CN113585504B - 一种a2级硬泡聚氨酯保温板及其加工工艺 - Google Patents

一种a2级硬泡聚氨酯保温板及其加工工艺 Download PDF

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CN113585504B
CN113585504B CN202110894733.4A CN202110894733A CN113585504B CN 113585504 B CN113585504 B CN 113585504B CN 202110894733 A CN202110894733 A CN 202110894733A CN 113585504 B CN113585504 B CN 113585504B
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王希安
刘访艺
徐祥东
许亚东
程栋
钟云
王耀西
高迎弟
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Wanhua New Materials Yantai Co ltd
Wanhua Building Technology Yantai Co Ltd
Wanhua Energysav Science and Technology Group Co Ltd
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Abstract

本发明专利涉及一种A2级硬泡聚氨酯保温板及其加工工艺，属于保温材料技术领域。包括上卷材、下卷材、设于上卷材及下卷材之间的芯材，芯材包括聚氨酯硬泡及均布于聚氨酯硬泡中的无机材料，无机材料占总质量的65%‑95%。采用本发明工艺制成的保温板能在保证泡沫绝热性能的前提下解决现有技术存在的燃烧过程中热值相关参数难以降低的问题。

Description

一种A2级硬泡聚氨酯保温板及其加工工艺
技术领域
本发明专利涉及一种A2级硬泡聚氨酯保温板及其加工工艺，属于保温材料技术领域。
背景技术
随着建筑节能标准的逐年提高，岩棉和聚苯板越来越难以满足日益提升的节能标准，聚氨酯硬泡作为保温效果最好的有机材料，市场空间会进一步加大。但市面上现有的聚氨酯板材产品最多只能做到B1级难燃，在燃烧过程中会释放大量的热，热值可达到20MJ/Kg以上，为了增加产品的阻燃效果，部分厂家会在产品中添加一些三聚氰胺、氢氧化铝、膨胀石墨等固体粉料，由于添加的粉料没有经过表面改性处理会在填料表面存留大量羟基与组合白料多元醇形成氢键，增加体系粘度，因此添加量有限，最多能达到白料质量的30%左右，制成泡沫后最多能达到泡沫质量的15%，对燃烧热值相关参数降低不大，达不到燃烧性能等级A2级，且填料表面的羟基可以与黑料反应，严重破坏泡孔结构，丧失聚氨酯优异的保温性能。
发明内容
本发明的目的在于解决上述现有技术存在的不足之处，提供一种A2级硬泡聚氨酯保温板及其加工工艺，采用该工艺制成的保温板能在保证保温绝热性能的前提下解决上述现有技术存在的燃烧过程中热值相关参数难以降低的问题。
一种A2级硬泡聚氨酯保温板，其特殊之处在于包括上卷材、下卷材、设于上卷材及下卷材之间的芯材，其特征在于芯材包括聚氨酯硬泡及均布于聚氨酯硬泡中的无机材料，无机材料占芯材总质量的65%-95%；
所述聚氨酯硬泡原料包括黑料及组合白料，黑料及组合白料的质量比为（1.0-1.8）：1；
所述组合白料在25℃下，粘度小于等于150mPa.S；
所述组合白料包括以下质量份的原料：低粘度（25℃粘度低于1000mPa.s）蔗糖或山梨醇起始剂聚醚0-40份、低粘度（25℃粘度低于800mPa.s）三聚氰胺聚醚0-30份、低粘度（25℃粘度低于500mPa.s）溴系阻燃聚醚0-30份、低粘（25℃粘度低于7000mPa.s）度阻燃聚酯多元醇10-50份、有机酸0.3-3份、硅油1-5份、催化剂1-10份、发泡剂10-50份;
所述无机材料为石英砂、玻化微珠、碳酸钙中的任意一种；
所述无机材料粒径在0.01mm-2.0mm；
所述无机材料表面用硅烷偶联剂或钛酸酯偶联剂进行活化处理；
所述A2级硬泡聚氨酯保温板导热系数小于等于0.030W/(m.K)。
本发明的一种A2级硬泡聚氨酯保温板的加工工艺，其特殊之处在于包括以下步骤：
1）将定量的黑料、组合白料送至高压发泡机；
2）黑料、组合白料在高压发泡机枪头混合后经管路输送至单螺杆混合输送装置，将定量的无机材料与混合好的黑料、组合白料在单螺杆混合输送装置中进行输送混合，往上述单螺杆混合输送装置中计量输送无机材料的方式也为单螺杆计量输送，通过螺杆的转速控制无机材料的流量；
3）黑料、组合白料与无机材料在单螺杆中混合输送至发泡机枪头，枪头在上卷材、下卷材之间进行布料发泡，制成一种A2级硬泡聚氨酯保温板。
本发明的一种A2级硬泡聚氨酯保温板及其加工工艺，有益效果如下：采用该加工工艺可以将无机填料的添加比例由原来最多占泡沫总量的15%提高至65%-95%，无机材料的添加极大地改善了硬泡聚氨酯的防火性能，可将硬泡聚氨酯燃烧性能等级由C级提高到A2级；组合白料中采用有机酸替代化学发泡剂水，用低粘度阻燃聚酯、聚醚替代物理阻燃剂，保证了泡沫的低导热；用过量的成核性硅油保证较高的闭孔率及泡孔均匀；无机材料表面处理后一方面杜绝了其表面的羟基等基团与黑料的反应，对泡孔不造成破坏，保证了导热系数λ≤0.030W/（m.K），另一方面减少了无机材料表面的极性基团与组合白料之间形成大量氢键，避免了粘度的急剧增加，改善了无机材料与硬泡聚氨酯的相容性。
附图说明
图1：本发明实施例1、实施例3一种以石英砂或碳酸钙为无机材料的A2级硬泡聚氨酯泡保温板结构示意图；
图2：本发明实施例2一种以石英砂和玻化微珠为无机材料的A2级硬泡聚氨酯泡保温板结构示意图。
具体实施方式
下面参照说明书附图将对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例1
本实施例的一种A2级硬泡聚氨酯保温板，参考附图1，包括上卷材、下卷材、设于上卷材及下卷材之间的芯材，芯材包括聚氨酯硬泡及均布于聚氨酯硬泡2中的无机材料，无机材料采用石英砂1，石英砂1占泡沫芯材质量份数的95%，使用前应采用硅烷偶联剂对石英砂1表面处理。
为达到良好的保温效果与150mPa.S以内的粘度，组合白料各成分质量份数如下：
江苏长能节能新材料科技有限公司产低粘度三聚氰胺聚醚5083L-KD 25份；
万华化学集团产低粘度溴系阻燃聚醚fr212 20份；
南京金陵斯斯泰潘化学有限公司产低粘度阻燃聚酯多元醇8004 50份；
天津市大茂化学试剂厂产甲酸 1份
迈图高新材料集团产硅油L16268 3份；
空气化工产复配催化剂 5份；
浙江三美化工股份有限公司产发泡剂141b 35份。
上述原料配成组合白料后粘度为145mPa.S，为使石英砂1与聚氨酯硬泡达到良好的相容性，石英砂1的粒径范围为1.5mm～2.0mm之间，其使用前用硅烷偶联剂对其活化，活化方式为：将无机材料放入固体搅拌机，将粉体质量0.7%的硅烷偶联剂喷洒在填料上并高速搅拌30min，结束后90℃-120℃烘干2小时。在硬泡聚氨酯保温板的生产过程中，黑料PM200与白料质量为1.3比1，黑白料经高压混合后与计量的石英砂1在单螺杆输送混合设备中混合输送至浇注枪头进行浇注发泡，制成一种以石英砂1为无机材料骨架的A2级硬泡聚氨酯保温板，其性能参数如表1所示：
表1：一种以石英砂为无机材料骨架的A2级硬泡聚氨酯保温板性能
实施例2
本实施例的一种A2级硬泡聚氨酯保温板，参考附图2，本实施例与实施例1的不同之处在于无机材料为石英砂1与玻化微珠3的混合物，无机材料占芯材质量份数为80%。
为达到良好的保温效果与150mPa.S以内的粘度，其白料各成分质量比如下：
句容宁武新材料股份有限公司低粘度蔗糖起始剂聚醚NJ6216 5份；
濮阳蔚林化工股份有限公司低粘度三聚氰胺聚醚fr718 10份；
万华化学集团产低粘度溴系阻燃聚醚fr212 25份；
淄博瑞诺化工科技有限公司产低粘度阻燃聚酯多元醇PF2016 30份；
北京茵泰德科技有限公司采购乳酸 0.8份；
江苏美思德化学股份有限公司产硅油8806 5份；
北京茵泰德科技有限公司采购复配催化剂 8份；
淄博澳帆化工有限公司产245fa 40份。
上述原料配成白料后粘度为140mPa.S。为使石英砂1、玻化微珠3与聚氨酯硬泡2达到良好的相容性，其粒径范围为1.0mm～1.5mm，其使用前用硅烷偶联剂对其活化，活化方式为：95%的乙醇及5%的H2O配成醇－水溶液，加入乙酸调节pH 为4.5-5.5，将硅烷偶联剂溶于上述溶液中，配成2%的硅烷偶联剂溶液，用该溶液对无机材料喷雾处理，无机材料表面风干后再90℃-120℃烘1h。在保温芯材的生产过程中，黑料PM400与白料质量比为1.5:1，黑白料经高压混合后与计量的石英砂1、玻化微珠3在单螺杆输送混合设备中混合输送至浇注枪头进行浇注发泡，制成一种以石英砂1和玻化微珠3为无机材料骨架的A2级硬泡聚氨酯泡保温板，其性能参数如表2所示：
表2：一种以石英砂和玻化微珠为无机材料骨架的A2级硬泡聚氨酯保温板性能
实施例3
本实施例的一种A2级硬泡聚氨酯保温板，参考附图1，本实施例与实施例1、实施例2的不同之处在于无机材料为碳酸钙1，无机材料料占芯材质量份数为65%。
为达到良好的保温效果与150mPa.S以内的粘度，其白料各成分质量比如下：
万华化学产低粘度溴系阻燃聚醚fr212 30份；
北京德美科创科技有限公司产低粘度阻燃聚酯多元醇 2013 25份；
江苏长能节能新材料科技有限公司产低粘度密胺树脂5083L-KD 15份；
北京茵泰德科技有限公司采购乳酸 0.8份；
江苏美思德化学股份有限公司产硅油M88716 3份；
北京茵泰德科技有限公司产复配催化剂 3份；
浙江三美化工股份有限公司产发泡剂141b 50份。
上述原料配成白料后粘度为135mPa.S。为使碳酸钙1与硬泡聚氨酯2达到良好的相容性，其粒径范围为0.2mm～1.0mm，其使用前用钛酸酯偶联剂对其活化，处理方式为：碳酸钙4在预热至100℃～110℃的高速混合机中搅拌烘干，然后均匀加入占碳酸钙质量份数0.5%的钛酸酯偶联剂(用适量的15#白油稀释)，搅拌15分钟即可出料。在保温芯材的生产过程中，黑料5005与白料质量比为1.6:1，黑白料经高压混合后与计量的碳酸钙1在单螺杆输送混合设备中混合输送至浇注枪头进行浇注发泡，制成一种以碳酸钙1为无机材料骨架的A2级硬泡聚氨酯泡保温板，其性能参数如表2所示：
表3：一种以碳酸钙为无机材料骨架的A2级硬泡聚氨酯保温板性能
由上述实施例可以看出，采用两步混合工艺（先黑白料混合然后混合好的黑白料与无机填料混合）可将无机填料由现有一步法混合工艺占泡沫芯材最多15%质量比提高到占泡沫芯材质量的65%以上，生产的板材在保证泡沫保温性能的前提下，可将泡沫总热值由20MJ/Kg以上降到3 MJ/Kg以下。
尽管已经示出和描述了本发明的实施例，对于本领域的普通技术人员而言，可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型，本发明的范围由所附权利要求及其等同物限定。

Claims (2)

1.一种A2级硬泡聚氨酯保温板，包括上卷材、下卷材、设于上卷材及下卷材之间的芯材，其特征在于芯材包括聚氨酯硬泡及均布于聚氨酯硬泡中的无机材料，无机材料占总质量的65%-95%；
所述无机材料为石英砂、玻化微珠、碳酸钙中的任意一种；
所述无机材料粒径在0.01mm-2.0mm；
所述无机材料表面用硅烷偶联剂或钛酸酯偶联剂进行活化处理；
所述A2级硬泡聚氨酯保温板芯材导热系数小于等于0.030W/(m.K)；
无机材料采用单螺杆计量、输送，并与聚氨酯硬泡在单螺杆混合输送装置中进行输送混合；
所述聚氨酯硬泡原料包括黑料及组合白料，黑料及组合白料的质量比为（1.0-1.8）：1；
所述组合白料包括以下质量份的原料：低粘度蔗糖或山梨醇起始剂聚醚0-40份、低粘度三聚氰胺聚醚0-30份、低粘度溴系阻燃聚醚0-30份、低粘度阻燃聚酯多元醇10-50份、有机酸0.3-3份、硅油1-5份、催化剂1-10份、发泡剂10-50份；
所述组合白料在25℃下，粘度小于等于150mPa.S。
2.按照权利要求1所述的一种A2级硬泡聚氨酯保温板的加工工艺，其特征在于包括以下步骤：
1）将定量的黑料、组合白料送至高压发泡机；
2）黑料、组合白料在高压发泡机枪头混合后经管路输送至单螺杆混合输送装置，将定量的无机材料与混合好的黑料、组合白料在单螺杆混合输送装置中进行输送混合，往上述单螺杆混合输送装置中计量输送无机材料的方式也为单螺杆计量输送，通过螺杆的转速控制无机材料的流量；
3）黑料、组合白料与无机材料在单螺杆中混合输送至发泡机枪头，枪头在上卷材、下卷材之间进行布料发泡，制成一种A2级硬泡聚氨酯保温板。
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