CN111844996A - 一种夹芯复合板材及其制备方法 - Google Patents

一种夹芯复合板材及其制备方法 Download PDF

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Publication number
CN111844996A
CN111844996A CN202010646043.2A CN202010646043A CN111844996A CN 111844996 A CN111844996 A CN 111844996A CN 202010646043 A CN202010646043 A CN 202010646043A CN 111844996 A CN111844996 A CN 111844996A
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China
Prior art keywords
resin
layer
core material
sandwich composite
board
Prior art date
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Granted
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CN202010646043.2A
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English (en)
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CN111844996B (zh
Inventor
刘喜宗
张继承
董会娜
何凤霞
龚祥明
姚栋嘉
张东生
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Gongyi Van Research Yihui Composite Material Co Ltd
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Gongyi Van Research Yihui Composite Material Co Ltd
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Application filed by Gongyi Van Research Yihui Composite Material Co Ltd filed Critical Gongyi Van Research Yihui Composite Material Co Ltd
Priority to CN202010646043.2A priority Critical patent/CN111844996B/zh
Publication of CN111844996A publication Critical patent/CN111844996A/zh
Priority to PCT/CN2021/104768 priority patent/WO2022007797A1/zh
Priority to US18/014,954 priority patent/US20230256725A1/en
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Abstract

本发明属于复合板材制备技术领域，公开一种夹芯复合板材及其制备方法。由上到下包括上面板层、芯材层和下面板层；上面板层、下面板层为玻璃或纤维增强树脂基复合片；芯材层由气凝胶、树脂和可膨胀微球发泡剂组成。方法①：将树脂加热熔化，得浆料A，冷却，加入气凝胶和可膨胀微球发泡剂，混合均匀，得浆料B；将下面板层平铺放置，涂刷浆料B，接着铺设上面板层，热压成型即可。方法②：将气凝胶、树脂、可膨胀微球发泡剂混合均匀，得混合料A；将混合料A装入无纺布袋中密封，得芯材B；将下面板层平铺放置，平铺芯材B，接着铺设上面板层，热压成型即可。本发明制备的夹芯复合板材厚度可控、密度可控、良好的隔热隔音降噪效果、整体性良好。

Description

一种夹芯复合板材及其制备方法
技术领域
本发明属于复合板材制备技术领域，具体涉及一种夹芯复合板材及其制备方法。
背景技术
随着人们生活水平的逐渐提高，对室内装饰的要求越来越高，各种材料的复合板在室内装饰中应用也越来越普及，被广泛地应用于门、室内墙壁上。然而目前满足应用需求的复合板材整体价格还是比较高，其牢固性、抗压抗冲击、隔热降噪等综合性能方面还并不完全成熟。目前生产的复合板材多采用夹芯板材的成型方式，通过将外面板层与夹心材料通过胶水粘接，然后进行热压烘干，再进行裁切打磨，最后刷漆成型，这种板材在使用一段时间后容易出现开裂、分层等情况，且隔音降噪、保温性能并不满足实际的应用要求，因此在一定程度上也限制了复合板材在建筑、装饰行业的普及。
噪音污染已被公认为当今社会的第三大公害，噪声的来源越来越多，噪音对人体的神经系统、心血管系统、消化系统、免疫系统乃至胎儿发育也都会有影响，室内造成污染成为目前广泛关注的噪声问题之一，国家对居住、商业、工业区等不同区域制定了相关的噪声标准，这对房屋的建筑及装饰材料提出了更高的要求，如何通过新材料的更新升级实现建筑装饰行业的降噪已经成为目前研究开发的热点，设计一种整体性好、同时具有良好的隔热、隔音降噪的复合板材，其有望在建筑、装饰等行业实现应用性开发。
发明内容
为克服现有技术中存在的不足之处，本发明的目的旨在提供一种夹芯复合板材及其制备方法。
为实现上述目的，本发明采取的技术方案如下：
一种夹芯复合板材，由上到下依次包括上面板层、芯材层和下面板层，上面板层和芯材层之间、下面板层和芯材层之间均为一体成型；所述上面板层、下面板层为玻璃或纤维增强树脂基复合片；以质量份数计，所述芯材层由气凝胶30-70份、树脂10-35份和可膨胀微球发泡剂2-4份组成。
较好地，所述玻璃为钢化玻璃、半钢化玻璃、超白玻璃、浮法玻璃、镀膜玻璃或贴膜玻璃。
较好地，所述纤维增强树脂基复合片中的纤维为玻璃纤维、碳纤维、硼纤维或芳纶纤维，树脂为不饱和聚酯、乙烯基树脂、聚氨酯树脂、环氧树脂、聚碳酸酯树脂、聚酰胺树脂或酚醛树脂。本发明中所述“纤维增强树脂基复合片”可通过市购或按现有技术制备获得。
较好地，所述气凝胶为二氧化硅气凝胶、氧化铝气凝胶、二氧化钛气凝胶或二氧化锆气凝胶。
较好地，芯材层中的树脂为热固性树脂或热塑性树脂。
较好地，所述热固性树脂为酚醛树脂、脲醛树脂、三聚氰胺-甲醛树脂、环氧树脂、不饱和树脂、聚氨酯、聚酰亚胺中的一种；所述热塑性树脂为聚乙烯树脂、聚丙烯树脂、聚碳酸酯树脂、聚氯乙烯树脂、聚苯乙烯树脂、聚酰胺树脂、聚甲醛树脂、聚苯醚树脂、聚砜树脂中的一种。
较好地，所述可膨胀微球发泡剂的粒径为10-50μm。
本发明提供了两种夹芯复合板材的制备方法，具体如下：
方法①，步骤如下：
（1）、将芯材层中的树脂加入容器内，在110-160℃加热使其熔化，得到浆料A，然后将其静止冷却至25-70℃；
（2）、在步骤（1）所得浆料A中加入气凝胶和可膨胀微球发泡剂，混合均匀，得到浆料B；
（3）、将下面板层平铺放置，将步骤（2）所得浆料B均匀涂刷在下面板层上，接着在浆料B上铺设上面板层，得到夹芯复合层；
（4）、将步骤（3）所得夹芯复合层热压成型，即得夹芯复合板材。
方法②，步骤如下：
（1）、按芯材层的组成，将气凝胶、树脂、可膨胀微球发泡剂加入容器中混合均匀，得到混合料A；
（2）、将步骤（1）中混合料A装入无纺布袋中，将袋子密封，得到芯材B；
（3）、将下面板层平铺放置，将步骤（2）所得芯材B均匀平铺于下面板层上，接着在芯材B上铺设上面板层，得到夹芯复合层；
（4）、将步骤（3）所得夹芯复合层热压成型，即得夹芯复合板材。
较好地，方法①和方法②的步骤（4）中，所述热压成型的温度为100-180℃、压力为2-5MPa、时间为30min-8h。
有益效果：
（1）、本发明制备的夹芯复合板材具有厚度可控性：可通过调控浆料B的涂刷厚度或调控无纺布袋中混合料A的量来制备得到不同厚度需求的板材；
（2）、本发明制备的夹芯复合板材具有密度可控性：加入可膨胀微球发泡剂能够显著降低板材的密度，可通过调节可膨胀微球发泡剂的加入量实现板材密度的可控性；
（3）、本发明制备的夹芯复合板材整体性良好：通过热压一体化成型得到夹芯板材，若上下面板层为纤维增强树脂基复合片时，在热压条件下纤维增强树脂基复合片可与芯材层实现一体化固化成型，层间结合状况良好；若上下面板层为玻璃层时，由于其在热压条件下会部分软化与芯材层的树脂熔融连接，保证了层与层之间良好的整体性，避免了使用过程中层与层分层、脱落的情况发生；另外，将混合料A装入无纺布袋中再进行热压成型，避免直接将混合料A放在上、下面板层之间热压成型出现的粉体掉落、边角破坏的情况发生，也保证了产品的整体性；
（4）、本发明制备的夹芯复合板材具有良好的隔热、隔音降噪效果：本发明采用气凝胶和可膨胀微球发泡剂作为夹芯结构，可膨胀微球发泡剂在发泡后具备的多孔特性可以使得到的泡沫具备一定的隔热隔音特性，在与气凝胶复合后能够保持泡沫材料的隔热保温性能；
（5）、本发明制备的夹芯复合板材具有良好的隔热、隔音降噪特性，使其满足日益发展的社会需求，可在建筑、装饰等行业的实现广泛的应用。
具体实施方式
以下结合具体实施例，对本发明做进一步说明。应理解，以下实施例仅用于说明本发明而非用于限制本发明的范围。
实施例1
一种夹心复合板材，由上到下依次包括上面板层、芯材层和下面板层，上面板层和芯材层之间、下面板层和芯材层之间均为一体成型；所述上面板层、下面板层为碳纤维增强酚醛树脂基复合片；以质量份数计，所述芯材层由二氧化硅气凝胶60份、聚乙烯树脂35份和可膨胀微球发泡剂EM406（日本油脂制药株式会社生产，平均直径20 μm）4份组成。
上述夹心复合板材的制备方法，包括以下具体步骤：
（1）、将聚乙烯树脂粉末加入容器内，在120℃加热使其熔化，得到浆料A，然后将其静止冷却至40℃；
（2）、在步骤（1）所得浆料A中加二氧化硅气凝胶粉和可膨胀微球发泡剂EM406，混合均匀，得到浆料B；
（3）、将下面板层碳纤维增强酚醛树脂基复合片平铺放置，将步骤（2）所得浆料B均匀涂刷在下面板层碳纤维增强酚醛树脂基复合片上，接着在浆料B上铺设上面板层碳纤维增强酚醛树脂基复合片，得到夹芯复合层；
（4）、将步骤（3）所得夹芯复合层在温度150℃、压力4MPa的条件下热压成型1h，得到夹心复合板材。
实施例2
一种夹心复合板材，由上到下依次包括上面板层、芯材层和下面板层，上面板层和芯材层之间、下面板层和芯材层之间均为一体成型；所述上面板层、下面板层为钢化玻璃；以质量份数计，所述芯材层由三氧化二铝气凝胶50份、酚醛树脂25份和可膨胀微球发泡剂EHM401（日本油脂制药株式会社生产，平均直径60μm）4份组成。
上述夹心复合板材的制备方法，包括以下具体步骤：
（1）、将酚醛树脂粉末加入容器内，在130℃加热使其熔化，得到浆料A，然后将其静止冷却至30℃；
（2）、在步骤（1）所得浆料A中加入三氧化二铝气凝胶粉和可膨胀微球发泡剂EHM401，混合均匀，得到浆料B；
（3）、将下面板层钢化玻璃平铺放置，将步骤（2）所得浆料B均匀涂刷在下面板层钢化玻璃上，接着在浆料B上铺设上面板层钢化玻璃，得到夹芯复合层；
（4）、将步骤（3）所得夹芯复合层在温度130℃、压力3MPa的条件下热压成型50min，得到夹心复合板材。
实施例3
一种夹心复合板材，由上到下依次包括上面板层、芯材层和下面板层，上面板层和芯材层之间、下面板层和芯材层之间均为一体成型；所述上面板层、下面板层为镀膜玻璃；以质量份数计，所述芯材层由二氧化钛气凝胶65份、环氧树脂35份和可膨胀微球发泡剂TEP-160（日本油脂制药株式会社生产，平均直径80μm）4份组成。
上述夹心复合板材的制备方法，包括以下具体步骤：
（1）、将环氧树脂粉末加入容器内，在150℃加热使其熔化，得到浆料A，然后将其静止冷却至50℃；
（2）、在步骤（1）所得浆料A中加入二氧化钛气凝胶粉和可膨胀微球发泡剂TEP-160，混合均匀，得到浆料B；
（3）、将下面板层镀膜玻璃平铺放置，将步骤（2）所得浆料B均匀涂刷在下面板层镀膜玻璃上，接着在浆料B上铺设上面板层镀膜玻璃，得到夹芯复合层；
（4）、将步骤（3）所得夹芯复合层在温度160℃、压力5MPa的条件下热压成型40min，得到夹心复合板材。
实施例4
一种夹心复合板材，由上到下依次包括上面板层、芯材层和下面板层，上面板层和芯材层之间、下面板层和芯材层之间均为一体成型；所述上面板层、下面板层为玻璃纤维增强环氧树脂基复合片；以质量份数计，所述芯材层由二氧化锆气凝胶40份、聚酰胺树脂20份和可膨胀微球发泡剂EM406（日本油脂制药株式会社生产，平均直径20 μm）2份组成。
上述夹心复合板材的制备方法，包括以下具体步骤：
（1）、将聚酰胺树脂粉末加入容器内，在140℃加热使其熔化，得到浆料A，然后将其静止冷却至45℃；
（2）在步骤（1）所得浆料A中加入二氧化锆气凝胶粉和可膨胀微球发泡剂EM406，混合均匀，得到浆料B；
（3）、将下面板层玻璃纤维增强环氧树脂基复合片平铺放置，将步骤（2）所得浆料B均匀涂刷在下面板层玻璃纤维增强环氧树脂基复合片上，接着在浆料B上铺设上面板层玻璃纤维增强环氧树脂基复合片，得到夹芯复合层；
（4）、将步骤（3）所得夹芯复合层在温度140℃、压力3MPa的条件下热压成型40min，得到夹心复合板材。
实施例5
一种夹心复合板材，由上到下依次包括上面板层、芯材层和下面板层，上面板层和芯材层之间、下面板层和芯材层之间均为一体成型；所述上面板层、下面板层为玻璃纤维增强聚碳酸酯树脂基复合片；以质量份数计，所述芯材层由二氧化硅气凝胶30份、酚醛树脂20份和膨胀微球发泡剂EM406（日本油脂制药株式会社生产，平均直径20 μm）3份组成。
上述夹心复合板材及其制备方法，包括以下具体步骤：
（1）、将二氧化硅气凝胶粉、酚醛树脂粉、可膨胀微球发泡剂EM406加入容器中混合均匀，得到混合料A；
（2）、将步骤（1）中混合料A装入无纺布袋中，将袋子密封，得到芯材B；
（3）、将下面板层玻璃纤维增强聚碳酸酯树脂基复合片平铺放置，将步骤（2）所得芯材B均匀平铺于下面板层玻璃纤维增强聚碳酸酯树脂基复合片上，接着在芯材B上铺设上面板层玻璃纤维增强聚碳酸酯树脂基复合片，得到夹芯复合层；
（4）、将步骤（3）所得夹芯复合层在温度150℃、压力4MPa的条件下热压成型1h，即得夹芯复合板材。
实施例6
一种夹心复合板材，由上到下依次包括上面板层、芯材层和下面板层，上面板层和芯材层之间、下面板层和芯材层之间均为一体成型；所述上面板层、下面板层为芳纶纤维增强聚酰胺树脂复合片；以质量份数计，所述芯材层由三氧化二铝气凝胶50份、聚苯乙烯树脂35份和膨胀微球发泡剂EM406（日本油脂制药株式会社生产，平均直径20 μm）4份组成。
上述夹心复合板材的制备方法，包括以下具体步骤：
（1）、将三氧化二铝气凝胶粉、聚苯乙烯树脂粉、可膨胀微球发泡剂EM406加入容器中混合均匀，得到混合料A；
（2）、将步骤（1）中混合料A装入无纺布袋中，将袋子密封，得到芯材B；
（3）、将下面板层芳纶纤维增强聚酰胺树脂基复合片平铺放置，将步骤（2）所得芯材B均匀平铺于下面板层芳纶纤维增强聚酰胺树脂基复合片上，接着在芯材B上铺设上面板层芳纶纤维增强聚酰胺树脂基复合片，得到夹芯复合层；
（4）、将步骤（3）所得夹芯复合层在温度130℃、压力3MPa的条件下热压成型50min，即得夹芯复合板材。
实施例7
一种夹心复合板材，由上到下依次包括上面板层、芯材层和下面板层，上面板层和芯材层之间、下面板层和芯材层之间均为一体成型；所述上面板层、下面板层为钢化玻璃；以质量份数计，所述芯材层由二氧化钛气凝胶45份、环氧树脂25份和可膨胀微球发泡剂EHM401（日本油脂制药株式会社生产，平均直径60μm）4份组成。
上述夹心复合板材的制备方法，包括以下具体步骤：
（1）、将二氧化钛气凝胶粉、环氧树脂粉、可膨胀微球发泡剂EHM401加入容器中混合均匀，得到混合料A；
（2）、将步骤（1）中混合料A装入无纺布袋中，将袋子密封，得到芯材B；
（3）、将下面板层钢化玻璃平铺放置，将步骤（2）所得芯材B均匀平铺于下面板层钢化玻璃上，接着在芯材B上铺设上面板层钢化玻璃，得到夹芯复合层；
（4）、将步骤（3）所得夹芯复合层在温度160℃、压力3MPa的条件下热压成型40min，即得夹芯复合板材。

Claims (10)

1.一种夹芯复合板材，其特征在于：由上到下依次包括上面板层、芯材层和下面板层，上面板层和芯材层之间、下面板层和芯材层之间均为一体成型；所述上面板层、下面板层为玻璃或纤维增强树脂基复合片；以质量份数计，所述芯材层由气凝胶30-70份、树脂10-35份和可膨胀微球发泡剂2-4份组成。
2.如权利要求1所述的夹芯复合板材，其特征在于：所述玻璃为钢化玻璃、半钢化玻璃、超白玻璃、浮法玻璃、镀膜玻璃或贴膜玻璃。
3.如权利要求1所述的夹芯复合板材，其特征在于：所述纤维增强树脂基复合片中的纤维为玻璃纤维、碳纤维、硼纤维或芳纶纤维，树脂为不饱和聚酯、乙烯基树脂、聚氨酯树脂、环氧树脂、聚碳酸酯树脂、聚酰胺树脂或酚醛树脂。
4.如权利要求1所述的夹芯复合板材，其特征在于：所述气凝胶为二氧化硅气凝胶、氧化铝气凝胶、二氧化钛气凝胶或二氧化锆气凝胶。
5.如权利要求1所述的夹芯复合板材，其特征在于：芯材层中的树脂为热固性树脂或热塑性树脂。
6.如权利要求5所述的夹芯复合板材，其特征在于：所述热固性树脂为酚醛树脂、脲醛树脂、三聚氰胺-甲醛树脂、环氧树脂、不饱和树脂、聚氨酯、聚酰亚胺中的一种；所述热塑性树脂为聚乙烯树脂、聚丙烯树脂、聚碳酸酯树脂、聚氯乙烯树脂、聚苯乙烯树脂、聚酰胺树脂、聚甲醛树脂、聚苯醚树脂、聚砜树脂中的一种。
7.如权利要求1所述的夹芯复合板材，其特征在于：所述可膨胀微球发泡剂的粒径为10-50μm。
8.一种如权利要求1-7之任一项所述的夹芯复合板材的制备方法，其特征在于，步骤如下：
（1）、将芯材层中的树脂加入容器内，在110-160℃加热使其熔化，得到浆料A，然后将其静止冷却至25-70℃；
（2）、在步骤（1）所得浆料A中加入气凝胶和可膨胀微球发泡剂，混合均匀，得到浆料B；
（3）、将下面板层平铺放置，将步骤（2）所得浆料B均匀涂刷在下面板层上，接着在浆料B上铺设上面板层，得到夹芯复合层；
（4）、将步骤（3）所得夹芯复合层热压成型，即得夹芯复合板材。
9.一种如权利要求1-7之任一项所述的夹芯复合板材的制备方法，其特征在于，步骤如下：
（1）、按芯材层的组成，将气凝胶、树脂、可膨胀微球发泡剂加入容器中混合均匀，得到混合料A；
（2）、将步骤（1）中混合料A装入无纺布袋中，将袋子密封，得到芯材B；
（3）、将下面板层平铺放置，将步骤（2）所得芯材B均匀平铺于下面板层上，接着在芯材B上铺设上面板层，得到夹芯复合层；
（4）、将步骤（3）所得夹芯复合层热压成型，即得夹芯复合板材。
10.如权利要求8或9所述的夹芯复合板材的制备方法，其特征在于：步骤（4）中，所述热压成型的温度为100-180℃、压力为2-5MPa、时间为30min-8h。
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