CN113444279A - 一种包覆改性eps泡沫制品及其制备方法 - Google Patents
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Abstract
本发明公开了一种包覆改性EPS泡沫制品及其制备方法,该泡沫制品以EPS泡沫粒子为基核,包覆了两层包覆层,第一层是聚丁二烯合成乳胶和硅烷偶联剂的表面处理层,第二层是以硅酸盐为包覆基体的阻燃防火层,两层结构使得所述泡沫制品整体力学性能更稳定,压缩、拉伸和弯曲强度更好。先对预发泡的EPS泡沫粒子表面进行预处理,使得其与无机阻燃剂更具亲合性,包覆粘黏效果更好,阻燃性能大大提升,垂直燃烧等级可达FV‑0。
Description
技术领域
本发明涉及一种建筑和包装行业使用的轻质、防火保温材料,具体涉及一种包覆改性EPS泡沫制品及其制备方法。
背景技术
EPS泡沫制品是聚苯乙烯(EPS)泡沫粒子,在发泡剂的作用下发泡熟化,再经模具加热成型而制成的。EPS泡沫具有质轻、隔热隔音性能好、耐冲击、抗老化等特点,在建筑和包装领域中被广泛应用。为改善其易燃、压缩、拉伸和弯曲强度不够的问题,在加工过程中加入阻燃剂和增强剂对EPS粒子包覆改性,或者对成品板材进行表面涂抹防火层或者溶液浸泡渗透改性,使得改性后的EPS泡沫制品具有良好的阻燃性和力学强度。
现有的EPS泡沫粒子包覆改性技术中,以无机材料为包覆基体,除了加入粘结剂,也需要加入表面处理剂,增加包覆基体与EPS泡沫粒子的亲合性,是对包覆基体进行表面处理改性后再加入其他添加剂制成包覆溶液或泥浆,再对预发泡的EPS泡沫粒子混合包覆,或者直接将基体和表面处理剂和其他添加剂与预发泡的EPS泡沫粒子通过溶液共混法来包覆。这两种方法流程简单,但产品只有一层包覆层,结构单一,易破坏,且直接混合包覆,各组分散均匀度不够,影响粘结效果和阻燃效果。
发明内容
为了提供一种制作流程简易,包覆结构稳定且具有一定阻燃性的EPS泡沫产品,本发明公开了一种包覆改性EPS泡沫制品,所述EPS泡沫制品以EPS泡沫粒子为基核,包覆了两层包覆层,第一层是EPS泡沫粒子的表面处理层,主要成分是偶联剂和聚合物乳胶粘合剂;第二层为无机阻燃增强防火层,主要成分是以无机阻燃剂为包覆基体的阻燃防火层。
一种包覆改性EPS泡沫制品的其制备方法,包含以下步骤:
S1、选用EPS原料粒子,加入发泡剂,在一定加热温度和蒸汽压力的作用下,预发一段时间,制得预发泡的EPS泡沫粒子;
S2、在改性设备中加入偶联剂和粘合剂对预发泡的EPS泡沫粒子进行表面处理,搅拌混合,包覆一层表面处理层,保温干燥,制得与无机阻燃剂更具亲合性的预发泡EPS泡沫粒子;
S3、将S2所得泡沫粒子和无机阻燃包覆基体混合,加入协效阻燃剂和分散剂,搅拌包覆第二层阻燃防火层;
S4、将包覆两层的预发泡的EPS泡沫粒子,打入熟化仓进行熟化,一定温度下熟化一段时间后,再打入模具内通入水蒸汽两次加热成型,冷却顶出烘干切割后制得所述包覆改性EPS泡沫制品。
优选的,S1步骤中:所述EPS原料粒子的粒径为0.7-0.9mm,所述发泡剂为正戊烷,含量为EPS原料粒子的4-7%,所述加热温度为70-90℃,所述蒸汽压力为0.11-0.16MPa,所述预发时间为5-10min。
优选的,S2步骤中:所述所述偶联剂为硅烷,加入量为粘合剂总质量的0.9%-1.4%,所述粘合剂为主要成分是聚丁二烯的合成乳胶,加入量为预发泡EPS泡沫粒子总质量的65%-75%。
优选的,S3步骤中:所述包覆基体为硅酸盐,加入量为预发泡EPS泡沫粒子总质量的75%-90%,所述协效阻燃剂为水灰比为5:8的水泥粉煤灰和聚丙烯纤维,所述水泥粉煤灰加入量为所述硅酸盐总质量的40-50%,所述聚丙烯纤维为所述硅酸盐总质量的总质量的0.3-0.6%,所述分散剂为磷酸钙、碳酸镁、滑石粉中的一种或多种。
优选的,S4步骤中:所述熟化时间为8-12h,所述熟化温度为50-60℃,所述成型时通入的水蒸气温度为120-130℃,压力为0.13-0.17MPa,所述两次水蒸汽通入加热时间分别为15s和10s。
本发明的优点在于:
1、在对表面处理后的EPS泡沫粒子进行再包覆时,由于其表面更具亲合性,阻燃剂分得散更均匀,粘黏、包覆效果更好,能达到很好的阻燃防火效果。
2、得到的EPS泡沫板材,其粒子有两层包覆层,第一层为表面处理层,第二层为阻燃层,两层结构使得整体力学性能更稳定,压缩、拉伸和弯曲强度更好。
具体实施方式
下面以五种方案制得的五种产品做性能对比,其中对比例1为空白实验方案,制得的是未改性处理的EPS泡沫板材;对比例2是先对包覆基体进行表面预处理,再直接和预发泡的EPS泡沫粒子混合包覆;实施例1-3是本发明提供的制备方法。
其各个配方组成见表1。
表1:
对比例1:
S1、粒径为0.8mm的EPS原料粒子100份,正戊烷5份,在80℃加热温度和0.14MPa蒸汽压力作用下预发泡7min,得到预发泡的EPS泡沫粒子。
S2、将预发泡的EPS泡沫粒子打入熟化仓,在55℃温度下熟化8h。
S3、将熟化的EPS泡沫粒子打入模具,通入125℃、0.15MPa的水蒸气,两次通入加热时间15s和10s,使EPS泡沫颗粒膨胀充满整个模具。
S4、采用水冷和真空冷却相结合的方式,将模具冷却后,用压缩空气将EPS泡沫顶出,烘干切割后得到产品A。
对比例2:
S1、同对比例1的S1制得预发泡的EPS泡沫粒子.
S2、将0.84份硅烷偶联剂加入70份乙醇分散剂,分散均匀。
S3、将80份硅酸盐脱水烘干1h,加入上述分散好的硅烷偶联剂,在75℃下混合搅拌15min,得到表面预处理的硅酸盐包覆液。
S4、将硅酸盐包覆液和预发泡的EPS粒子混合,加入水灰比为5:8的36份水泥粉煤灰和0.32份聚丙烯纤维,在6.5份滑石粉分散剂作用下搅拌混合包覆,搅拌30min。
S5、将包覆过后EPS泡沫粒子脱水烘干,同对比例1的S2-S4熟化成型烘干切割得到产品B。
实施例1:
S1、同对比例1的S1制得预发泡的EPS泡沫粒子。
S2、在改性设备中加入70份主要成分是聚丁二烯的合成乳胶和0.84份硅烷偶联剂,和预发泡的EPS泡沫粒子混合,搅拌15min,包覆一层表面处理层,在40℃温度下保温干燥1h,制得与无机阻燃剂更具亲合性的预发泡EPS泡沫粒子。
S3、加入80份硅酸盐,加入水灰比为5:8的36份水泥粉煤灰和0.32份聚丙烯纤维,在6.5份滑石粉分散剂的作用下和S2所得的泡沫粒子搅拌混合,搅拌30min,包覆第二层阻燃防火层。
S4、将包覆两层的预发泡EPS泡沫粒子同对比例1的S2-S4熟化成型烘干切割得到产品C。
实施例2:
S1、粒径为0.7mm的EPS原料粒子100份,正戊烷4份,在75℃加热温度和0.12MPa蒸汽压力作用下预发泡10min,得到预发泡的EPS泡沫粒子。
S2、在改性设备中加入65份主要成分是聚丁二烯的合成乳胶和0.65份硅烷偶联剂,和预发泡的EPS泡沫粒子混合,搅拌15min,包覆一层表面处理层,在40℃温度下保温干燥1h,制得与无机阻燃剂更具亲合性的预发泡EPS泡沫粒子。
S3、加入75份硅酸盐,加入水灰比为5:8的30份水泥粉煤灰和0.23份聚丙烯纤维,在6.5份磷酸钙分散剂的作用下和S2所得的泡沫粒子搅拌混合,搅拌30min,包覆第二层阻燃防火层。
S4、将预发泡的EPS泡沫粒子打入熟化仓,在60℃温度下熟化10h。
S5、将熟化的EPS泡沫粒子打入模具,通入120℃、0.13MPa的水蒸气,两次通入加热时间15s和10s,使EPS泡沫颗粒膨胀充满整个模具。
S6、采用水冷和真空冷却相结合的方式,将模具冷却后,用压缩空气将EPS泡沫顶出,烘干切割后得到产品D。
实施例3:
S1、粒径为0.9mm的EPS原料粒子100份,正戊烷7份,在90℃加热温度和0.15MPa蒸汽压力作用下预发泡5min,得到预发泡的EPS泡沫粒子。
S2、在改性设备中加入75份主要成分是聚丁二烯的合成乳胶和1.05份硅烷偶联剂,和预发泡的EPS泡沫粒子混合,搅拌15min,包覆一层表面处理层,在40℃温度下保温干燥1h,制得与无机阻燃剂更具亲合性的预发泡EPS泡沫粒子。
S3、加入90份硅酸盐,加入水灰比为5:8的45份水泥粉煤灰和0.54份聚丙烯纤维,在6.5份碳酸镁分散剂的作用下和S2所得的泡沫粒子搅拌混合,搅拌30min,包覆第二层阻燃防火层。
S4、将预发泡的EPS泡沫粒子打入熟化仓,在50℃温度下熟化12h。
S5、将熟化的EPS泡沫粒子打入模具,通入130℃、0.17MPa的水蒸气,两次通入加热时间15s和10s,使EPS泡沫颗粒膨胀充满整个模具。
S6、采用水冷和真空冷却相结合的方式,将模具冷却后,用压缩空气将EPS泡沫顶出,烘干切割后得到产品E。
对产品A、B、C、D、E做力学性能测试和燃烧性能测试,其性能如表2。
依据GB/T8813-2008对泡沫试样进行压缩强度性能测试,以恒定的速率5mm/min对试样进行压缩,测定达到10%相对形变量时的压缩应力。
依据GB/T9641-1988对泡沫试样进行拉伸强度性能测试,拉伸速率为5mm/min。
依据GB/T9341-2008对泡沫试样进行弯曲强度性能测试,试验速率设定为10mm/min。
依据GB/T2406.2-2009对泡沫试样进行氧指数的测定,指一定的情况下,泡沫试样在一定比例的混合氮气氧气中,刚好维持试样燃烧所需最低氧浓度,以氧气的体积分数表示。
依据GB/T2408-2008对泡沫试样进行垂直燃烧等级测定,指按一定的火焰高度和一定的施焰角度对垂直状态的泡沫试样定时施燃若干次,以泡沫试样点燃、灼热燃烧的持续时间和泡沫试样下铺垫的引燃物是否引燃来评定其燃烧性。
表2:
本发明制得的产品C、D、E都有良好的力学性能和阻燃效果。产品C较产品A压缩强度提高了235.2%,拉伸强度提高了18.2%,弯曲强度提高了17.1%,极限氧指数提高了109.6%,较制品B压缩强度提高了16.3%,拉伸强度提高了6.5%,弯曲强度提高了4.2%,极限氧指数提高了14.5%。
Claims (6)
1.一种包覆改性EPS泡沫制品,其特征在于:以EPS泡沫粒子为基核,包覆了两层包覆层,第一层是EPS泡沫粒子的表面处理层,主要成分是偶联剂和聚合物乳胶粘合剂;第二层为主要以无机阻燃剂为包覆基体的阻燃防火层。
2.一种权利要求1所述的包覆改性EPS泡沫制品的制备方法,其特征在于,包含以下步骤:
S1、选用EPS原料粒子,加入发泡剂,在一定加热温度和蒸汽压力的作用下,预发一段时间,制得预发泡的EPS泡沫粒子;
S2、在改性设备中加入偶联剂和粘合剂对预发泡的EPS泡沫粒子进行表面处理,搅拌混合,包覆一层表面处理层,保温干燥,制得与无机阻燃剂更具亲合性的预发泡EPS泡沫粒子;
S3、将S2所得泡沫粒子和无机阻燃包覆基体混合,加入协效阻燃剂和分散剂,搅拌包覆第二层阻燃防火层;
S4、将包覆两层的预发泡的EPS泡沫粒子,打入熟化仓进行熟化,一定温度下熟化一段时间后,再打入模具内通入水蒸汽两次加热成型,冷却顶出烘干切割后制得所述包覆改性EPS泡沫制品。
3.根据权利要求2所述的一种包覆改性EPS泡沫制品的制备方法,其特征在于,S1步骤中:所述EPS原料粒子的粒径为0.7-0.9mm,所述发泡剂为正戊烷,含量为EPS原料粒子的4%-7%,所述加热温度为70-90℃,所述蒸汽压力为0.11-0.16MPa,所述预发时间为5-10min。
4.根据权利要求2所述的一种包覆改性EPS泡沫制品的制备方法,其特征在于,S2步骤中:所述偶联剂为硅烷,加入量为粘合剂总质量的0.9%-1.4%,所述粘合剂为主要成分是聚丁二烯的合成乳胶,加入量为预发泡EPS泡沫粒子总质量的65%-75%。
5.根据权利要求2所述的一种包覆改性EPS泡沫制品的制备方法,其特征在于,S3步骤中:所述包覆基体为硅酸盐,加入量为预发泡EPS泡沫粒子总质量的75%-90%,所述协效阻燃剂为水灰比为5:8的水泥粉煤灰和聚丙烯纤维,所述水泥粉煤灰加入量为所述硅酸盐总质量的40-50%,所述聚丙烯纤维为所述硅酸盐总质量的总质量的0.3-0.6%,所述分散剂为磷酸钙、碳酸镁、滑石粉中的一种或多种。
6.根据权利要求2所述的一种包覆改性EPS泡沫制品的制备方法,其特征在于,S4步骤中:所述熟化时间为8-12h,所述熟化温度为50-60℃,所述成型时通入的水蒸气温度为120-130℃,压力为0.13-0.17MPa,所述两次水蒸汽通入加热时间分别为15s和10s。
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