CN112111128A - 一种新型轨道车辆保温材料及其制备方法 - Google Patents

一种新型轨道车辆保温材料及其制备方法 Download PDF

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CN112111128A
CN112111128A CN202010901404.3A CN202010901404A CN112111128A CN 112111128 A CN112111128 A CN 112111128A CN 202010901404 A CN202010901404 A CN 202010901404A CN 112111128 A CN112111128 A CN 112111128A
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parts
insulation material
thermal insulation
rubber
acid
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高伟
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Celefo Lianyungang Composite Material Co ltd
Cellofoam Lianyungang Composite Materials Co Ltd
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Abstract

本发明公开了一种轨道车辆保温材料及其制备方法，属于保温材料技术领域。所述的轨道车辆保温材料，由内向外依次为基本面、疏水板、保温材料、复合表皮，所述基本面为矿棉，复合表皮为铝箔；所述保温材料包括以下组份：橡塑共混材料、酚醛树脂、酸性蒙脱土、碳纤维、稳定剂、填料、增塑剂、发泡剂、氧化锌、阻燃剂、固化剂、润滑剂和增韧剂。本发明的轨道车辆保温材料，用以提高轨道车辆保温材料的压缩强度和弯曲强度。

Description

一种新型轨道车辆保温材料及其制备方法
技术领域
本发明属于保温材料技术领域，具体涉及一种轨道车辆保温材料及其制备方法。
背景技术
酚醛泡沫以其优良的阻燃性、热稳定性、隔热性、低毒性、耐腐蚀性、以及高模量等独特长处，在建筑、石油化工、车辆船舶、航空航天及植物栽培领域中获得了广泛应用。简单介绍如下：
建筑业：酚醛泡沫具有良好的防火保温性能，隔热效果比传统保温材料高2-3倍。据调查，毒害气体和浓烟是一般火灾中人员伤亡的主要因素，酚醛泡沫作为一种低烟、难燃、绝热、低毒的材料在建筑保温行业前景诱人。酚醛泡沫与其它面层材料复合后，可用于宾馆、公寓、医院等高要求建筑物墙体、隔热天花板等各类房屋及隔板的保温。
交通运输：目前在交通运输行业中，将酚醛泡沫包覆铝板或铁板制成夹芯板材，作为飞机、火车等交通工具的外壳越来越普遍，这种复合材料不但保留了外层金属壳体的强度，而且阻燃和隔热性能优越。
石油化工：目前越来越多的石油化工容器、油罐、管道等采用酚醛泡沫保温，不仅因为它优良的防火性能，而且绝热、耐腐蚀、防老化性能也是很可观的。
冷风管系统：冷风管系统是对保温要求较高的领域之一，其保温材料不仅需要导热系数低、使用温度高而且应便于施工，还需具有一定的机械强度。酚醛泡沫凭其优异的性能成为冷风管道保温的首选材料。
现有技术中的保温材料一般设置其具有较优的阻燃性能，但是存在压缩强度和弯曲强度不足的问题，且车辆外敷材料整体结构不够优化，无法满足车辆长期运行的要求。
发明内容
本发明的目的是提供一种轨道车辆保温材料及其制备方法，以解决现有技术中的保温材料存在的压缩强度和弯曲强度不足的问题。
为了解决以上技术问题，本发明采用以下技术方案：
一种轨道车辆保温材料，由内向外依次为基本面、疏水板、保温材料、复合表皮，所述基本面为矿棉，复合表皮为铝箔；所述保温材料包括以下组份：橡塑共混材料、酚醛树脂、酸性蒙脱土、碳纤维、稳定剂、填料、增塑剂、发泡剂、氧化锌、阻燃剂、固化剂、润滑剂和增韧剂；
所述酸性蒙脱土的制备工艺为将钠基蒙脱土分散到水中，加盐酸调节pH值为2-3，在80℃的温度下搅拌4h后，再加盐酸重新调节 pH值为2-3，再搅拌4h，离心反复水洗至中性，干燥后球磨机粉碎至粒径为20-40μm即得；
所述橡塑共混材料由乙烯-醋酸乙烯酯橡胶和聚氯乙烯在开炼机中混合后进行塑炼得到；
所述酚醛树脂由苯酚、甲醛、丙酮、乙醇、氯丁橡胶、磷酸、聚乙烯醇缩乙醛和间苯二酚制成，且所述酚醛树脂制成后还在碱性条件下用有机硼化合物改性。所述酚醛树脂、酸性蒙脱土、碳纤维的重量比为(30-40)∶(3.2-4.8)∶(1.5-2.8)。
优选地，所述酚醛树脂、酸性蒙脱土、碳纤维的重量比为35∶4∶2。
优选地，以重量份为单位，包括以下原料：橡塑共混材料40-50 份、酚醛树脂30-40份、酸性蒙脱土3.2-4.8份、碳纤维1.5-2.8份、稳定剂2-5份、填料90-100份、增塑剂30-50份、发泡剂20-26 份、氧化锌2-6份、阻燃剂8-15份、固化剂0.1-0.5份、润滑剂0.2-0.6 份和增韧剂0.1-0.8份。
优选地，以重量份为单位，包括以下原料：橡塑共混材料45份、酚醛树脂35份、酸性蒙脱土4份、碳纤维2份、稳定剂4份、填料 95份、增塑剂40份、发泡剂24份、氧化锌4份、阻燃剂12份、固化剂0.3份、润滑剂0.4份和增韧剂0.5份。
优选地，所述稳定剂为硬脂酸铅。
优选地，所述固化剂为六亚甲基四胺或草酸。
优选地，所述润滑剂为油酸、硬脂酸与硬脂酸盐中的一种。
优选地，所述增韧剂为天然橡胶、丁腈橡胶、羟基丁腈橡胶、羟端基聚丁二烯中的一种。
优选地，所述阻燃剂为硼酸锌、三氧化二锑、十溴二苯乙烷中的一种或多种；所述发泡剂为偶氮二甲酰胺、正戊烷或碳酸氢钙中的任一种；所述填料为氢氧化镁、氢氧化铝中的一种或多种；所述增塑剂为邻苯二甲酸二辛酯、氯化石蜡油中的一种或多种。
本发明还提供一种轨道车辆保温材料的制备方法，包括以下步骤：
S1：按比例称取橡塑共混材料、酚醛树脂、酸性蒙脱土、碳纤维、稳定剂、填料、增塑剂、发泡剂、氧化锌、阻燃剂、固化剂、润滑剂和增韧剂混合并搅拌均匀，装入钢制模具；
S2：在压缩比为1.8-2.2，热压成型温度215-230℃条件下热压成型，保压1.5-2.5h，即得到酚醛树脂保温材料。
优选地，所述步骤S2中，在压缩比为2，热压成型温度220℃条件下热压成型，保压2h。
本发明具有以下有益效果：
(1)本发明在轨道车辆保温材料加入橡塑共混材料，该橡塑共混材料由乙烯-醋酸乙烯酯橡胶和聚氯乙烯在开炼机中混合后进行塑炼得到，其具有较好的弹性和抗冲击力，从而能够提升轨道车辆保温材料的压缩强度和弯曲强度。
(2)本发明提供的轨道车辆保温材料的组分还包括酚醛树脂、酸性蒙脱土、碳纤维，三者在制备轨道车辆保温材料中起到了协同作用，协同提高了轨道车辆保温材料的压缩强度和弯曲强度。
(3)其中的酚醛树脂由苯酚、甲醛、丙酮、乙醇、氯丁橡胶、磷酸、聚乙烯醇缩乙醛和间苯二酚制成，且所述酚醛树脂制成后还在碱性条件下用有机硼化合物改性，改性后的酚醛树脂具有非常好的耐热性和韧性，从而不仅保证了该轨道车辆保温材料的保温效果，而且进一步提升了其弯曲强度。
(4)优化的材料层内外结构，能够较好地适应外部试用环境，达到阻燃、隔热保温、耐腐蚀、较好的压缩强度弯曲强度的技术效果。
具体实施方式
为了更好地理解本发明，现采用以下实施例加以说明，以下实施例属于本发明的保护范围，但不限制本发明的保护范围。
以下实施例中，所述轨道车辆保温材料，由内向外依次为基本面、疏水板、保温材料、复合表皮，所述基本面为矿棉，复合表皮为铝箔；以重量份为单位，包括以下原料：橡塑共混材料40-50份、酚醛树脂30-40份、酸性蒙脱土3.2-4.8份、碳纤维1.5-2.8份、稳定剂2-5份、填料90-100份、增塑剂30-50份、发泡剂20-26份、氧化锌 2-6份、阻燃剂8-15份、固化剂0.1-0.5份、润滑剂0.2-0.6份和增韧剂0.1-0.8份。
所述橡塑共混材料由乙烯-醋酸乙烯酯橡胶和聚氯乙烯在开炼机中混合后进行塑炼得到，优选的，以重量份为单位，乙烯-醋酸乙烯酯(EVM)橡胶为70份，聚氯乙烯(PVC)为30份；所述稳定剂为硬脂酸铅；所述阻燃剂为硼酸锌、三氧化二锑、十溴二苯乙烷中的一种或多种；所述发泡剂为偶氮二甲酰胺、正戊烷或碳酸氢钙中的任一种；所述填料为氢氧化镁、氢氧化铝中的一种或多种；所述增塑剂为邻苯二甲酸二辛酯、氯化石蜡油中的一种或多种；固化剂为六亚甲基四胺或草酸；润滑剂为油酸、硬脂酸与硬脂酸盐中的一种；增韧剂为天然橡胶、丁腈橡胶、羟基丁腈橡胶、羟端基聚丁二烯中的一种。
所述酸性蒙脱土的制备工艺为将钠基蒙脱土分散到水中，加盐酸调节pH值为2-3，在80℃的温度下搅拌4h后，再加盐酸重新调节 pH值为2-3，再搅拌4h，离心反复水洗至中性，干燥后球磨机粉碎至粒径为20-40μm即得。
所述酚醛树脂由苯酚、甲醛、丙酮、乙醇、氯丁橡胶、磷酸、聚乙烯醇缩乙醛和间苯二酚制成，且所述酚醛树脂制成后还在碱性条件下用有机硼化合物改性。
以上所述的轨道车辆保温材料的制备方法，包括以下步骤：
S1：按比例称取橡塑共混材料、酚醛树脂、酸性蒙脱土、碳纤维、稳定剂、填料、增塑剂、发泡剂、氧化锌、阻燃剂、固化剂、润滑剂和增韧剂混合并搅拌均匀，装入钢制模具；
S2：在压缩比为1.8-2.2，热压成型温度215-230℃条件下热压成型，保压1.5-2.5h，即得到上述轨道车辆保温材料。
本发明通过更具体的实施例加以说明。
实施例1
一种轨道车辆保温材料，由内向外依次为基本面、疏水板、保温材料、复合表皮，所述基本面为矿棉，复合表皮为铝箔；以重量份为单位，包括以下原料：橡塑共混材料45份、酚醛树脂35份、酸性蒙脱土4份、碳纤维2份、硬脂酸铅4份、氢氧化镁95份、邻苯二甲酸二辛酯40份、偶氮二甲酰胺24份、氧化锌4份、硼酸锌12 份、六亚甲基四胺0.3份、油酸0.4份和天然橡胶0.5份；
所述酸性蒙脱土的制备工艺为将钠基蒙脱土分散到水中，加盐酸调节pH值为2，在80℃的温度下搅拌4h后，再加盐酸重新调节 pH值为2，再搅拌4h，离心反复水洗至中性，干燥后球磨机粉碎至粒径为30μm即得。
以上所述的轨道车辆保温材料的制备方法，包括以下步骤：
S1：按比例称取橡塑共混材料、酚醛树脂、酸性蒙脱土、碳纤维、稳定剂、填料、增塑剂、发泡剂、氧化锌、阻燃剂、固化剂、润滑剂和增韧剂混合并搅拌均匀，装入钢制模具；
S2：在压缩比为2，热压成型温度220℃条件下热压成型，保压 2h，即得到上述轨道车辆保温材料。
实施例2
一种轨道车辆保温材料，由内向外依次为基本面、疏水板、保温材料、复合表皮，所述基本面为矿棉，复合表皮为铝箔；以重量份为单位，包括以下原料：橡塑共混材料40份、酚醛树脂38份、酸性蒙脱土4.2份、碳纤维2.2份、硬脂酸铅2份、氢氧化铝100份、氯化石蜡油45份、正戊烷20份、氧化锌2份、三氧化二锑8份、草酸0.5份、硬脂酸0.5份和丁腈橡胶0.8份；
所述酸性蒙脱土的制备工艺为将钠基蒙脱土分散到水中，加盐酸调节pH值为3，在80℃的温度下搅拌4h后，再加盐酸重新调节 pH值为3，再搅拌4h，离心反复水洗至中性，干燥后球磨机粉碎至粒径为40μm即得。
以上所述的轨道车辆保温材料的制备方法，包括以下步骤：
S1：按比例称取橡塑共混材料、酚醛树脂、酸性蒙脱土、碳纤维、稳定剂、填料、增塑剂、发泡剂、氧化锌、阻燃剂、固化剂、润滑剂和增韧剂混合并搅拌均匀，装入钢制模具；
S2：在压缩比为2.1，热压成型温度230℃条件下热压成型，保压1.5h，即得到酚醛树脂保温材料。
实施例3
一种轨道车辆保温材料，由内向外依次为基本面、疏水板、保温材料、复合表皮，所述基本面为矿棉，复合表皮为铝箔；以重量份为单位，包括以下原料：橡塑共混材料50份、酚醛树脂40份、酸性蒙脱土4.8份、碳纤维2.8份、硬脂酸铅4份、氢氧化镁45份、氢氧化铝45份、邻苯二甲酸二辛酯25份、氯化石蜡油25份、碳酸氢钙22份、氧化锌4份、十溴二苯乙烷10份、六亚甲基四胺0.1份、油酸0.6份和羟基丁腈橡胶0.1份；
所述酸性蒙脱土的制备工艺为将钠基蒙脱土分散到水中，加盐酸调节pH值为2，在80℃的温度下搅拌4h后，再加盐酸重新调节 pH值为2，再搅拌4h，离心反复水洗至中性，干燥后球磨机粉碎至粒径为20μm即得。
以上所述的轨道车辆保温材料的制备方法，包括以下步骤：
S1：按比例称取橡塑共混材料、酚醛树脂、酸性蒙脱土、碳纤维、稳定剂、填料、增塑剂、发泡剂、氧化锌、阻燃剂、固化剂、润滑剂和增韧剂混合并搅拌均匀，装入钢制模具；
S2：在压缩比为2.2，热压成型温度215℃条件下热压成型，保压2.2h，即得到上述轨道车辆保温材料。
实施例4
一种轨道车辆保温材料，由内向外依次为基本面、疏水板、保温材料、复合表皮，所述基本面为矿棉，复合表皮为铝箔；以重量份为单位，包括以下原料：橡塑共混材料42份、酚醛树脂30份、酸性蒙脱土3.2份、碳纤维1.5份、硬脂酸铅5份、氢氧化镁98份、邻苯二甲酸二辛酯30份、碳酸氢钙26份、氧化锌6份、硼酸锌15 份、六亚甲基四胺0.2份、硬脂酸0.2份和羟端基聚丁二烯0.3份；
所述酸性蒙脱土的制备工艺为将钠基蒙脱土分散到水中，加盐酸调节pH值为3，在80℃的温度下搅拌4h后，再加盐酸重新调节 pH值为3，再搅拌4h，离心反复水洗至中性，干燥后球磨机粉碎至粒径为25μm即得。
以上所述的轨道车辆保温材料的制备方法，包括以下步骤：
S1：按比例称橡塑共混材料、取酚醛树脂、酸性蒙脱土、碳纤维、稳定剂、填料、增塑剂、发泡剂、氧化锌、阻燃剂、固化剂、润滑剂和增韧剂混合并搅拌均匀，装入钢制模具；
S2：在压缩比为1.8，热压成型温度225℃条件下热压成型，保压2.5h，即得到上述保温材料。
对比例1
与实施例1的制备方法基本相同，不同之处在于制备轨道车辆保温材料的原料中缺少酚醛树脂、酸性蒙脱土、碳纤维。
对比例2
与实施例1的制备方法基本相同，不同之处在于制备轨道车辆保温材料的原料中缺少酚醛树脂。
对比例3
与实施例1的制备方法基本相同，不同之处在于制备轨道车辆保温材料的原料中缺少酸性蒙脱土。
对比例4
与实施例1的制备方法基本相同，不同之处在于制备轨道车辆保温材料的原料中缺少碳纤维。
对比例5
采用中国专利文献″一种橡塑共混高阻燃绝热保温材料(专利号为：ZL201510064677.6)″中实施例1中所述方法制备保温材料。
对实施例1-4和对比例1-5所述的保温材料进行性能检测，结果见下表所示。
Figure RE-GDA0002744060720000101
Figure RE-GDA0002744060720000111
由上表可知：(1)由实施例1-4和对比例5的数据可见，实施例1-4制得的轨道车辆保温材料的压缩强度和弯曲强度显著大于对比例5制得的压缩强度的压缩强度和弯曲强度；同时由实施例1-4 的数据可见，实施例1为最优实施例。
(2)由实施例1和对比例1-4的数据可见，酚醛树脂、酸性蒙脱土、碳纤维在制备轨道车辆保温材料中起到了协同作用，协同提高了轨道车辆保温材料的压缩强度和弯曲强度，这是因为：
酚醛树脂为泡沫保温材料，本身具有难燃性、绝热性等优良特性。酚醛树脂中极性键和酸性蒙脱土中的硅氧键极性相近，具有很强的亲和性，酸性蒙脱土中的氢离子进入到酚醛树脂中进行酸催化反应，反应的生成物和反应热利于蒙脱土的剥离，使蒙脱土片层在酚醛树脂中呈纳米级分布，在酚醛树脂泡沫中起到了填料的作用，强化了泡壁，从而提高了保温材料的压缩强度。碳纤维与酚醛树脂具有很好的亲和性，在发泡过程中碳纤维分散在酚醛树脂中，使碳纤维表面被酚醛树脂紧密包覆，并且贯穿了多个气泡，增加了泡沫的密度，从而增加了保温材料的压缩强度；此外，碳纤维在酚醛树脂中构成了酚醛泡沫的基本骨架，当泡沫受到弯曲应力时，碳纤维就像混凝土中的钢筋一样，承载一定的拉力，能够阻止裂缝或者裂纹的产生和扩展，进而提高了保温材料的弯曲强度。
以上内容不能认定本发明具体实施只局限于这些说明，对于本发明所属技术领域的普通技术人员来说，在不脱离本发明构思前提下，还可以做出若干简单推演或替换，都应当视为属于本发明由所提交的权利要求书确定的专利保护范围。

Claims (10)

1.一种轨道车辆保温材料，其特征在于，由内向外依次为基本面、疏水板、保温材料、复合表皮，所述基本面为矿棉，复合表皮为铝箔；所述保温材料包括以下组份：橡塑共混材料、酚醛树脂、酸性蒙脱土、碳纤维、稳定剂、填料、增塑剂、发泡剂、氧化锌、阻燃剂、固化剂、润滑剂和增韧剂；
所述酸性蒙脱土的制备工艺为将钠基蒙脱土分散到水中，加盐酸调节pH值为2-3，在80℃的温度下搅拌4h后，再加盐酸重新调节pH值为2-3，再搅拌4h，离心反复水洗至中性，干燥后球磨机粉碎至粒径为20-40μm即得；
所述酚醛树脂、酸性蒙脱土、碳纤维的重量比为(30-40)∶(3.2-4.8)∶(1.5-2.8)；
所述橡塑共混材料由乙烯-醋酸乙烯酯橡胶和聚氯乙烯在开炼机中混合后进行塑炼得到；
所述酚醛树脂由苯酚、甲醛、丙酮、乙醇、氯丁橡胶、磷酸、聚乙烯醇缩乙醛和间苯二酚制成，且所述酚醛树脂制成后还在碱性条件下用有机硼化合物改性。
2.根据权利要求1所述的轨道车辆保温材料，其特征在于，所述酚醛树脂、酸性蒙脱土、碳纤维的重量比为35∶4∶2。
3.根据权利要求1所述的轨道车辆保温材料，其特征在于，以重量份为单位，所述轨道车辆保温材料包括以下原料：橡塑共混材料40-50份、酚醛树脂30-40份、酸性蒙脱土3.2-4.8份、碳纤维1.5-2.8份、稳定剂2-5份、填料90-100份、增塑剂30-50份、发泡剂20-26份、氧化锌2-6份、阻燃剂8-15份、固化剂0.1-0.5份、润滑剂0.2-0.6份和增韧剂0.1-0.8份。
4.根据权利要求3所述的轨道车辆保温材料，其特征在于，以重量份为单位，所述轨道车辆保温材料包括以下原料：橡塑共混材料45份、酚醛树脂35份、酸性蒙脱土4份、碳纤维2份、稳定剂4份、填料95份、增塑剂40份、发泡剂24份、氧化锌4份、阻燃剂12份、固化剂0.3份、润滑剂0.4份和增韧剂0.5份。
5.根据权利要求1、3或4所述的轨道车辆保温材料，其特征在于，所述稳定剂为硬脂酸铅。
6.根据权利要求1、3或4所述的轨道车辆保温材料，其特征在于，所述固化剂为六亚甲基四胺或草酸。
7.根据权利要求1、3或4所述的轨道车辆保温材料，其特征在于，所述润滑剂为油酸、硬脂酸与硬脂酸盐中的一种。
8.根据权利要求1、3或4所述的轨道车辆保温材料，其特征在于，所述增韧剂为天然橡胶、丁腈橡胶、羟基丁腈橡胶、羟端基聚丁二烯中的一种；
优选的，所述阻燃剂为硼酸锌、三氧化二锑、十溴二苯乙烷中的一种或多种；所述发泡剂为偶氮二甲酰胺、正戊烷或碳酸氢钙中的任一种；所述填料为氢氧化镁、氢氧化铝中的一种或多种；所述增塑剂为邻苯二甲酸二辛酯、氯化石蜡油中的一种或多种。
9.一种根据权利要求1-8任一项所述的轨道车辆保温材料的制备方法，其特征在于，包括以下步骤：
S1：按比例称取橡塑共混材料、酚醛树脂、酸性蒙脱土、碳纤维、稳定剂、填料、增塑剂、发泡剂、氧化锌、阻燃剂、固化剂、润滑剂和增韧剂混合并搅拌均匀，装入钢制模具；
S2：在压缩比为1.8-2.2，热压成型温度215-230℃条件下热压成型，保压1.5-2.5h，即得到树脂保温材料。
10.根据权利要求9所述的轨道车辆保温材料的制备方法，其特征在于，所述步骤S2中，在压缩比为2，热压成型温度220℃条件下热压成型，保压2h，得到树脂保温材料。
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