包含按质量比(70~80)∶(20~30)配比的麻纤维和丙纶纤维。
3.根据权利要求1或2所述的一种轻质玻璃钢墙板预浸料,其特征在于:所述复合麻纤维毡的规格为200~600g/m2。
4.根据权利要求1所述的一种轻质玻璃钢墙板预浸料,其特征在于:所述不饱和聚酯树脂的粘度为1300~1600Pa·s;所述饱和树脂的粘度为200~500Pa·s;所述低收缩剂为聚丙烯粉、聚乙烯醇粉、质量浓度40%的苯乙烯糊的其中一种或至少两种混合;所述固化剂为过氧化苯甲酸叔丁酯、过氧化甲乙酮、过氧化苯甲酰、异丁酸叔丁酯的其中一种或至少两种混合;所述脱膜剂为硬酯酸锌;所述发泡剂为具有壳体结构的热塑性膨胀微珠发泡剂、柠檬酸、碳酸氢钠的其中一种或至少两种混合;所述填充剂为碳酸钙、硅铝微珠、滑石粉的其中一种或至少两种混合;所述阻燃剂为氢氧化铝、甲基膦酸二甲酯、聚磷酸铵、三聚氰胺、氰尿酸盐的其中一种或至少两种混合;所述增稠剂为氧化镁、氢氧化钙、二异氰酸酯的其中一种或至少两种混合;所述稀释剂为苯乙烯。
5.根据权利要求4所述的一种轻质玻璃钢墙板预浸料,其特征在于:所述微珠发泡剂选用开始温度100~110℃,最高温度150~160℃。
6.一种权利要求1~5任一所述的轻质玻璃钢墙板预浸料的制造方法,其特征在于包括以下步骤:
步骤一,称量:按照配方称取各原料;
步骤二,发泡树脂糊混合:将除增稠剂外的发泡树脂糊原料,全部倒入高剪切型分散机中搅拌混合10~15min,然后加入增稠剂再搅拌混合5~10min,制得发泡树脂糊;
步骤三,设定浸渍参数、恒温浸渍:设定浸渍槽的浸渍液温度20~30℃、牵伸速度1~9m/min;将制得的发泡树脂糊倒入浸渍槽中,将复合麻纤维毡引入浸渍槽,沉降在前后两旋转辊压辊下进行浸渍;
步骤四,验证浸渍料克重:将浸渍后的复合麻纤维毡引向浸渍槽后,一边通过浸渍槽后的第一对旋转辊筒将浸渍料往前推进与完成粗调克重,并通过浸渍槽后的第二对旋转辊筒调节辊距,完成细调克重,再裁剪样品验证预浸料片材是否为符合设定克重;
步骤五,牵伸薄膜包腹:将验证合格的预浸料片材一边推进一边由上下开卷薄膜包装;
步骤六,裁切:将经过薄膜包腹的预浸料片材,进入裁切机根据产品规格尺寸裁切成预浸料片,裁切速度与浸渍牵伸速度同步相匹配;
步骤七,集包装、增稠烘房、入库:将裁切后的预浸料片,送到平台若干片叠合后,用镀铝塑料薄膜集包装密封后,送烘房增稠,然后进仓入库,待热压固化。
7.根据权利要求6所述的制造方法,其特征在于:步骤七中,增稠温度为30~60℃,增稠时间为20~30h。
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CN101173088A (zh) * | 2006-10-30 | 2008-05-07 | 陈志勇 | 植物纤维复合玻璃钢材料及其制备工艺 |
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CN102602067A (zh) * | 2012-03-02 | 2012-07-25 | 江阴延利汽车饰件有限公司 | 轻质环保型麻纤维复合板及其制备方法 |
CN109777062A (zh) * | 2019-01-23 | 2019-05-21 | 镇江三阳装饰材料有限公司 | 一种纤维毡增强的不饱和聚酯树脂发泡复合材料及制造方法 |
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CN112812502A (zh) * | 2021-02-10 | 2021-05-18 | 上海东杰高分子材料有限公司 | 一种仿巴沙木轻质高强复合型材及其制备方法 |
CN112812502B (zh) * | 2021-02-10 | 2024-01-30 | 上海东杰高分子材料有限公司 | 一种仿巴沙木轻质高强复合型材及其制备方法 |
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