CN112726855B - 一种高效隔热保温板及其制备方法 - Google Patents
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Abstract
本发明属于复合板的制备技术领域,公开一种高效隔热保温板及其制备方法。包括第一面板层、第二面板层、夹芯层,其中夹芯层为一层泡沫层或两层以上泡沫层叠加而成,每层泡沫层由若干个泡沫块相互拼接而成;夹心层位于第一面板层和第二面板层之间,夹心层的下表面和第一面板层之间、夹心层的上表面和第二面板层之间、夹心层的四周边缘以及夹心层中任意两个相邻泡沫块的拼接缝中设置有功能结构层;所述第一面板层和第二面板层同时为纤维增强树脂复合材料;所述泡沫块为聚氨酯泡沫块、PVC泡沫块或酚醛泡沫块;所述功能结构层由气凝胶和功能填料组成。本发明设置具有包括隔热、缓冲、力学性能的功能结构层,进一步提高复合板材整体的综合性能优势。
Description
技术领域
本发明属于复合板的制备技术领域,具体涉及一种高效隔热保温板及其制备方法。
背景技术
轻质、保温隔热的性能一直是板材应用中重要的功能属性,也是板材领域中研究的热点方向。尤其在建筑材料领域,质轻且保温性能优良的板材非常受青睐,这是因为,这种板材密度小,极大减轻了建筑骨架承重负担,且降低了施工难度,保温性也能达到应用要求。
目前,这种轻质保温复合板材多由隔热夹心层与面板组成,面板多采用高强度的纤维板材、石板等,隔热夹心层材料绝大多数为普通有机泡沫类如聚苯乙烯泡沫、聚氨酯泡沫等,使所得的保温复合板材具备一定的保温及抗冲击性能。SiO2气凝胶作为一种新兴的超级隔热材料,其导热系数极低,远低于常温下静态空气0.25 W/m•K的导热系数,具有其他材料无法比拟的隔热保温效果,且密度低、防水阻燃、绿色环保、防腐蚀、不易老化、使用寿命长,被称为超级保温隔热材料,将其用在保温复合板材的制备当中将对隔热性能的提高极为有利。
为了提高泡沫作为夹心层的抗冲击等力学性能,采用在泡沫层表面设置骨架支撑层,骨架支撑层可以包括气凝胶材料、纤维增强树脂基复合材料以及复合泡沫等。但是存在泡沫之间的骨架支撑层之间结合力度不够容易造成开裂问题,并不能保证夹心层的隔热均匀性,致使泡沫与泡沫之间存在缝隙,这对力学性能及透光性能的影响均会导致复合板材综合性能的降低。
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高效隔热保温板及其制备方法。
为实现上述目的,本发明采取的技术方案如下:
一种高效隔热保温板,包括第一面板层、第二面板层、夹芯层,其中夹芯层为一层泡沫层或两层以上泡沫层叠加而成,每层泡沫层由若干个泡沫块相互拼接而成;夹心层位于第一面板层和第二面板层之间,夹心层的下表面和第一面板层之间、夹心层的上表面和第二面板层之间、夹心层的四周边缘以及夹心层中任意两个相邻泡沫块的拼接缝中设置有功能结构层;
所述第一面板层和第二面板层同时为纤维增强树脂复合材料;
所述泡沫块为聚氨酯泡沫块、PVC泡沫块或酚醛泡沫块;
所述功能结构层由气凝胶和功能填料组成。
进一步地,所述泡沫块的外表面设置有骨架支撑层;所述骨架支撑层为气凝胶毡层或纤维增强树脂复合材料。
较好地,骨架支撑层中所述的气凝胶毡层由气凝胶和纤维毡复合而成,所述气凝胶为二氧化硅气凝胶、氧化铝气凝胶、二氧化锆气凝胶或二氧化钛气凝胶,所述纤维毡为玻璃纤维毡、碳纤维毡、莫来石纤维毡、石英纤维毡、硅酸铝纤维毡、陶瓷纤维毡、氧化铝纤维毡、岩棉纤维毡、苎麻纤维毡、玄武岩纤维毡、聚丙烯腈纤维毡、PET纤维毡或PP纤维毡。
较好地,第一面板层、第二面板层和骨架支撑层中所述的纤维增强树脂复合材料,其中的纤维为玻璃纤维、碳纤维、硼纤维或芳纶纤维,其中的树脂为不饱和聚酯、乙烯基树脂、聚氨酯树脂、环氧树脂或酚醛树脂。
较好地,功能结构层中所述的气凝胶为二氧化硅气凝胶、二氧化钛气凝胶、氧化铝气凝胶、氧化锆气凝胶中的一种或多种;所述功能填料为弹性体微球、空心玻璃微球、硅酸铝空心微球、硼酸盐空心微球、氧化铝空心微球、二氧化硅空心微球、氧化锆空心微球、粉煤灰漂珠、聚苯乙烯空心微球中的一种或多种。
较好地,所述弹性体微球为橡胶微球,所述橡胶为丁苯橡胶、天然橡胶、氯丁橡胶、丁基橡胶、丁腈橡胶、丁二烯橡、胶、乙丙橡胶、聚异戊二烯橡胶、氟橡胶或硅橡胶。
较好地,第一面板层的厚度为0.5-5 mm,第二面板层的厚度为0.5-5 mm,夹心层的厚度控制在5-50 mm。
所述的高效隔热保温板的制备方法,制备步骤如下:
(1)、首先将每个泡沫块相互拼接起来形成与泡沫层层数相同的拼接层,当拼接层为一层时,该拼接层直接作为拼接体,当拼接层为两层以上时,所有拼接层叠加后作为拼接体;
(2)、制备混合溶胶:采用现有制备功能结构层中气凝胶所对应的溶胶的方法,并在制备原料中加入功能填料,获得混合溶胶;
(3)、由下至上依次将离型膜、第一脱模布、第一纤维增强树脂预浸带、拼接体进行铺层;
(4)、将步骤(2)所得混合溶胶浸渍到拼接体中,静置陈化后得到湿凝胶,然后再在拼接体表面涂刷一层树脂;
(5)、在拼接体的上表面依次铺设第二纤维增强树脂预浸带、第二脱模布,至此获得层叠体;
(6)、将步骤(5)铺层完成的层叠体热压固化成型;
(7)、固化完成后脱模处理,即得到高效隔热保温板;
所述第一纤维增强树脂预浸带、第二纤维增强树脂预浸带中的纤维和树脂分别对应为纤维增强树脂复合材料中的纤维和树脂,步骤(4)中涂刷的树脂亦对应为纤维增强树脂复合材料中的树脂。本发明所述“第一纤维增强树脂预浸带”、“第二纤维增强树脂预浸带”和“第三纤维增强树脂预浸带”均可按现有技术制备获得或通过市购获得。
进一步地,步骤(1)中,首先将每个泡沫块各自用气凝胶毡或第三纤维增强树脂预浸带包裹起来,第三纤维增强树脂预浸带中的纤维和树脂分别对应为纤维增强树脂复合材料中的纤维和树脂,然后接着进行后续的拼接。
较好地,步骤(4)中,所述静置陈化的时间为6-24 h。
较好地,步骤(5)中,热压固化成型的压力为0.5-5 Mpa,固化温度为40-180 ℃,固化时间为6-12 h。
较好地,所述离型膜为PET膜、PE膜、PI膜或OPP膜;
较好地,所述第一脱模布和第二脱模布为聚四氟乙烯脱模布、尼龙66脱模布、尼龙6脱模布或聚酯脱模布。
有益效果:
(1)、本发明在夹心层位于第一面板层和第二面板层之间、夹心层的下表面和第一面板层之间、夹心层的上表面和第二面板层之间、夹心层的四周边缘以及夹心层中任意两个相邻泡沫块的拼接缝中设置具有包括隔热、缓冲、力学性能的功能结构层,进一步提高了复合板材整体的综合性能优势;
(2)、本发明采用在泡沫块外表包裹气凝胶毡,能够使制得的板材同时具备气凝胶和泡沫块优异的特性,制备得到的板材具备轻质、高强、优异的隔热保温功能;同时将气凝胶毡设置在泡沫块表面,由于其良好的柔韧性,能够在受到外界冲击时对泡沫块起到很好的缓冲作用,保证泡沫块的完整性,进而保证夹心层良好的力学性能;此外,本发明将气凝胶毡用在面板层之间能够很好地解决气凝胶掉粉的问题;
(3)、本发明将泡沫块采用拼接的方式得到夹心层,能够避免由于夹心层的整体性在受到外界冲击时直接导致整个夹心层力学强度的破坏;本发明的功能结构层在与预浸带面板层热压成型的过程中能够很好地提高夹心层与面板层的结合强度,同时形成致密均匀的夹心层结构,避免泡沫块与泡沫块之间、夹心层与面板层之间因结合强度低出现分层的现象;
(4)、本发明包含有泡沫块、骨架支撑层以及功能结构层,使制备得到的复合板材在保持良好力学性能的前提下相比现有板材其隔热性能更具优势,其将在厢式货车等对保温性能、力学性能要求更高的领域实现广阔的应用前景;
(5)、本发明提供的复合板材的制备工艺简单,能够实现工业化生产应用,同时可以根据需求制备得到不同大小、厚度的板材,扩大了其在不同场合的应用范围。
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
一种高效隔热保温板,包括第一面板层、第二面板层、夹芯层,其中夹芯层为一层泡沫层,该泡沫层由若干个泡沫块相互拼接而成;夹心层位于第一面板层和第二面板层之间,夹心层的下表面和第一面板层之间、夹心层的上表面和第二面板层之间、夹心层的四周边缘以及夹心层中任意两个相邻泡沫块的拼接缝中设置有功能结构层;所述第一面板层、第二面板层均为玻璃纤维增强不饱和聚酯复合材料;所述泡沫块为聚氨酯泡沫块;所述功能结构层由二氧化硅气凝胶和丁苯橡胶微球组成;第一面板层的厚度为1 mm,第二面板层的厚度为1 mm,泡沫层的厚度为6 mm。
所述高效隔热保温板,制备步骤如下:
(1)、首先将聚氨酯泡沫块相互拼接起来形成一拼接层,该拼接层直接作为拼接体;
(2)、制备混合溶胶:取正硅酸乙酯、无水乙醇、水、丁苯橡胶微球混合均匀,之后依次加入NH4F溶液和氨水搅拌均匀,得到混合溶胶;其中,以摩尔比计,正硅酸乙酯∶无水乙醇∶水=1∶10∶3;丁苯橡胶微球质量占正硅酸乙酯质量的10%;NH4F溶液的加入量保证以摩尔比计,NH4F∶正硅酸乙酯=0.005∶1;氨水的加入量保证以摩尔比计,NH3∶正硅酸乙酯=0.006∶1;
(3)、由下至上依次将PET离型膜、聚四氟乙烯脱模布、玻璃纤维增强不饱和聚酯预浸带、拼接体进行铺层;
(4)、将步骤(2)所得混合溶胶浸渍到拼接体中,静置陈化后得到湿凝胶,此时拼接体的表面形成功能结构包裹层,然后再在拼接体表面涂刷一层不饱和聚酯树脂;
(5)、在拼接体的上表面依次铺设玻璃纤维增强不饱和聚酯预浸带、聚四氟乙烯脱模布,至此获得层叠体;
(6)、将步骤(5)铺层完成的层叠体置于热压机上于0.5 Mpa、70 ℃热压固化6 h;
(7)、固化完成后脱模处理,即得到高效隔热保温板。
本实施例制备的高效隔热保温板的密度为0.21 g/cm3,压缩强度为3.3 Mpa。
实施例2
一种高效隔热保温板,结构与实施例1的不同之处在于:所述泡沫块外表面设置有二氧化硅气凝胶毡骨架支撑层;制备方法与实施例1的不同之处在于:步骤(1)中,首先将每个泡沫块各自用二氧化硅气凝胶毡包裹起来,然后接着进行后续的拼接;其它同实施例1。
本实施例制备的车厢板的密度为0.22g/cm3,压缩强度为3.6Mpa。
实施例3
一种高效隔热保温板,结构与实施例1的不同之处在于:所述泡沫块外表面设置有玻璃纤维增强不饱和聚酯骨架支撑层;制备方法与实施例1的不同之处在于:步骤(1)中,首先将每个泡沫块各自用玻璃纤维增强不饱和聚酯预浸带包裹起来,然后接着进行后续的拼接;其它同实施例1。
本实施例制备的车厢板的密度为0.25 g/cm3,压缩强度为4.0 Mpa。
实施例4
一种高效隔热保温板,包括第一面板层、第二面板层、夹芯层,其中夹芯层为两层泡沫层叠加而成,每层泡沫层由若干个泡沫块相互拼接而成;夹心层位于第一面板层和第二面板层之间,夹心层的下表面和第一面板层之间、夹心层的上表面和第二面板层之间、夹心层的四周边缘以及夹心层中任意两个相邻泡沫块的拼接缝中设置有功能结构层;所述第一面板层、第二面板层均为玻璃纤维增强环氧树脂复合材料;所述泡沫块为聚氨酯泡沫块;所述功能结构层由二氧化硅气凝胶和空心玻璃微球组成;第一面板层的厚度为2 mm,第二面板层的厚度为2 mm,夹心层的厚度为8 mm。
所述高效隔热保温板,制备步骤如下:
(1)、首先将聚氨酯泡沫块相互拼接起来形成两层拼接层,这两层拼接层上下对齐叠加后作为拼接体;
(2)、制备混合溶胶:取正硅酸乙酯、无水乙醇、水、空心玻璃微球混合均匀,之后依次加入NH4F溶液和氨水搅拌均匀,得到混合溶胶;其中,以摩尔比计,正硅酸乙酯∶无水乙醇∶水=1∶9∶4;空心玻璃微球质量占正硅酸乙酯质量的5%;NH4F溶液的加入量保证以摩尔比计,NH4F∶正硅酸乙酯=0.008∶1;氨水的加入量保证以摩尔比计,NH3∶正硅酸乙酯=0.008∶1;
(3)、由下至上依次将PET离型膜、尼龙66脱模布、玻璃纤维增强环氧树脂预浸带、拼接体进行铺层;
(4)、将步骤(2)所得混合溶胶浸渍到拼接体中,静置陈化后得到湿凝胶,此时拼接体的表面形成功能结构包裹层,然后再在拼接体表面涂刷一层环氧树脂;
(5)、在拼接体的上表面依次铺设玻璃纤维增强环氧树脂预浸带、尼龙66脱模布,至此获得层叠体;
(6)、将步骤(5)铺层完成的层叠体置于热压机上于1 Mpa,110 ℃热压固化8 h;
(7)、固化完成后脱模处理,即得到高效隔热保温板。
本实施例制备的高效隔热保温板的密度为0.20 g/cm3,压缩强度4.0 Mpa。
实施例5
一种高效隔热保温板,包括第一面板层、第二面板层、夹芯层,其中夹芯层为三层泡沫层叠加而成,每层泡沫层由若干个泡沫块相互拼接而成;夹心层位于第一面板层和第二面板层之间,夹心层的下表面和第一面板层之间、夹心层的上表面和第二面板层之间、夹心层的四周边缘以及夹心层中任意两个相邻泡沫块的拼接缝中设置有功能结构层;
所述第一面板层、第二面板层均为芳纶纤维增强聚氨酯复合材料;所述泡沫块为聚氨酯泡沫块;所述功能结构层由二氧化硅气凝胶、二氧化硅空心微球和空心玻璃微球组成;第一面板层的厚度为2.5 mm,第二面板层的厚度为2.5 mm,夹心层的厚度为6 mm。
所述高效隔热保温板,制备步骤如下:
(1)、首先将聚氨酯泡沫块相互拼接起来形成三层拼接层,这三层拼接层上下对齐叠加后作为拼接体;
(2)、制备混合溶胶:取正硅酸乙酯、无水乙醇、水、二氧化硅空心微球、空心玻璃微球混合均匀,之后依次加入NH4F溶液和氨水搅拌均匀,得到混合溶胶;其中,以摩尔比计,正硅酸乙酯∶无水乙醇∶水=1∶8∶2;二氧化硅空心微球质量占正硅酸乙酯质量的5%,空心玻璃微球质量占正硅酸乙酯质量的5%;NH4F溶液的加入量保证以摩尔比计,NH4F∶正硅酸乙酯=0.012∶1;氨水的加入量保证以摩尔比计,NH3∶正硅酸乙酯=0.01∶1;
(3)、由下至上依次将PET离型膜、尼龙66脱模布、芳纶纤维增强聚氨酯预浸带、拼接体进行铺层;
(4)、将步骤(2)所得混合溶胶浸渍到拼接体中,静置陈化后得到湿凝胶,此时拼接体的表面形成功能结构包裹层,然后再在拼接体表面涂刷一层聚氨酯树脂;
(5)、在拼接体的上表面依次铺设芳纶纤维增强聚氨酯预浸带、尼龙66脱模布,至此获得层叠体;
(6)、将步骤(5)铺层完成的层叠体置于热压机上于1.2 Mpa、100 ℃热压固化10h;
(7)、固化完成后脱模处理,即得到高效隔热保温板。
本实施例制备的高效隔热保温板的密度为0.22 g/cm3,压缩强度为3.8 Mpa。
Claims (10)
1.一种高效隔热保温板,其特征在于:包括第一面板层、第二面板层、夹芯层,其中夹芯层为一层泡沫层或两层以上泡沫层叠加而成,每层泡沫层由若干个泡沫块相互拼接而成;夹心层位于第一面板层和第二面板层之间,夹心层的下表面和第一面板层之间、夹心层的上表面和第二面板层之间、夹心层的四周边缘以及夹心层中任意两个相邻泡沫块的拼接缝中设置有功能结构层;
所述第一面板层和第二面板层同时为纤维增强树脂复合材料;
所述泡沫块为聚氨酯泡沫块、PVC泡沫块或酚醛泡沫块;
所述功能结构层由气凝胶和功能填料组成。
2.如权利要求1所述的高效隔热保温板,其特征在于:所述泡沫块的外表面设置有骨架支撑层;所述骨架支撑层为气凝胶毡层或纤维增强树脂复合材料。
3.如权利要求2所述的高效隔热保温板,其特征在于:骨架支撑层中所述的气凝胶毡层由气凝胶和纤维毡复合而成,所述气凝胶为二氧化硅气凝胶、氧化铝气凝胶、二氧化锆气凝胶或二氧化钛气凝胶,所述纤维毡为玻璃纤维毡、碳纤维毡、莫来石纤维毡、石英纤维毡、硅酸铝纤维毡、陶瓷纤维毡、氧化铝纤维毡、岩棉纤维毡、苎麻纤维毡、玄武岩纤维毡、聚丙烯腈纤维毡、PET纤维毡或PP纤维毡。
4.如权利要求2所述的高效隔热保温板,其特征在于:第一面板层、第二面板层和骨架支撑层中所述的纤维增强树脂复合材料,其中的纤维为玻璃纤维、碳纤维、硼纤维或芳纶纤维,其中的树脂为不饱和聚酯、乙烯基树脂、聚氨酯树脂、环氧树脂或酚醛树脂。
5.如权利要求1所述的高效隔热保温板,其特征在于:功能结构层中所述的气凝胶为二氧化硅气凝胶、二氧化钛气凝胶、氧化铝气凝胶、氧化锆气凝胶中的一种或多种;所述功能填料为弹性体微球、空心玻璃微球、硅酸铝空心微球、硼酸盐空心微球、氧化铝空心微球、二氧化硅空心微球、氧化锆空心微球、粉煤灰漂珠或聚苯乙烯空心微球中的一种或多种。
6.如权利要求1所述的高效隔热保温板,其特征在于:第一面板层的厚度为0.5-5 mm,第二面板层的厚度为0.5-5 mm,夹心层的厚度控制在5-50 mm。
7.一种如权利要求1、5-6中任一项所述的高效隔热保温板的制备方法,其特征在于,制备步骤如下:
(1)、首先将每个泡沫块相互拼接起来形成与泡沫层层数相同的拼接层,当拼接层为一层时,该拼接层直接作为拼接体,当拼接层为两层以上时,所有拼接层叠加后作为拼接体;
(2)、制备混合溶胶:采用现有制备功能结构层中气凝胶所对应的溶胶的方法,并在制备原料中加入功能填料,获得混合溶胶;
(3)、由下至上依次将离型膜、第一脱模布、第一纤维增强树脂预浸带、拼接体进行铺层;
(4)、将步骤(2)所得混合溶胶浸渍到拼接体中,静置陈化后得到湿凝胶,然后再在拼接体表面涂刷一层树脂;
(5)、在拼接体的上表面依次铺设第二纤维增强树脂预浸带、第二脱模布,至此获得层叠体;
(6)、将步骤(5)铺层完成的层叠体热压固化成型;
(7)、固化完成后脱模处理,即得到高效隔热保温板;
所述第一纤维增强树脂预浸带、第二纤维增强树脂预浸带中的纤维和树脂分别对应为纤维增强树脂复合材料中的纤维和树脂,步骤(4)中涂刷的树脂亦对应为纤维增强树脂复合材料中的树脂。
8.如权利要求7所述的高效隔热保温板的制备方法,其特征在于:步骤(1)中,首先将每个泡沫块各自用气凝胶毡或第三纤维增强树脂预浸带包裹起来,第三纤维增强树脂预浸带中的纤维和树脂分别对应为纤维增强树脂复合材料中的纤维和树脂,然后接着进行后续的拼接。
9.如权利要求7所述的高效隔热保温板的制备方法,其特征在于:步骤(4)中,所述静置陈化的时间为6-24 h。
10.如权利要求7所述的高效隔热保温板的制备方法,其特征在于:步骤(5)中,热压固化成型的压力为0.5-5 Mpa,固化温度为40-180 ℃,固化时间为6-12 h。
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