CN111635208A - 一种无烧结釉面发泡陶瓷保温板及其应用的外墙保温板 - Google Patents
一种无烧结釉面发泡陶瓷保温板及其应用的外墙保温板 Download PDFInfo
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Abstract
本发明公开了一种无烧结釉面发泡陶瓷保温板及其应用的外墙保温板,包括采用发泡工艺成型得到的发泡陶瓷保温板基体,所述发泡陶瓷保温板基体包括如下重量份数原料:陶瓷粉50‑70份;凝胶材料10‑15份,作为陶瓷粉的发泡剂;纳米级无机多孔材料0.5‑1份;增电石墨烯0.1‑3份;所述增电石墨烯的D90粒径小于50微米;增强纤维1‑3份;分散剂0.1‑1份;水20‑40份;采用表面增强剂对所述发泡陶瓷保温板基体表面进行渗透增强涂覆处理,用于在所述发泡陶瓷保温板基体表面形成一层疏水防护薄膜;本发明在具有优异保温、防火性能的前提下,制造成本低,重量轻,同时具有良好的疏水性和耐久性,具有对外墙保温板的持久耐候防护以及装饰效果。
Description
技术领域
本发明属于建筑建材领域,具体涉及了一种无烧结釉面发泡陶瓷保温板,本发明还涉及了该无烧结釉面发泡陶瓷保温板应用的外墙保温板。
背景技术
随着能源危机的日益加剧,国内越来越重视建筑建材的节能管理,推进建筑建材节能已经成为建设低碳经济、实现节能减排目标,保持社会经济可持续发展的重要发展方向。外墙保温属于节能建筑建材中的一种主要体现形式,发泡陶瓷保温板作为外墙保温材料中的一种被大量应用于建筑物外墙保温。
具体来说,无烧结釉面发泡陶瓷保温板属于发泡陶瓷保温板中的一种,当应用作为建筑物外墙保温时,在无烧结釉面发泡陶瓷保温板表面进行抹面胶浆,然后涂抹涂料作为装饰面层。无烧结釉面发泡陶瓷保温板的主要原料为陶瓷粉,然后经过发泡成型得到高气孔率的闭孔陶瓷材料,而具有烧结釉面发泡陶瓷保温板的成本高,而且保温效果差,导热系数高。
对此技术现状,同时基于本申请发明人在建筑建材领域的专注研发经验以及所累积的理论知识,同时通过大量实际应用案例验证,最终提出本申请技术方案对上述技术问题进行改进。
发明内容
有鉴于此,本发明的目的在于提供一种无烧结釉面发泡陶瓷保温板及其应用的外墙保温板,在具有优异保温、防火性能的前提下,制造成本低,重量轻,同时具有良好的疏水性和耐久性,具有对外墙保温板的持久耐候防护以及装饰效果。
本发明采用的技术方案如下:
一种无烧结釉面发泡陶瓷保温板,包括采用发泡工艺成型得到的发泡陶瓷保温板基体,所述发泡陶瓷保温板基体包括如下重量份数原料:
采用表面增强剂对所述发泡陶瓷保温板基体表面进行渗透增强涂覆处理,用于在所述发泡陶瓷保温板基体表面形成一层疏水防护薄膜;其中,所述无烧结釉面发泡陶瓷保温板的吸水率不大于5%、且导热系数不大于0.08W(m.K)。
优选地,所述活性矿物采用水泥和/或活性矿物,其中,所述水泥采用硫铝酸盐水泥和硅酸盐水泥中的一种或两种的混合,所述活性矿物采用石英、矿渣、粉煤灰、磨细天然沸石、石膏、硅灰和偏高岭土中的一种或几种的混合。
优选地,所述增强纤维采用增强玻璃纤维,所述分散剂采用表面活性剂。
优选地,所述表面增强剂采用有机硅渗透型防水剂,所述有机硅渗透型防水剂通过涂覆在所述发泡陶瓷保温板基体表面与空气中的二氧化碳发生自聚合反应,在所述发泡陶瓷保温板基体表面形成一层具有自清洁效果的疏水硅树脂薄膜。
优选地,所述疏水防护薄膜的厚度范围为10-100微米,所述发泡陶瓷保温板基体的厚度范围为50-300mm。
优选地,所述无烧结釉面发泡陶瓷保温板的制备工艺包括如下操作步骤:
A10)、将陶瓷粉、纳米级无机多孔材料、增电石墨烯、增强纤维、分散剂和水全部置于搅拌装置中,通过搅拌装置的旋转搅拌将其原料搅拌均匀;
A20)、向所述搅拌装置中添加凝胶材料,搅拌均匀后得到发泡体浆料,将该发泡体浆料通过模具浇筑成型得到发泡陶瓷保温板胚体;
A30)、对所述发泡陶瓷保温板胚体依次进行拆模、养护、切割、除尘处理后得到所述发泡陶瓷保温板基体;
A40)、向所述发泡陶瓷保温板基体表面喷涂或刷涂有机硅渗透型防水剂,所述有机硅渗透型防水剂与空气中的二氧化碳发生自聚合反应,在所述发泡陶瓷保温板基体表面形成一层具有自清洁效果的疏水硅树脂薄膜,得到所述无烧结釉面发泡陶瓷保温板。
优选地,在所述步骤A10)前,对所述增强纤维和增电石墨烯进行预复合处理得到预复合体,所述预复合体用于提高与所述有机硅渗透型防水剂的相容性,提高所述疏水防护薄膜的强度,其中,所述预复合处理的操作步骤包括:
a1)、将所述增强纤维预先放置在封闭式容器内,所述封闭式容器将温度加热并保持在40-60℃;
a2)、将所述增电石墨烯添加到所述封闭式容器内,同时向所述封闭式容器添加作为流动助剂的蜡粉,启动高速搅拌,所述高速搅拌的速度不低于800转/分钟,搅拌时间不少于5分钟;
a3)、停止高速搅拌和加热,待冷却至室温后出料得到所述预复合体。
优选地,一种如上所述的无烧结釉面发泡陶瓷保温板应用的外墙保温板,在所述无烧结釉面发泡陶瓷保温板的表面静电喷涂氟碳热固性粉末涂料或超耐候聚酯热固性粉末涂料,经过热固化成型得到作为耐候装饰效果的热固涂层,所述疏水防护薄膜位于所述发泡陶瓷保温板基体与所述热固涂层之间。
优选地,所述热固涂层的厚度为80-150微米。
优选地,所述热固化成型的温度为180-200℃,固化时间为18-22分钟。
本发明首先在制备原料中采用凝胶材料作为陶瓷粉的发泡剂,同时增加纳米级无机多孔材料作为在发泡过程中的发泡泡体尺寸调节的孔调节助剂,利于发泡陶瓷保温板基体的均匀发泡成型效果,确保发泡陶瓷保温板基体具有优异的保温以及防火性能;本发明进一步添加有增强纤维和增电石墨烯分别作为发泡陶瓷保温板基体的增强以及增电效果,在具体实施时,将增强纤维和增电石墨烯进行预复合进一步有利于有机硅渗透型防水剂的相容性,提高所述疏水防护薄膜的强度,同时由于增电石墨烯的存在,在后续进行热固性粉末涂料静电喷涂时,可以进一步利于粉末涂料在疏水防护薄膜上的增电上粉效果,确保热固涂层在无烧结釉面发泡陶瓷保温板上的附着力;因此,本发明不需要设置成本高、重量重的烧结釉面的基础上,有效保证了发泡陶瓷保温板具有良好的疏水性和耐久性,且制造成本低,重量轻,同时具有对外墙保温板的持久耐候防护以及装饰效果。
附图说明
图1是本发明具体实施方式下无烧结釉面发泡陶瓷保温板的结构示意图;
图2是本发明具体实施方式下外墙保温板的结构示意图;
图3是本发明具体实施方式下无烧结釉面发泡陶瓷保温板的制备工艺操作步骤框图;
图4是本发明具体实施方式下预复合体的预复合处理操作步骤框图。
具体实施方式
本发明实施例公开了一种无烧结釉面发泡陶瓷保温板,包括采用发泡工艺成型得到的发泡陶瓷保温板基体,发泡陶瓷保温板基体包括如下重量份数原料:
采用表面增强剂对发泡陶瓷保温板基体表面进行渗透增强涂覆处理,用于在发泡陶瓷保温板基体表面形成一层疏水防护薄膜;其中,无烧结釉面发泡陶瓷保温板的吸水率不大于5%、且导热系数不大于0.08W(m.K)。
本发明实施例还公开了一种如上的无烧结釉面发泡陶瓷保温板应用的外墙保温板,在无烧结釉面发泡陶瓷保温板的表面静电喷涂氟碳热固性粉末涂料或超耐候聚酯热固性粉末涂料,经过热固化成型得到作为耐候装饰效果的热固涂层,疏水防护薄膜位于发泡陶瓷保温板基体与热固涂层之间。
为了使本技术领域的人员更好地理解本发明中的技术方案,下面将结合本发明实施例中的附图,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,都应当属于本发明保护的范围。
实施例1:请参见图1所示,一种无烧结釉面发泡陶瓷保温板1,包括采用发泡工艺成型得到的发泡陶瓷保温板基体10,发泡陶瓷保温板基体10包括如下重量份数原料:
陶瓷粉 60份;
凝胶材料 10份,作为陶瓷粉的发泡剂;
纳米级无机多孔材料 0.8份;优选地,在本实施方式中,活性矿物采用5份水泥和/5份活性矿物,其中,水泥采用硫铝酸盐水泥和硅酸盐水泥中的一种或两种的混合,活性矿物采用石英、矿渣、粉煤灰、磨细天然沸石、石膏、硅灰和偏高岭土中的一种或几种的混合,本实施例对其不做特别限定;
增电石墨烯 0.2份;增电石墨烯的D90粒径小于50微米;
增强纤维 2份;
分散剂 0.5份;
优选地,在本实施方式中,增强纤维采用增强玻璃纤维,分散剂采用表面活性剂,利于陶瓷粉浆料在发泡时的流动浸润;
水 余量(100份总重量份);
采用表面增强剂对发泡陶瓷保温板基体10表面进行渗透增强涂覆处理,用于在发泡陶瓷保温板基体10表面形成一层疏水防护薄膜20;其中,无烧结釉面发泡陶瓷保温板的吸水率不大于5%、且导热系数不大于0.08W(m.K);优选地,在本实施方式中,表面增强剂采用有机硅渗透型防水剂,有机硅渗透型防水剂通过涂覆在发泡陶瓷保温板基体10表面与空气中的二氧化碳发生自聚合反应,在发泡陶瓷保温板基体10表面形成一层具有自清洁效果的疏水硅树脂薄膜20;
优选地,在本实施方式中,疏水防护薄膜20的厚度范围为10-100微米,发泡陶瓷保温板基体10的厚度范围为50-300mm;
优选地,请进一步参见图3和图4所示,在本实施方式中,无烧结釉面发泡陶瓷保温板1的制备工艺包括如下操作步骤:
在进入步骤A10)前,对增强纤维和增电石墨烯进行预复合处理得到预复合体,预复合体用于提高与有机硅渗透型防水剂的相容性,提高疏水防护薄膜的强度,其中,预复合处理的操作步骤包括:
a1)、将增强纤维预先放置在封闭式容器内,封闭式容器将温度加热并保持在40-60℃;
a2)、将增电石墨烯添加到封闭式容器内,同时向封闭式容器添加作为流动助剂的蜡粉,启动高速搅拌,高速搅拌的速度不低于800转/分钟,搅拌时间不少于5分钟;
a3)、停止高速搅拌和加热,待冷却至室温后出料得到预复合体;
A10)、将陶瓷粉、纳米级无机多孔材料、预复合体、分散剂和水全部置于搅拌装置中,通过搅拌装置的旋转搅拌将其原料搅拌均匀;
A20)、向搅拌装置中添加凝胶材料,搅拌均匀后得到发泡体浆料,将该发泡体浆料通过模具浇筑成型得到发泡陶瓷保温板胚体;
A30)、对发泡陶瓷保温板胚体依次进行拆模、养护、切割、除尘处理后得到发泡陶瓷保温板基体10;
A40)、向发泡陶瓷保温板基体10表面喷涂或刷涂有机硅渗透型防水剂,有机硅渗透型防水剂与空气中的二氧化碳发生自聚合反应,在发泡陶瓷保温板基体表面形成一层具有自清洁效果的疏水硅树脂薄膜20,得到无烧结釉面发泡陶瓷保温板1。
优选地,请进一步参见图2所示,本实施例还提出了采用以上所述的无烧结釉面发泡陶瓷保温板1应用的外墙保温板2,在无烧结釉面发泡陶瓷保温板1的表面静电喷涂氟碳热固性粉末涂料或超耐候聚酯热固性粉末涂料,经过热固化成型得到作为耐候装饰效果的热固涂层30,疏水防护薄膜20位于发泡陶瓷保温板基体10与热固涂层30之间;优选地,在本实施方式中,热固涂层30的厚度为80-150微米,热固化成型的温度为180-200℃,固化时间为18-22分钟。
实施例2:本实施例2的其余技术方案同实施例1,区别在于,本实施例2提出了一种无烧结釉面发泡陶瓷保温板,其发泡陶瓷保温板基体包括如下重量份数原料:
实施例3:本实施例3的其余技术方案同实施例1,区别在于,本实施例3提出了一种无烧结釉面发泡陶瓷保温板,其发泡陶瓷保温板基体包括如下重量份数原料:
对比例1:本对比例1采用实施例1中的发泡陶瓷保温板基体。
对比例2:本对比例2采用现有技术中的无烧结釉面发泡陶瓷保温板。
对比例3:本对比例3采用现有技术中的烧结釉面发泡陶瓷保温板。
本申请人对以上实施例1-3以及对比例1-3进行了实施效果比较,请直接参见下表1所示的试验效果验证对比(各相实施效果都是参照建筑行业对其应用建材的性能标准进行测试):
表1:本申请各实施例与对比例的实施效果对比
本实施例1-3首先在制备原料中采用凝胶材料作为陶瓷粉的发泡剂,同时增加纳米级无机多孔材料作为在发泡过程中的发泡泡体尺寸调节的孔调节助剂,利于发泡陶瓷保温板基体的均匀发泡成型效果,确保发泡陶瓷保温板基体具有优异的保温以及防火性能;本实施例进一步添加有增强纤维和增电石墨烯分别作为发泡陶瓷保温板基体的增强以及增电效果,在具体实施时,将增强纤维和增电石墨烯进行预复合进一步有利于有机硅渗透型防水剂的相容性,提高所述疏水防护薄膜的强度,同时由于增电石墨烯的存在,在后续进行热固性粉末涂料静电喷涂时,可以进一步利于粉末涂料在疏水防护薄膜上的增电上粉效果,确保热固涂层在无烧结釉面发泡陶瓷保温板上的附着力;因此,本实施例不需要设置成本高、重量重的烧结釉面的基础上,有效保证了发泡陶瓷保温板具有良好的疏水性和耐久性,且制造成本低,重量轻,同时具有对外墙保温板的持久耐候防护以及装饰效果。
需要说明的是,在本申请其他实施方式中,也可以采用本实施例提出的其他优选范围的相关参数选择,均可以获得本实施例所述的优异技术效果,这些都是本领域技术人员根据本技术方案内容可以做出的常规技术选择,因此,本申请实施例不再一一展开说明。
对于本领域技术人员而言,显然本发明不限于上述示范性实施例的细节,而且在不背离本发明的精神或基本特征的情况下,能够以其他的具体形式实现本发明。因此,无论从哪一点来看,均应将实施例看作是示范性的,而且是非限制性的,本发明的范围由所附权利要求而不是上述说明限定,因此旨在将落在权利要求的等同要件的含义和范围内的所有变化囊括在本发明内。不应将权利要求中的任何附图标记视为限制所涉及的权利要求。
此外,应当理解,虽然本说明书按照实施方式加以描述,但并非每个实施方式仅包含一个独立的技术方案,说明书的这种叙述方式仅仅是为清楚起见,本领域技术人员应当将说明书作为一个整体,各实施例中的技术方案也可以经适当组合,形成本领域技术人员可以理解的其他实施方式。
Claims (10)
2.根据权利要求1所述的无烧结釉面发泡陶瓷保温板,其特征在于,所述活性矿物采用水泥和/或活性矿物,其中,所述水泥采用硫铝酸盐水泥和硅酸盐水泥中的一种或两种的混合,所述活性矿物采用石英、矿渣、粉煤灰、磨细天然沸石、石膏、硅灰和偏高岭土中的一种或几种的混合。
3.根据权利要求1所述的无烧结釉面发泡陶瓷保温板,其特征在于,所述增强纤维采用增强玻璃纤维,所述分散剂采用表面活性剂。
4.根据权利要求1所述的无烧结釉面发泡陶瓷保温板,其特征在于,所述表面增强剂采用有机硅渗透型防水剂,所述有机硅渗透型防水剂通过涂覆在所述发泡陶瓷保温板基体表面与空气中的二氧化碳发生自聚合反应,在所述发泡陶瓷保温板基体表面形成一层具有自清洁效果的疏水硅树脂薄膜。
5.根据权利要求1或4所述的无烧结釉面发泡陶瓷保温板,其特征在于,所述疏水防护薄膜的厚度范围为10-100微米,所述发泡陶瓷保温板基体的厚度范围为50-300mm。
6.根据权利要求4所述的无烧结釉面发泡陶瓷保温板,其特征在于,所述无烧结釉面发泡陶瓷保温板的制备工艺包括如下操作步骤:
A10)、将陶瓷粉、纳米级无机多孔材料、增电石墨烯、增强纤维、分散剂和水全部置于搅拌装置中,通过搅拌装置的旋转搅拌将其原料搅拌均匀;
A20)、向所述搅拌装置中添加凝胶材料,搅拌均匀后得到发泡体浆料,将该发泡体浆料通过模具浇筑成型得到发泡陶瓷保温板胚体;
A30)、对所述发泡陶瓷保温板胚体依次进行拆模、养护、切割、除尘处理后得到所述发泡陶瓷保温板基体;
A40)、向所述发泡陶瓷保温板基体表面喷涂或刷涂有机硅渗透型防水剂,所述有机硅渗透型防水剂与空气中的二氧化碳发生自聚合反应,在所述发泡陶瓷保温板基体表面形成一层具有自清洁效果的疏水硅树脂薄膜,得到所述无烧结釉面发泡陶瓷保温板。
7.根据权利要求6所述的无烧结釉面发泡陶瓷保温板,其特征在于,在所述步骤A10)前,对所述增强纤维和增电石墨烯进行预复合处理得到预复合体,所述预复合体用于提高与所述有机硅渗透型防水剂的相容性,提高所述疏水防护薄膜的强度,其中,所述预复合处理的操作步骤包括:
a1)、将所述增强纤维预先放置在封闭式容器内,所述封闭式容器将温度加热并保持在40-60℃;
a2)、将所述增电石墨烯添加到所述封闭式容器内,同时向所述封闭式容器添加作为流动助剂的蜡粉,启动高速搅拌,所述高速搅拌的速度不低于800转/分钟,搅拌时间不少于5分钟;
a3)、停止高速搅拌和加热,待冷却至室温后出料得到所述预复合体。
8.一种如权利要求1-7之一所述的无烧结釉面发泡陶瓷保温板应用的外墙保温板,其特征在于,在所述无烧结釉面发泡陶瓷保温板的表面静电喷涂氟碳热固性粉末涂料或超耐候聚酯热固性粉末涂料,经过热固化成型得到作为耐候装饰效果的热固涂层,所述疏水防护薄膜位于所述发泡陶瓷保温板基体与所述热固涂层之间。
9.根据权利要求8所述的外墙保温板,其特征在于,所述热固涂层的厚度为80-150微米。
10.根据权利要求8所述的外墙保温板,其特征在于,所述热固化成型的温度为180-200℃,固化时间为18-22分钟。
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