CN111499406A - 一种泡体填充岩棉制品及其制备方法 - Google Patents
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Abstract
本发明涉及一种泡体填充岩棉制品及其制备方法，岩棉保温制品由岩棉丝和掺入岩棉丝的发泡剂与改性剂组成，发泡剂为草酸铵或/和4，4’‑氧代双苯磺酰肼，改性剂为石墨、SiO2气凝胶或/和石墨‑SiO2气凝胶。制备过程为：在一定温度下，将发泡剂加入到水中溶解，添加改性物质和发泡基体，搅拌均匀，形成发泡改性分散液，在成纤过程中将其与酚醛树脂胶黏剂分别同时喷洒于岩棉丝上，形成改性岩棉丝，经集棉、传送、打褶、加压、固化后得到岩棉制品。本发明通过添加发泡剂和改性剂对岩棉保温制品进行改性，制备的泡体填充岩棉制品具有导热系数低、保温效果好的优点。
Description
技术领域
本发明属于建筑材料生产技术领域，涉及一种泡体填充岩棉制品及其制备方法。
背景技术
目前常用的保温材料主要分为无机保温材料和有机保温材料，有机保温材料导热系数低，保温性能好，但有机保温材料易燃烧，阻燃等级低，并且有机保温材料燃烧时释放烟雾量大、毒性大，使用安全性比较低。无机保温材料具有良好的阻燃性能，并且没有毒性。
岩棉保温制品以玄武岩为材料，经高温融熔加工而成，具有质量轻、导热系数小、吸热、不燃的特点。岩棉保温制品的应用为中国建设更多的绿色建筑提供了有力的保障与支持。但是其作为外墙保温材料，导热系数高于有机保温材料，保温效果不理想，难以满足建筑节能75％标准要求。
材料的导热系数，主要取决于材料中的空气含量，聚苯乙烯泡沫与聚氨酯泡沫通过发泡，在材料内部引入大量空气，且密度较小，导热系数大幅度降低。岩棉保温制品密度是有机发泡材料的5～10倍，且其中空气含量较少，导热系数较高，若将更多空气引入岩棉保温制品中，制备出一种具有更低导热系数且不燃的岩棉保温制品成为可能。
发明内容
本发明的目的是提供一种泡体填充岩棉制品，在不改变岩棉制品的原有制备工艺流程的情况下，通过添加发泡剂与改性剂对原有的岩棉保温制品进行改性，以降低外墙保温用岩棉保温制品的导热系数，提高其保温效果。本发明的另一目的是提供一种泡体填充岩棉制品的制备方法，
本发明的技术方案是：泡体填充岩棉制品由岩棉丝与掺入岩棉的发泡剂和改性剂组成，发泡剂加入量为岩棉保温制品质量的0.01％～5％，改性剂的添加量为泡体填充岩棉制品质量的0％～10％。发泡剂为草酸铵或/和4，4’-氧代双苯磺酰肼(OBSH)，改性剂为石墨、SiO2气凝胶或石墨-SiO2气凝胶。
泡体填充岩棉制品的导热系数为0.030～0.035W/(m·K)，阻燃等级为A级。
本发明泡体填充岩棉制品的制备方法是在现有生产线上将岩棉与发泡剂和改性剂同步复合而成。制备过程如下：
(一)发泡改性分散液的制备：将发泡剂与改性剂加入到温水中，使发泡剂溶解并与改性剂混合均匀，温水的量以使发泡剂溶解为宜；然后加入树脂溶液通过机械搅拌混合均匀，制备出发泡改性分散液；
(二)孔发泡岩棉保温板的制备：
⑴制备岩棉丝：将玄武岩、矿渣、白云石和焦炭按重量比33～35：8～12： 15～20：15～20的配比装入加热炉，原料通过富氧燃烧高温熔化成岩浆。岩浆在四辊离心机高速旋转和高压吹离风下制成岩棉丝，吹制过程中将发泡改性分散液和酚醛树脂胶液均匀的喷洒在岩棉丝上，含有酚醛树脂胶液和发泡改性分散液的岩棉丝在高压吹离风的作用下进入集棉室；
⑵制备岩棉束：集棉室内通过负压风将岩棉丝吸附到捕集带进行集棉，捕集带收集岩棉丝形成岩棉束，岩棉束通过一级传送带、二级传送带传送至摆锤机；
⑶制备岩棉保温制品：岩棉束通过摆锤机、集棉带、打褶机、加压机、固化炉和切割锯平台制备出多孔发泡岩棉保温制品。
发泡剂的溶解温度为30～50℃，发泡剂与树脂溶液的质量为1:17～50。树脂溶液为水性聚氨酯、水性环氧树脂或水性丙烯酸酯。机械搅拌速度为100～ 1000rpm，搅拌时间1～2h。固化炉的固化温度为160℃～220℃，固化时间为10～ 30min。
本发明将发泡剂和改性剂与发泡基体混合均匀制备出发泡改性分散液，通过添加发泡改性分散液，对岩棉保温制品进行发泡改性，制备出的泡体填充岩棉制品具有导热系数低、保温效果好的优点。本发明泡体填充岩棉制品的制备方法，在不改变岩棉的原有制备工艺流程的情况下对其进行改性，有利于降低设备投资和生产成本，提高企业经济效益。
附图说明
图1为1#岩棉保温制品的示意图；
图2为2#岩棉保温制品的示意图；
图3为3#岩棉保温制品的示意图；
其中：1—1#岩棉保温制品、2—气孔、3—岩棉丝、4—石墨、5—SiO2气凝胶、6—2#岩棉保温制品、7—3#岩棉保温制品、8—石墨-SiO2气凝胶。
具体实施方式
下面结合实施例和附图对本发明进行详细说明。本发明保护范围不限于实施例，本领域技术人员在权利要求限定的范围内做出任何改动也属于本发明保护的范围。
实施例1
本发明在现有生产线上将岩棉与发泡剂和改性剂同步复合而成泡体填充岩棉制品。制备过程包括以下步骤：
㈠发泡改性分散液的制备：将发泡剂草酸铵与改性剂石墨加入到40℃温水中，温水的量以能将发泡剂溶解为准，使发泡剂草酸铵溶解并与改性剂石墨混合均匀，以500rpm的转速机械搅拌1.5h。然后加入水性聚氨酯，使草酸铵和石墨混合液与水性聚氨酯混合均匀，制备出发泡改性分散液。草酸铵加入量为岩棉保温制品质量的2％，石墨的添加量为泡体填充岩棉制品质量4％，草酸铵与水性聚氨酯的质量比为1:30。
㈡泡体填充岩棉制品的制备：
⑴制备岩棉丝：将原料玄武岩、矿渣、白云石和焦炭按照重量份34：10： 16：19的配比装入加热炉，原料通过富氧燃烧高温熔化成岩浆。岩浆在四辊离心机高速旋转和高压吹离风下制成岩棉丝，吹制过程中将发泡改性分散液和酚醛树脂胶液均匀的喷洒在岩棉丝上，含有酚醛树脂胶液和发泡改性分散液的岩棉丝在高压吹离风的作用下进入集棉室。酚醛树脂胶液的用量为岩棉保温制品质量的8％，酚醛树脂的固含量为10％。
⑵制备岩棉束：集棉室内通过负压风将岩棉丝吸附到捕集带进行集棉，捕集带收集岩棉丝形成岩棉束，岩棉束通过一级传送带、二级传送带传送至摆锤机；
⑶制备岩棉保温制品：岩棉束通过摆锤机、集棉带、打褶机、加压机、固化炉和切割锯平台制备出草酸铵为发泡剂，石墨为改性剂的泡体填充岩棉制品，即为1#岩棉保温制品。固化炉的固化温度为200℃，固化时间为20min。其它设备的加工过程为常规工艺过程。
如图1所示，1#改性岩棉制品1由岩棉丝3制备而成，岩棉丝中含有改性剂石墨4和气孔2。1#改性岩棉制品经切割机纵向切割成改性岩棉保温条。
实施例2
发泡改性分散液的制备：将发泡剂4，4'-氧代双苯磺酰肼(OBSH)与改性剂 SiO2气凝胶加入到40℃温水中，使发泡剂溶解并与改性剂混合均匀，以600rpm 的转速机械搅2h。加入水性环氧树脂，使4，4'-氧代双苯磺酰肼(OBSH)和SiO2气凝胶混合液与水性环氧树脂混合均匀，制备出发泡改性分散液。发泡剂加入量为岩棉保温制品质量的3％，石墨的添加量为泡体填充岩棉制品质量4.5％，草酸铵与水性聚氨酯的质量为1:35。本实施的泡体填充岩棉制品制备过程与实施例1相同，制备出4，4'-氧代双苯磺酰肼(OBSH)为发泡剂，SiO2气凝胶为改性剂的泡体填充岩棉制品，即为2#岩棉保温制品6。
如图2所示，2#改性岩棉制品6由岩棉丝3制备而成，岩棉丝中含有改性剂 SiO2气凝胶5和气孔2。
实施例3
发泡改性分散液的制备：将发泡剂草酸铵与改性剂石墨-SiO2气凝胶加入到 45℃温水中，使发泡剂溶解并与改性剂混合均匀，以500rpm的转速机械搅拌 1.5h。然后加入水性丙烯酸酯，使草酸铵和石墨-SiO2气凝胶混合液与水性丙烯酸酯混合均匀，制备出发泡改性分散液。草酸铵加入量为岩棉保温制品质量的 2％，石墨-SiO2气凝胶的添加量为泡体填充岩棉制品质量6％，草酸铵与水性聚氨酯的质量为1:40。泡体填充岩棉制品制备过程与实施例1相同，制备出草酸铵为发泡剂，石墨-SiO2气凝胶为改性剂的泡体填充岩棉制品，即为3#岩棉保温制品7。
如图3所示，3#改性岩棉制品7由岩棉丝3制备而成，岩棉丝中含有改性剂石墨-SiO2气凝胶8和气孔2。
实施例4
发泡改性分散液的制备：将发泡剂OBSH与改性剂石墨加入到40℃温水中，使发泡剂溶解并与改性剂混合均匀，以500rpm的转速机械搅拌2h。加入水性聚氨酯，使OBSH和石墨溶解液与水性聚氨酯混合均匀，制备出发泡改性分散液。 OBSH加入量为岩棉保温制品质量的2％，石墨的添加量为泡体填充岩棉制品质量 6％，OBSH与水性聚氨酯的质量为1:45。泡体填充岩棉制品制备过程与实施例1 相同，制备出OBSH为发泡剂，石墨为改性剂的泡体填充岩棉制品，即为4#岩棉保温制品。
对实施例1～4制备的泡体填充岩棉制品进行性能测试，测试结果见表1。作为对比，将现有技术生产的岩棉保温制品的性能测试结果一同列入表1。
表1.泡体填充岩棉制品测试结果
表1结果表明，本发明制备的泡体填充岩棉制品的导热系数降低到了 0.030～0.035W/(m·K)，阻燃等级A级，有效降低了外墙保温用岩棉保温制品的导热系数，提高了岩棉保温制品的保温效果。
Claims (8)
1.一种泡体填充岩棉制品，其特征是：所述岩棉制品由岩棉丝、泡体和改性剂组成，且泡体填充于岩棉制品孔隙当中。其中发泡剂为草酸铵或4，4’-氧代双苯磺酰肼，所述发泡剂加入量为泡体填充岩棉制品质量的0.01％～5％；改性剂为石墨、SiO2气凝胶或石墨-SiO2气凝胶其中的一种或多种，改性剂的添加量为泡体填充岩棉制品质量的0％～10％。
2.根据权利要求1所述的一种泡体填充岩棉制品，其特征是：泡体形成于岩棉制品固化过程中，即发泡剂在一定温度作用下，于发泡基体中分解释放气体形成泡孔结构，均匀分散于岩棉制品的孔隙当中。
3.根据权利要求2所述，一种泡体填充岩棉制品，其特征是：发泡基体为水性聚氨酯、水性环氧树脂或水性丙烯酸酯。
4.根据权利要求1所述的岩棉丝100重量份数计，原料包括33-35份玄武岩、8-12份矿渣、15-20份白云石和15-20份焦炭。
5.根据权利要求1所述改性岩棉制品，其特征是：本发明制备的岩棉制品包含岩棉板、岩棉条及以岩棉板或岩棉条为芯材制备的复合制品。
6.一种权利要求1所述的泡体填充岩棉制品的制备方法，其特征是：在一定温度下，将发泡剂加入到水中溶解，添加改性物质和发泡基体，搅拌均匀，形成发泡改性分散液，在成纤过程中将其与酚醛树脂胶黏剂分别同时喷洒于岩棉丝上，形成改性岩棉丝，经集棉、传送、打褶、加压、固化后得到岩棉制品。
7.根据权利要求6所述的泡体填充岩棉制品的制备方法，其特征是：所述发泡剂的溶解温度为30～50℃，发泡剂与树脂溶液的质量比为1:17～50。
8.根据权利要求6所述的泡体填充岩棉制品的制备方法，其特征是：所述固化温度为160℃～220℃，固化时间为10～30min。
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