CN112339381A - 一种真空绝热板及其制备方法 - Google Patents
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Abstract
本发明公开了一种真空绝热板及其制备方法,其中真空绝热板包括芯材和复合包覆膜,芯材包括内芯和包覆于内芯的外部的过滤层;复合包覆膜包括外包覆膜和约束膜,外包覆膜包覆于芯材的外部;约束膜具有热收缩作用,约束膜包覆于外包覆膜的外部并与外包覆膜熔融为一体。通过该制备方法制得的真空绝热板的外部具有自约束力,避免了真空绝热板因施工刺破或因内外温差变化大造成其膨胀变形发生胀袋漏气问题,并且解决了真空绝热板包覆膜易被破坏及破坏漏气后真空保温板保温性能下降的问题,使真空绝热板长期维持其超级绝热保温性能得到了保障。
Description
技术领域
本发明涉及保温材料技术领域,尤其涉及一种真空绝热板及其制备方法。
背景技术
真空绝热板是真空保温材料中的一种,是由填充芯材与真空保护表层复合而成,它有效地避免空气对流引起的热传递,因此导热系数可大幅度降低,具有环保和高效节能的特性,是目前世界上最先进的高效保温材料,以其极低的导热系数,在保温技术要求相同时有保温层厚度薄、体积小、重量轻的优点,适用于节能要求较高的产品,有较大技术经济意义。
一般地,真空绝热板由芯材和外包覆膜组成。外包覆膜一方面为了包裹芯材,维持内部真空状态,一方面在真空绝热板的使用过程中,能够阻止外部气体的渗透,延长真空绝热板的使用寿命,因此对覆膜材料都要求具有阻隔性,能够阻隔常见气体的渗透。
真空绝热板作为一种超级绝热保温材料,虽然在建筑墙体保温领域已得到广泛应用,但其仍然存在因施工破坏、气候温差变化大等因素而造成的真空板漏气膨胀或受热膨胀变形等问题,给墙体保温施工带来了困难,同时也存在安全隐患。
为降低真空板漏气膨胀或受热膨胀变形对施工造成的影响,现有技术中有采取将真空绝热板的内部芯材与外包覆膜热熔在一起、形成芯膜一体化的处理工艺,以此避免真空绝热板被刺破后发生胀袋漏气现象,但此工艺无法解决真空绝热板易被刺破的问题及刺破漏气后真空保温板保温性能下降的问题。
需要说明的是,上述内容属于发明人的技术认知范畴,并不必然构成现有技术。
发明内容
为了解决上述问题,本发明的目的是提供一种真空绝热板及其制备方法,通过该制备方法制得的真空绝热板的外部具有自约束力,避免了真空绝热板因施工刺破或因内外温差变化大造成其膨胀变形发生胀袋漏气问题,并且解决了真空绝热板包覆膜易被破坏及破坏漏气后真空保温板保温性能下降的问题,使真空绝热板长期维持其超级绝热保温性能得到了保障。
为实现上述目的,第一方面,本发明首先提出了一种真空绝热板,包括芯材和复合包覆膜,所述芯材包括内芯和包覆于所述内芯的外部的过滤层;所述复合包覆膜包括外包覆膜和约束膜,所述外包覆膜包覆于所述芯材的外部;所述约束膜具有热收缩作用,所述约束膜包覆于所述外包覆膜的外部并与所述外包覆膜熔融为一体。本发明中的约束膜本身具有热收缩作用且与外包覆膜熔融为一体,通过约束膜对外包覆膜的热缩约束及热熔约束作用,显著增大了外包覆膜因抵抗内部真空度变化而产生的拉应力,因而使外包覆膜的抗拉强度增大,耐穿刺强度提高,保持内部真空度的能力增强,有效降低了真空绝热板因外部或内部受力造成真空度降低等情况的发生,避免了真空绝热板因真空度变化造成外包覆膜拉应力增大而漏气的问题,使真空绝热板长期维持其超级绝热保温性能得到保障。
在一个示例中,所述复合包覆膜的耐穿刺强度≥30N,所述真空绝热板的膨胀变形率≤3%。在外包覆膜之外增加具有热收缩作用的约束膜并将两者熔融为一体后,真空绝热板所具有的复合包覆膜的耐穿刺强度≥30N,真空绝热板的膨胀变形率≤3%,可见外包覆膜的抗拉强度增大,耐穿刺强度提高,保持内部真空度的能力也大大增强。
在一个示例中,所述复合包覆膜还包括设置于所述外包覆膜与所述约束膜之间的阻隔板,所述外包覆膜与所述约束膜分别与所述阻隔板的两侧面熔融相连,所述外包覆膜与所述约束膜通过所述阻隔板熔融为一体。在约束膜与外包覆膜增加阻隔板,且将约束膜、阻隔板与外包覆膜熔融为一体,在约束膜对阻隔板以及外包覆膜的热缩约束及热熔约束作用显著增大外包覆膜因抵抗内部真空度变化而产生的拉应力之外,阻隔板作为刚性板状材料,其本身也可进一步增加外包覆膜的抗拉强度以及耐穿刺强度,有效降低真空绝热板因外部或内部受力造成真空度降低等情况的发生,避免了真空绝热板因真空度变化造成外包覆膜拉应力增大而漏气的问题,使真空绝热板长期维持其超级绝热保温性能得到保障。
在一个示例中,所述复合包覆膜的耐穿刺强度≥60N,所述真空绝热板的膨胀变形率≤1%。在外包覆膜之外增加具有热收缩作用的约束膜以及阻隔板并将三者熔融为一体之后,真空绝热板所具有的复合包覆膜的耐穿刺强度≥60N,真空绝热板的膨胀变形率≤1%,可见外包覆膜的抗拉强度进一步增大,耐穿刺强度进一步提高,保持内部真空度的能力也进一步增强。
在一个示例中,所述约束膜的结构组成由内到外依次为聚乙烯、热缩层、玻纤层;所述热缩层材质由 PP膜、OPP膜、PE膜、PET膜、POF膜或EVA膜一层或多层共挤而成。
在一个示例中,所述阻隔板的材质为碳纤维复合板、玻璃纤维复合板、硅酸铝纤维板、发泡陶瓷板或发泡玻璃板等一种或多种复合。
在一个示例中,所述外包覆膜具有真空阻气作用,所述外包覆膜由内到外依次为热封层、阻气层、防护层,所述热封层由聚乙烯、聚丙烯中的一种或一种以上组合而成,所述阻气层由聚乙烯、尼龙、聚酯、聚丙烯、铝箔、镀铝膜、聚氯乙烯、乙烯-醋酸乙烯共聚膜中的一种或一种以上组合而成,所述防护层由玻纤布、碳纤布、无纺布、化纤布、纺织布中的一种或一种以上组合而成。
在一个示例中,所述过滤层由起过滤作用的无纺布、纺织布、玻纤毡、滤纸等过滤包裹布组成。
第二方面,本发明还提出了一种上述真空绝热板的制备方法,包括以下步骤:
S1、所述芯材烘干后包覆所述外包覆膜,抽真空并封口;
S2、在所述外包覆膜外部包覆所述约束膜,抽真空并封口,得到包覆有所述外包覆膜和所述约束膜的所述芯材;
S3、将包覆有所述外包覆膜和所述约束膜的所述芯材加压热合或直接加热烘烤,使所述外包覆膜与所述约束膜熔融为一体,得到所述真空绝热板。
在一个示例中,所述S1中抽真空至100Pa以下,所述封口温度100-300℃。
在一个示例中,所述S2还包括:在所述外包覆膜外部包覆所述约束膜,经加热收缩后,抽真空并封口。
在一个示例中,所述S2中,所述加热收缩的温度为40-90℃,所述加热收缩的时间为5-20min,抽真空至1000Pa以下,所述封口温度40-250℃。
在一个示例中,所述S3中,所述外包覆膜与所述约束膜的加压热合温度为80-300℃,压力为50-500KPa,时间为1-10min。
在一个示例中,所述S2与所述S3具体包括:
S21、在所述外包覆膜外部包覆所述约束膜并在所述外包覆膜与所述约束膜之间放置阻隔板,抽真空并封口,得到包覆有所述外包覆膜、所述阻隔板和所述约束膜的所述芯材;
S31、将包覆有所述外包覆膜、所述阻隔板和所述约束膜的所述芯材加压热合或直接加热烘烤,使所述外包覆膜与所述约束膜经所述阻隔板连接后熔融为一体,得到所述真空绝热板。
在一个示例中,所述S31中,所述加压热合的温度为80-400℃,所述加压热合的压力为100-1000KPa,所述加压热合的时间为1-10min。
附图说明
此处所说明的附图仅仅用来辅助本领域技术人员理解本发明的技术方案,本发明结合附图说明的示意性实施例仅仅用于解释本发明的技术方案,并不构成对本发明的不当限定。在附图中:
图1为本发明实施例提供的真空绝热板的局部剖视图;
图2为本发明另一实施例提供的真空绝热板的局部剖视图;
图3为本发明又一实施例提供的真空绝热板的局部剖视图;
图4为本发明再一实施例提供的真空绝热板的局部剖视图。
附图标记列表:
真空绝热板1;芯材10、内芯11、过滤层12;复合包覆膜20、外包覆膜21、约束膜22、阻隔板23。
具体实施方式
为了更清楚的阐释本发明的整体构思,下面结合说明书附图以示例的方式进行详细说明。
在本发明的描述中,需要理解的是,术语“中心”、“上”、“下”、“前”、“后”、“左”、“右”、“竖直”、“水平”、“顶”、“底”、“内”、“外”、“轴向”、“径向”、“周向”等指示的方位或位置关系为基于附图所示的方位或位置关系,仅是为了便于描述本发明和简化描述,而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作,因此不能理解为对本发明的限制。
此外,术语“第一”、“第二”仅用于描述目的,而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量。由此,限定有“第一”、“第二”的特征可以明示或者隐含地包括一个或者更多个该特征。在本发明的描述中,“多个”的含义是两个或两个以上,除非另有明确具体的限定。
在本发明中,除非另有明确的规定和限定,术语“安装”、“相连”、“连接”、“固定”等术语应做广义理解,例如,可以是固定连接,也可以是可拆卸连接,或成一体;可以是机械连接,也可以是电连接,还可以是通信;可以是直接相连,也可以通过中间媒介间接相连,可以是两个元件内部的连通或两个元件的相互作用关系。对于本领域的普通技术人员而言,可以根据具体情况理解上述术语在本发明中的具体含义。
在本发明中,除非另有明确的规定和限定,第一特征在第二特征“上”或“下”可以是第一和第二特征直接接触,或第一和第二特征通过中间媒介间接接触。在本说明书的描述中,参考术语“一个方案”、“一些方案”、“示例”、“具体示例”、或“一些示例”等的描述意指结合该方案或示例描述的具体特征、结构、材料或者特点包含于本发明的至少一个方案或示例中。在本说明书中,对上述术语的示意性表述不必须针对的是相同的方案或示例。而且,描述的具体特征、结构、材料或者特点可以在任一个或多个方案或示例中以合适的方式结合。
如图1至图4所示,第一方面,本发明首先提出了一种真空绝热板1,包括芯材10和复合包覆膜20,芯材10包括内芯11和包覆于内芯11的外部的过滤层12;复合包覆膜20包括外包覆膜21和约束膜22,外包覆膜21包覆于芯材10的外部;约束膜22具有热收缩作用,约束膜22包覆于外包覆膜21的外部并与外包覆膜21熔融为一体。本发明中的约束膜22本身具有热收缩作用且与外包覆膜21熔融为一体,通过约束膜22对外包覆膜21的热缩约束及热熔约束作用,显著增大了外包覆膜21因抵抗内部真空度变化而产生的拉应力,因而使外包覆膜21的抗拉强度增大,耐穿刺强度提高,保持内部真空度的能力增强,有效降低了真空绝热板1因外部或内部受力造成真空度降低等情况的发生,避免了真空绝热板1因真空度变化造成外包覆膜拉应力增大而漏气的问题,使真空绝热板1长期维持其超级绝热保温性能得到保障。具体地,上述真空绝热板1的复合包覆膜20的耐穿刺强度≥30N,真空绝热板1的膨胀变形率≤3%。在外包覆膜21之外增加具有热收缩作用的约束膜22并将两者熔融为一体后,真空绝热板1所具有的复合包覆膜20的耐穿刺强度≥30N,真空绝热板1的膨胀变形率≤3%,可见外包覆膜21的抗拉强度增大,耐穿刺强度提高,保持内部真空度的能力也大大增强。
在一个具体实施例中,如图2至图4所示,复合包覆膜20还包括设置于外包覆膜21与约束膜22之间的阻隔板23,外包覆膜21与约束膜22分别与阻隔板23的两侧面熔融相连,外包覆膜21与约束膜22通过阻隔板23熔融为一体。在约束膜22与外包覆膜21增加阻隔板23,且将约束膜22、阻隔板23与外包覆膜21熔融为一体,在约束膜22对阻隔板23以及外包覆膜21的热缩约束及热熔约束作用显著增大外包覆膜21因抵抗内部真空度变化而产生的拉应力之外,阻隔板23作为刚性板状材料,其本身也可进一步增加外包覆膜21的抗拉强度以及耐穿刺强度,有效降低真空绝热板1因外部或内部受力造成真空度降低等情况的发生,避免了真空绝热板1因真空度变化造成外包覆膜21拉应力增大而漏气的问题,使真空绝热板1长期维持其超级绝热保温性能得到保障。具体地,上述真空绝热板1的复合包覆膜20的耐穿刺强度≥60N,真空绝热板1的膨胀变形率≤1%。在外包覆膜21之外增加具有热收缩作用的约束膜22以及阻隔板23并将三者熔融为一体之后,真空绝热板1所具有的复合包覆膜20的耐穿刺强度≥60N,真空绝热板1的膨胀变形率≤1%,可见外包覆膜21的抗拉强度进一步增大,耐穿刺强度进一步提高,保持内部真空度的能力也进一步增强。
具体地,由于真空绝热板1具有两个侧面,阻隔板23可仅设置于一侧,例如如图3所示的真空绝热板1,仅在真空绝热板1上侧面的外包覆膜21与约束膜22之间放置阻隔板23,也可如图4所示,仅在真空绝热板1下侧面的外包覆膜21与约束膜22之间放置阻隔板23,也可如图2中所示同时设置上下两块阻隔板23,具体设置方式可根据不同的生产要求而定,本申请在此不作具体限定。
在一个具体实施例中,约束膜22的结构组成由内到外依次为聚乙烯、热缩层、玻纤层;热缩层材质由 PP膜(PP膜是聚丙烯膜,由丙烯聚合而制得的一种热塑性树脂)、OPP膜(OPP英文全称为Oriented Polypropylene,单向拉伸聚丙烯,意思是在横向对流延出来的聚丙烯薄膜进行拉伸)、PE膜(全名为Polyethylene,是结构最简单的高分子有机化合物)、PET膜(聚酯薄膜)、POF膜(多层共挤聚烯烃热收缩膜)或EVA膜(一种热固性有粘性的胶膜,全称Polyethylene vinylacetate,是聚乙烯-聚醋酸乙烯酯共聚物的简称)一层或多层共挤而成。
在一个具体实施例中,阻隔板23的材质为碳纤维复合板、玻璃纤维复合板、硅酸铝纤维板、发泡陶瓷板或发泡玻璃板等一种或多种复合。
在一个具体实施例中,外包覆膜21具有真空阻气作用,外包覆膜21由内到外依次为热封层、阻气层、防护层,热封层由聚乙烯、聚丙烯中的一种或一种以上组合而成,阻气层由聚乙烯、尼龙、聚酯、聚丙烯、铝箔、镀铝膜、聚氯乙烯、乙烯-醋酸乙烯共聚膜中的一种或一种以上组合而成,防护层由玻纤布、碳纤布、无纺布、化纤布、纺织布中的一种或一种以上组合而成。
在一个具体实施例中,过滤层12由起过滤作用的无纺布、纺织布、玻纤毡、滤纸等过滤包裹布组成。
第二方面,本发明还提出了一种上述真空绝热板1的制备方法,包括以下步骤:
S1、芯材10烘干后包覆外包覆膜21,抽真空并封口;
S2、在外包覆膜21外部包覆约束膜22,抽真空并封口,得到包覆有外包覆膜21和约束膜22的芯材;
S3、将包覆有外包覆膜21和约束膜22的芯材10加压热合或直接加热烘烤,使外包覆膜21与约束膜22熔融为一体,得到真空绝热板1。
在一个具体实施例中,步骤S1中抽真空至100Pa以下,封口温度100-300℃。
在一个具体实施例中,步骤S2还包括:在外包覆膜21外部包覆约束膜22,经加热收缩后,抽真空并封口。
在一个具体实施例中,步骤S2中,加热收缩的温度为40-90℃,加热收缩的时间为5-20min,抽真空至1000Pa以下,封口温度40-250℃。
在一个具体实施例中,步骤S3中,外包覆膜21与约束膜22的加压热合温度为80-300℃,压力为50-500KPa,时间为1-10min。
在一个具体实施例中,在制作如图2至图4所示的真空绝热板1时,步骤S2具体包括:
S21、在外包覆膜21外部包覆约束膜22并在外包覆膜21与约束膜22之间放置阻隔板23,抽真空并封口,得到包覆有外包覆膜21、阻隔板23和约束膜22的芯材。
在一个具体实施例中,在制作如图2至图4所示的真空绝热板1时,步骤S3具体包括:
S31、将包覆有外包覆膜21、阻隔板23和约束膜22的芯材10加压热合或直接加热烘烤,使外包覆膜21与约束膜22经阻隔板23连接后熔融连接为一体,得到真空绝热板1。
在一个具体实施例中,步骤S31中,加压热合的温度为80-400℃,加压热合的压力为100-1000KPa,加压热合的时间为1-10min。
本说明书中的各个实施例均采用递进的方式描述,各个实施例之间相同相似的部分互相参见即可,每个实施例重点说明的都是与其他实施例的不同之处。尤其,对于系统实施例而言,由于其基本相似于方法实施例,所以描述的比较简单,相关之处参见方法实施例的部分说明即可。
以上所述仅为本发明的实施例而已,并不用于限制本发明。对于本领域技术人员来说,本发明可以有各种更改和变化。凡在本发明的精神和原理之内所作的任何修改、等同替换、改进等,均应包含在本发明的权利要求范围之内。
Claims (10)
1.一种真空绝热板,其特征在于,包括:
芯材,所述芯材包括内芯和包覆于所述内芯的外部的过滤层;
复合包覆膜,所述复合包覆膜包括外包覆膜和约束膜,所述外包覆膜包覆于所述芯材的外部;所述约束膜具有热收缩作用,所述约束膜包覆于所述外包覆膜的外部并与所述外包覆膜熔融为一体。
2.根据权利要求1所述的真空绝热板,其特征在于,所述复合包覆膜还包括设置于所述外包覆膜与所述约束膜之间的阻隔板,所述外包覆膜与所述约束膜分别与所述阻隔板的两侧面熔融相连,所述外包覆膜与所述约束膜通过所述阻隔板熔融为一体。
3.根据权利要求1或2所述的真空绝热板,其特征在于,所述约束膜的结构组成由内到外依次为聚乙烯、热缩层、玻纤层;所述热缩层材质由 PP膜、OPP膜、PE膜、PET膜、POF膜或EVA膜一层或多层共挤而成。
4.根据权利要求2所述的真空绝热板,其特征在于,所述阻隔板的材质为碳纤维复合板、玻璃纤维复合板、硅酸铝纤维板、发泡陶瓷板或发泡玻璃板等一种或多种复合。
5.根据权利要求1或2所述的真空绝热板,其特征在于,所述外包覆膜具有真空阻气作用,所述外包覆膜由内到外依次为热封层、阻气层、防护层,所述热封层由聚乙烯、聚丙烯中的一种或一种以上组合而成,所述阻气层由聚乙烯、尼龙、聚酯、聚丙烯、铝箔、镀铝膜、聚氯乙烯、乙烯-醋酸乙烯共聚膜中的一种或一种以上组合而成,所述防护层由玻纤布、碳纤布、无纺布、化纤布、纺织布中的一种或一种以上组合而成。
6.根据权利要求1所述的真空绝热板,其特征在于,所述复合包覆膜的耐穿刺强度≥30N,所述真空绝热板的膨胀变形率≤3%。
7.根据权利要求2所述的真空绝热板,其特征在于,所述复合包覆膜的耐穿刺强度≥60N,所述真空绝热板的膨胀变形率≤1%。
8.一种权利要求1所述的真空绝热板的制备方法,其特征在于,包括以下步骤:
S1、所述芯材烘干后包覆所述外包覆膜,抽真空并封口;
S2、在所述外包覆膜外部包覆所述约束膜,抽真空并封口,得到包覆有所述外包覆膜和所述约束膜的所述芯材;
S3、将包覆有所述外包覆膜和所述约束膜的所述芯材加压热合或直接加热烘烤,使所述外包覆膜与所述约束膜熔融为一体,得到所述真空绝热板。
9.根据权利要求8所述的真空绝热板的制备方法,其特征在于,所述S2与所述S3具体包括:
S2、在所述外包覆膜外部包覆所述约束膜并在所述外包覆膜与所述约束膜之间放置阻隔板,抽真空并封口,得到包覆有所述外包覆膜、所述阻隔板和所述约束膜的所述芯材;
S3、将包覆有所述外包覆膜、所述阻隔板和所述约束膜的所述芯材加压热合或直接加热烘烤,使所述外包覆膜与所述约束膜经所述阻隔板连接后熔融为一体,得到所述真空绝热板。
10.根据权利要求8所述的真空绝热板的制备方法,其特征在于,所述S2还包括:在所述外包覆膜外部包覆所述约束膜,经加热收缩后,抽真空并封口。
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