CN113635628A - 一种保温防火材料及其制备方法和应用 - Google Patents
一种保温防火材料及其制备方法和应用 Download PDFInfo
- Publication number
- CN113635628A CN113635628A CN202111019647.5A CN202111019647A CN113635628A CN 113635628 A CN113635628 A CN 113635628A CN 202111019647 A CN202111019647 A CN 202111019647A CN 113635628 A CN113635628 A CN 113635628A
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- Prior art keywords
- heat
- insulating
- layer
- fireproof material
- resin
- Prior art date
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Links
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Abstract
本发明涉及保温防火材料技术领域,尤其涉及一种保温防火材料及其制备方法和应用。本发明提供了一种保温防火材料,所述保温防火材料为层状结构,所述层状结构包括依次层叠循环设置的非织造层和纳米绝热材料层,且所述层状结构的上表面和下表面均为非织造层;所述层状结构为法向针刺增强结构;所述层状结构的表层浸渍有酚醛树脂;所述非织造层的材料为无机短切纤维;所述保温防火材料的厚度为0.8~20cm。本发明所述保温防火材料在较薄的厚度下同时具有较好的防火性、无烟毒性和降噪性能。
Description
技术领域
本发明涉及保温防火材料技术领域,尤其涉及一种保温防火材料及其制备方法和应用。
背景技术
随着人民生活水平的提高,人们对生活品质有了新的追求,对节能环保、可持续发展的认识也提高到了新的高度。而对于传统建筑领域来说,由于岩棉板具有较好的绝热性能(导热系数仅为0.044),保温性能好,燃烧等级为A级为较好的防火材料,板缝处应力低不易出现裂缝等优势而广泛应用于建筑外墙的保温防火处理。但是岩棉板还存在一些缺陷,例如施工难度大、人体接触不了,系统容易发生开裂、渗漏甚至脱落等质量通病进而造成人们的生命和财产的安全隐患。也正是因为这些缺陷,同时为了保证人们的生命和财产安全,各地已经陆续禁止岩棉类材料在新建、扩建和改建的工程项目中使用了。外墙保温材料也因此出现了既安全又环保的保温材料的短缺。目前人们常用的XPS\EPS\IPS等产品无法达到安全防火等级,无法有效阻断建筑外墙火灾的发生以及脱落事故的发生,而如果采用内墙保温,由于保温板的厚度(一般在10~120cm)较厚,会在很大程度上占用住户套内使用面积,且其在发生火灾后还会具有产烟毒性。因此,开发一种在较薄的厚度下,同时具有较好的防火性、无烟毒性和降噪性能的保温防火材料具有非常重要的实际意义。
发明内容
本发明的目的在于提供了一种保温防火材料及其制备方法和应用。所述保温防火材料在较薄的厚度下同时具有较好的防火性、无烟毒性和降噪性能。
为了实现上述发明目的,本发明提供以下技术方案:
本发明提供了一种保温防火材料,所述保温防火材料为层状结构,所述层状结构包括依次层叠循环设置的非织造层和纳米绝热材料层,且所述层状结构的上表面和下表面均为非织造层;
所述层状结构为法向针刺增强结构;
所述层状结构的表层浸渍有树脂;
所述非织造层的材料为无机短切纤维;
所述保温防火材料的厚度为0.8~20cm。
优选的,以一层非织造层和一层纳米绝热材料层为一个循环单元,所述循环单元的个数为4~200。
优选的,所述无机短切纤维、纳米绝热材料层中的纳米绝热材料和树脂的质量比为180:(1~2):(8~20)。
优选的,所述无机短切纤维为石英纤维短切丝、陶瓷纤维短切丝、玄武岩纤维短切丝、莫来石纤维短切丝、矿棉纤维短切丝、碳纤维短切丝和玻璃纤维短切丝中的一种或几种;
所述纳米绝热材料层中的纳米绝热材料的导热系数≤0.018W/m·K;
所述树脂包括酚醛树脂、糠醛树脂、环氧树脂或双马树脂。
优选的,所述纳米绝热材料层中的纳米绝热材料包括疏水性二氧化硅气凝胶、Al2O3气凝胶、ZrO2气凝胶、TiO2气凝胶和稀土氧化物中的一种或几种;
所述酚醛树脂包括水溶性酚醛树脂或醇溶性酚醛树脂。
优选的,所述层状结构的表层还浸渍有白炭黑;所述白炭黑均匀分散在所述树脂中;
所述无机短切纤维和白炭黑的质量比为180:(1~2)。
本发明还提供了上述技术方案所述的保温防火材料的制备方法,包括以下步骤:
将无机短切纤维进行非织造,得到非织造预产物层;
按照“非织造层/纳米绝热材料层/非织造层/纳米绝热材料层…………/非织造层”的循环顺序进行铺网后,沿法向进行针刺处理,得到保温防火材料的骨架结构;
将所述保温防火材料的骨架结构在树脂溶液中进行浸渍后,进行固化,得到所述保温防火材料。
优选的,所述浸渍的方式为压浸或真空浸渍;
所述压浸包括依次循环进行的压缩和虹吸;
所述压缩在厚度方向上的变形量为8~12%;
所述循环的次数为3~5次。
优选的,所述固化包括依次进行的第一阶段、第二阶段和第三阶段;
所述第一阶段为在80~85℃保温15~120min;
所述第二阶段为在120~129℃保温20~50min;
所述第三阶段为在240~250℃保温10~30min;
所述第一阶段和第二阶段在微波加热的条件下进行,所述第三阶段在红外加热的条件下进行。
本发明还提供了上述技术方案所述的保温防火材料或上述技术方案所述的制备方法制备得到的保温防火材料在建筑领域、航海领域、工业设备领域和航空航天烧蚀领域中的应用。
本发明提供了一种保温防火材料,所述保温防火材料为层状结构,所述层状结构包括依次层叠循环设置的非织造层和纳米绝热材料层,且所述层状结构的上表面和下表面均为非织造层;所述层状结构为法向针刺增强结构;所述层状结构的表层浸渍有树脂;所述非织造层的材料为无机短切纤维;所述保温防火材料的厚度为0.8~20cm。本发明所述的保温防火材料的上下表面浸渍有树脂可以有利于隔绝无机短切纤维与空气环境的接触,提高无机短切纤维的抗老化能力;同时在所述非织造布的层与层之间设置纳米绝热材料可以保证所述树脂不会扩散到所述层状结构的内部,而只附着在层状结构的表面,并且所述树脂只对层状结构的表面起到封孔的作用,抑制双侧表面间的对流传热,提高热阻塞效果,降低导热系数;同时层状结构内部的孔结构增加了声波的传递路径,而纳米绝热材料由于其大表面积特性,可以达到消音降噪的效果。由于热量的传导主要有三种方式:固体传热、气体对流传热和热辐射。而本发明所述的保温防火材料利用非织造层的微孔结构,并结合层间的纳米绝热材料和表层的树脂,形成一种表面封闭,内部为介孔结构的一种复合材料,从而有效的降低了同等体积条件下的固体热传导;同时空气在内部传播路径增长且容易受到纳米绝热材料的阻隔而无法有效的传播,因此,也降低了空气流动造成的传热;纳米绝热材料和树脂固化后形成的小分子以及表层由于浸渍树脂形成的光滑表面也能够增加辐射反射路径并有效吸收辐射,降低热辐射的传播。从而实现了降低材料导热系数、实现高效隔热以及超薄化的目的。最后,由于烟毒的产生主要来源于有机物遇火燃烧后产生的毒性烟气,而本发明所述的保温防火材料以无机物为主,不易燃烧。根据实施例的记载,本发明所述的保温防火材料具有良好的表面闭孔,有效的阻隔了水气、水分,具有较好的耐老化性;同时所述保温防火材料的消音降噪系数NRC>0.85,烟毒性实验达到了AQ2级,导热系数为0.016~0.020W/m·K。
附图说明
图1为本发明所述保温防火材料的结构示意图,其中,1-浸渍有固化后的酚醛树脂的表层,2-非织造材料层,3-纳米绝热材料层;
图2为本发明所述铺网后得到的产物的结构示意图;
图3为本发明所述的法向针刺增强结构示意图。
具体实施方式
如图1所示,本发明提供了一种保温防火材料,所述保温防火材料为层状结构,所述层状结构包括依次层叠循环设置的非织造层和纳米绝热材料层,且所述层状结构的上表面和下表面均为非织造层;
所述层状结构为法向针刺增强结构;
所述层状结构的表层浸渍有树脂;
所述非织造层的材料为无机短切纤维;
所述保温防火材料的厚度为0.8~20cm。
在本发明中,所述非织造层的材料为无机短切纤维;所述无机短切纤维的长度优选为6~8cm,直径优选为4~6μm。在本发明中,所述无机短切纤维优选为石英纤维短切丝、陶瓷纤维短切丝、玄武岩纤维短切丝、莫来石纤维短切丝、矿棉纤维短切丝、碳纤维短切丝和玻璃纤维短切丝中的一种或几种;当所述无机短切纤维为上述具体选择中的两种以上时,本发明对上述具体物质的配比没有任何特殊的限定,采用本领域技术人员熟知的过程进行即可。在本发明中,所述玻璃纤维短切丝优选为玻纤行业的固体废物;所述固体废物优选为开刀丝或剥桶丝的边角料。在本发明的具体实施例中,所述玻璃纤维短切丝具体为短切淀粉型无碱E玻纤或质量比为(1~4):1的短切淀粉型无碱E玻纤和短切硅烷型无碱E玻纤的混合物。
在本发明中,单层所述非织造层的厚度优选为0.3~0.9mm,更优选为0.5~0.8mm。
在本发明中,所述纳米绝热材料层中的纳米绝热材料的直径优选为2~6nm,密度优选为3~300kg/m3。
在本发明中,所述纳米绝热材料层中的纳米绝热材料的导热系数优选≤0.018W/m·K,更优选为0.012~0.016W/m·K。
在本发明中,所述纳米绝热材料层中的纳米绝热材料优选包括疏水性二氧化硅气凝胶、Al2O3气凝胶、ZrO2气凝胶、TiO2气凝胶和稀土氧化物中的一种或几种;所述稀土氧化物优选包括钕氧化物和铈氧化物;所述钕氧化物和铈氧化物的质量比优选为10:(0.5~1),更优选为10:(0.6~0.8)。所述纳米绝热材料更优选为疏水性二氧化硅其凝胶。当所述纳米绝热材料为上述具体选择中的两种以上时,本发明对上述具体物质的配比没有任何特殊的限定,按任意配比进行混合即可。
在本发明中,所述纳米绝热材料层中的纳米绝热材料的堆积密度优选为0.1g/cm3,比表面积优选为235.36m2/g。
在本发明中,所述纳米绝热材料层的厚度优选为0.12~0.20mm,更优选为0.13~0.16mm。
在本发明中,所述层状结构的表层(即外表面的非织造层)浸渍有树脂;所述树脂优选包括酚醛树脂、糠醛树脂、环氧树脂或双马树脂,更优选包括酚醛树脂;所述酚醛树脂优选包括水溶性酚醛树脂或醇溶性酚醛树脂,更优选包括水溶性酚醛树脂。本发明对所述水溶性酚醛树脂的种类没有任何特殊的限定,采用本领域技术人员熟知的种类即可。在本发明的具体实施例中,所述水溶性酚醛树脂的游离苯酚≤1.8wt%,在25℃的游离甲醛≤0.8wt%,在25℃的粘度为10.0~13.0cP,水溶性为50%,pH值为8.0~9.0,135℃烘干1h后的固含量≥46wt%,25℃的水溶性≥1500%。
在本发明中,所述酚醛树脂在所述层状结构的表层浸渍的厚度优选为3~4mm。
在本发明中,所述无机短切纤维、纳米绝热材料层中的纳米绝热材料和酚醛树脂的质量比优选为180:(1~2):(8~20),更优选为180:(1.2~1.8):(10~16),最优选为180:(1.4~1.6):(12~13)。
在本发明中,以非织造层和一层纳米绝热材料层为一个循环单元,所述循环单元的个数优选为4~200,更优选为40~160,最优选为80~120。
在本发明中,所述保温防火材料的厚度为0.8~20cm,优选为2.5~10cm,更优选为3~5cm。在本发明中,所述保温防火材料在上述厚度范围内其导热系数、燃烧性能和力学性能均能够达到且高于国家标准要求,在小于5cm的厚度下,其生产成本更低。
在本发明中,所述层状结构为法向针刺增强结构,所述法向针刺增强结构可以理解为所述层状结构通过沿所述层状结构的法向方向进行针刺,实现层状结构力学性能增强的目的(所述法向针刺增强结构的结构示意图如图2所示)。
在本发明中,所述层状结构的表层还浸渍有白炭黑,所述白炭黑均匀分散在所述树脂中。
在本发明中,所述白炭黑优选为气相白炭黑;所述气相白炭黑的粒径优选为7~100nm,更优选为7~40nm,最优选为7~20nm。所述无机短切纤维和白炭黑的质量比优选为180:(1~2),更优选为180:(1.2~1.8),最优选为180:(1.4~1.6)。
在本发明中,所述白炭黑在上述粒径范围内具有较大的比表面积,表面吸附力强,表面吉布斯自由能较大,同时热阻高,并且耐高温、不燃、无毒无味,作为活性剂并且提高所述保温防火材料的机械强度。
本发明还提供了上述技术方案所述的保温防火材料的制备方法,包括以下步骤:
将无机短切纤维进行非织造,得到非织造预产物层;
按照“非织造层/纳米绝热材料层/非织造层/纳米绝热材料层…………/非织造层”的循环顺序,将所述非织造预产物层进行铺网的同时,在所述单层非织造预产物层的表面散布纳米绝热材料后,沿法向进行针刺处理,得到保温防火材料的骨架结构;
将所述保温防火材料的骨架结构在树脂溶液中进行浸渍后,进行固化,得到所述保温防火材料。
在本发明中,若无特殊说明,所有制备原料均为本领域技术人员熟知的市售产品。
本发明将无机短切纤维进行非织造,得到非织造预产物层。
在本发明中,所述非织造的过程优选包括依次进行的上料、开松和梳理;所述开松优选包括依次进行的粗开松、混棉和精开松。本发明对上述上料、开松和梳理的具体条件参数没有任何特殊的限定,利用本领域技术人员熟知的条件参数即可。在本发明的具体实施例中,所述非织造的过程具体为将无机短切纤维上料后依次经过粗开松机进行初步开松后,进入混棉大仓将初步开松后的物料进行临时存储,然后进入精开松机进行完全开松,并通过斜帘棉箱传送至双林梳理机进行梳理。
得到非织造预产物层后,本发明按照“非织造层/纳米绝热材料层/非织造层/纳米绝热材料层…………/非织造层”的循环顺序,将所述非织造预产物层进行铺网的同时,在所述单层非织造预产物层的表面散布纳米绝热材料后,沿法向进行针刺处理,得到保温防火材料的骨架结构。
在本发明中,所述铺网的过程具体优选为:将得到的非织造预产物层随皮带传送至铺网机落棉小车,并在单层所述非织造预产物层上同时散布纳米绝热材料后,铺网小车将带有纳米绝热材料的非织造预产物层进行铺层(所述铺网后混合形式如图3所示)。
在本发明中,所述非织造预产物层的传送速度优选为30~40m/min,更优选为32~36m/min。所述纳米绝热材料的散布速度优选为60~90g/min,更优选为70~80g/min。
在本发明中,所述铺网的过程中,上网帘的频率优选为32Hz,往复帘的频率优选为26.6Hz,底帘的频率优选为4.42Hz。
所述铺网完成后,本发明优选进行夹持处理并通过喂入机以喂入的方式进行后续的针刺处理。
本发明对所述夹持的过程没有任何特殊的限定,采用本领域技术人员熟知的过程使夹持后的非织造网的厚度达到40cm以内即可,更优选使夹持后的非织造往的厚度达到5~20cm即可。
在本发明中,所述针刺优选包括依次进行的预针刺和主针刺。
在本发明中,所述预针刺的工艺参数优选为:针的分布优选为6排每排125根/延米,针的长度优选为105mm,针的震动频率优选为15Hz。
在本发明中,所述主针刺的工艺参数优选为:针的分布优选为7排每排125根/延米,针的长度优选为85mm,针的震动频率优选为18Hz。
在本发明中,所述预针刺和主针刺相结合的工艺可以进一步的提高所述保温防火材料的骨架结构的强度。
得到保温防火材料的骨架结构后,本发明将所述保温防火材料的骨架结构在树脂溶液中进行浸渍后,进行固化,得到所述保温防火材料。
在本发明中,所述树脂溶液中包括树脂、偶联剂和溶剂;在本发明中,所述偶联剂优选为KH550和/或KH560。在本发明中,所述溶剂优选为水或醇类溶剂,更优选为水;所述醇类溶剂优选为乙醇。
在本发明中,当所述树脂为醇溶性树脂时,所述溶剂优选为醇类溶剂;当所述树脂为水溶性树脂时,所述溶剂优选为水。
在本发明中,所述树脂溶液中树脂的浓度优选为30~50%,更优选为37~46%。在本发明中,所述树脂溶液中偶联剂的浓度优选为2~5‰,更优选为3~4‰。
在本发明中,所述树脂溶液中还优选包括白炭黑,所述白炭黑优选为气凝胶白炭黑;当所述树脂溶液中包括白炭黑时,所述树脂溶液中的白炭黑的浓度优选为1~2.5‰,更优选为2~2.2‰。
在本发明中,所述浸渍的方式优选为压浸或真空浸渍;当所述浸渍的方式为压浸时,所述压浸优选包括依次循环进行的压缩和虹吸;所述压缩在厚度方向上的变形量优选为8~12%,更优选为8~10%;本发明对所述虹吸的过程没有任何特殊的限定,采用本领域技术人员熟知的过程进行即可。即在压缩后的恢复形体的过程中,通过虹吸作用表面浸渍树脂。所述循环的次数优选为3~5次。
本发明对所述真空浸渍的过程没有任何特殊的限定,即采用本领域技术人员熟知的先将所述保温防火材料的骨架结构抽真空后再进行浸渍的过程进行即可。
在本发明中,对所述浸渍过程的控制可以进一步的使酚醛树脂更好的浸渍至外表面的非织造层中。
在本发明中,所述固化优选包括依次进行的第一阶段、第二阶段和第三阶段;所述第一阶段优选为在80~85℃保温15~120min;所述第二阶段优选为在120~129℃保温20~50min;所述第三阶段优选为在240~250℃保温10~30min。即所述固化的过程优选为:依次在80~85℃的温度中保温15~120min,在120~129℃的温度中保温20~50min和在240~250℃的温度中保温10~30min;更优选为依次在82~84℃的温度中保温50~100h,在123~126℃的温度中保温30~40h和在242~245℃的温度中保温15~25min。在本发明中,所述固化的前两个阶段优选在微波加热的条件下进行,所述固化的第三个阶段优选在红外加热的条件下进行。
所述固化完成后,本发明还优选包括冷却的过程,所述冷却的方式优选为急冷;所述急冷的方式可以避免过热自燃的问题出现。
本发明还提供了上述技术方案所述的保温防火材料或上述技术方案所述的制备方法制备得到的保温防火材料在建筑领域、航海领域、工业设备领域和航空航天烧蚀领域中的应用。
在本发明中,当所述保温防火材料应用于建筑领域时,既可以作为保温防火材料应用于建筑物的外墙体也可以应用于建筑物的内墙体。
本发明对所述应用的方法没有任何特殊的限定,采用本领域技术人员熟知的方法进行即可。
下面结合实施例对本发明提供的保温防火材料及其制备方法和应用进行详细的说明,但是不能把它们理解为对本发明保护范围的限定。
实施例1
以短切淀粉型无碱E玻纤(长度为6.2~6.5cm,直径为4~6μm)作为非织造层的原料,将其上料后依次经过粗开松机进行初步开松后,进入混棉大仓将初步开松后的物料进行临时存储,然后进入精开松机进行完全开松,并通过斜帘棉箱传送至双林梳理机进行梳理后,随皮带传送至铺网机落棉小车,并在单层所述非织造预产物层上同时散布疏水性二氧化硅气凝胶(导热系数为0.012W/m·K,密度为0.035g/cm3)后,铺网小车将带有疏水性二氧化硅气凝胶的非织造预产物层进行铺网(层数为60层),其中,铺网的工艺参数为上网帘的频率为32Hz,往复帘的频率为26.6Hz,底帘的频率为4.42Hz;然后通过喂入机以喂入的方式依次进行后续的预针刺(所述预针刺的工艺参数为针的分布为6排每排125根/延米,针的长度为105mm,针的震动频率为15Hz)和主针刺(所述主针刺的工艺参数为针的分布为7排每排125根/延米,针的长度为85mm,针的震动频率为18Hz),得到保温防火材料的骨架结构;
将50kg水溶性酚醛树脂(具体种类为W4006A)、10kg气相白炭黑、25kg偶联剂KH550和1500kg水混合,得到树脂溶液;
将所述保温防火材料骨架结构在所述树脂溶液中进行真空浸渍,依次在80℃的温度中保温45min,在120℃的温度中保温30min和在220℃的温度中保温6min进行固化,得到所述保温防火材料(厚度为2.5cm,每层非织造层的厚度为0.32mm,纳米绝热材料层的厚度为0.1mm,无机短切纤维、疏水性二氧化硅气凝胶和酚醛树脂的质量比为91:1:8)。
实施例2
以短切淀粉型无碱E玻纤(长度为8~12cm,直径为4~6μm)作为非织造层的原料,将其上料后依次经过粗开松机进行初步开松后,进入混棉大仓将初步开松后的物料进行临时存储,然后进入精开松机进行完全开松,并通过斜帘棉箱传送至双林梳理机进行梳理后,随皮带传送至铺网机落棉小车,并在单层所述非织造预产物层上同时散布疏水性二氧化硅气凝胶(导热系数为0.012W/m·K,密度为0.035g/cm3)后,铺网小车将带有疏水性二氧化硅气凝胶的非织造预产物层进行铺网(层数为160层),其中,铺网的工艺参数为上网帘的频率为32Hz,往复帘的频率为26.6Hz,底帘的频率为4.42Hz;然后通过喂入机以喂入的方式依次进行后续的预针刺(所述预针刺的工艺参数为针的分布为6排每排125根/延米,针的长度为105mm,针的震动频率为15Hz)和主针刺(所述主针刺的工艺参数为针的分布为7排每排125根/延米,针的长度为85mm,针的震动频率为18Hz),得到保温防火材料的骨架结构;
将500kg水溶性酚醛树脂(具体种类为W4006A)、15kg气相白炭黑、25kg偶联剂KH550和1500kg水混合,得到树脂溶液;
将所述保温防火材料骨架结构在所述树脂溶液中进行真空浸渍,依次在80℃的温度中保温1h,在120℃的温度中保温1h和在220℃的温度中保温10min进行固化,得到所述保温防火材料(厚度为15cm,每层非织造层的厚度为0.8mm,纳米绝热材料层的厚度为0.13mcm,无机短切纤维、疏水性二氧化硅气凝胶和酚醛树脂的质量比为91:1:8)。
实施例3
以质量比为4:1的短切淀粉型无碱E玻纤和短切硅烷型无碱E玻纤的混合物(长度为6~8cm,直径为4~6μm)作为非织造层的原料,将其上料后依次经过粗开松机进行初步开松后,进入混棉大仓将初步开松后的物料进行临时存储,然后进入精开松机进行完全开松,并通过斜帘棉箱传送至双林梳理机进行梳理后,随皮带传送至铺网机落棉小车,并在单层所述非织造预产物层上同时散布疏水性二氧化硅气凝胶(导热系数为0.012W/m·K,密度为0.035g/cm3)后,铺网小车将带有疏水性二氧化硅气凝胶的非织造预产物层进行铺网(层数为120层),其中,铺网的工艺参数为上网帘的频率为32Hz,往复帘的频率为26.6Hz,底帘的频率为4.42Hz;然后通过喂入机以喂入的方式依次进行后续的预针刺(所述预针刺的工艺参数为针的分布为6排每排125根/延米,针的长度为105mm,针的震动频率为15Hz)和主针刺(所述主针刺的工艺参数为针的分布为7排每排125根/延米,针的长度为85mm,针的震动频率为18Hz),得到保温防火材料的骨架结构;
将500…kg水溶性酚醛树脂(具体种类为W4006A)、20kg气相白炭黑、25kg偶联剂KH550和1500kg水混合,得到树脂溶液;
将所述保温防火材料骨架结构在所述树脂溶液中进行真空浸渍,依次在80℃的温度中保温1h,在120℃的温度中保温50min和在220℃的温度中保温10min进行固化,得到所述保温防火材料(厚度为10cm,每层非织造层的厚度为0.7mm,纳米绝热材料层的厚度为0.13mm,无机短切纤维、疏水性二氧化硅气凝胶和酚醛树脂的质量比为90:2:8)。
实施例4
以切淀粉型无碱E玻纤(长度为6~8cm,直径为4~6μm)作为非织造层的原料,将其上料后依次经过粗开松机进行初步开松后,进入混棉大仓将初步开松后的物料进行临时存储,然后进入精开松机进行完全开松,并通过斜帘棉箱传送至双林梳理机进行梳理后,随皮带传送至铺网机落棉小车,并在单层所述非织造预产物层上同时散布疏水性二氧化硅气凝胶(导热系数为0.012W/m·K,密度为0.035g/cm3)后,铺网小车将带有疏水性二氧化硅气凝胶的非织造预产物层进行铺网(层数为60层),其中,铺网的工艺参数为上网帘的频率为32Hz,往复帘的频率为26.6Hz,底帘的频率为4.42Hz;然后通过喂入机以喂入的方式依次进行后续的预针刺(所述预针刺的工艺参数为针的分布为6排每排125根/延米,针的长度为85mm,针的震动频率为15Hz)和主针刺(所述主针刺的工艺参数为针的分布为7排,每排125根/延米,针的长度为65mm,针的震动频率为18Hz),得到保温防火材料的骨架结构;
将500kg醇溶性酚醛树脂、1000kg乙醇、20kg气相白炭黑和25kg偶联剂KH550混合,得到树脂溶液;
将所述保温防火材料骨架结构在所述树脂溶液中进行真空浸渍,依次在80℃的温度中保温70min,在120℃的温度中保温20min,在220℃的温度中保温10min进行固化,得到所述保温防火材料(厚度为5cm,每层非织造层的厚度为0.7mm,纳米绝热材料层的厚度为0.13mm,无机短切纤维、疏水性二氧化硅气凝胶和酚醛树脂的质量比为90:2:8)。
测试例
按照GB/T 20247标准,将实施例1~4制备得到的保温防火材料进行消音降噪系数的测试;
按照GB/T 8624标准,将实施例1~4制备得到的保温防火材料进行烟毒性测试;
按照GB/T 10294标准,将实施例1~4制备得到的保温防火材料进行导热性能测试;
按照GB/T 29906标准,将实施例1~4制备得到的保温防火材料进行力学性能测试;测试结果如表1所示:
表1实施例1~4制备得到的保温防火材料的性能指标
实施例 | 实施例1 | 实施例2 | 实施例3 | 实施例4 |
消音降噪系数 | 0.80 | 0.90 | 0.85 | 0.85 |
烟毒性级别 | AQ2 | AQ2 | AQ2 | AQ2 |
导热系数(W/m·K) | 0.020 | 0.016 | 0.018 | 0.016 |
垂直板面拉伸强度(MPa) | 350 | 200 | 300 | 400 |
由表1可知,本发明所述的保温防火材料在较薄的厚度下具有较好的防火性、无烟毒性和降噪性能,同时力学性能满足行业要求。
以上所述仅是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围。
Claims (10)
1.一种保温防火材料,其特征在于,所述保温防火材料为层状结构,所述层状结构包括依次层叠循环设置的非织造层和纳米绝热材料层,且所述层状结构的上表面和下表面均为非织造层;
所述层状结构为法向针刺增强结构;
所述层状结构的表层浸渍有树脂;
所述非织造层的材料为无机短切纤维;
所述保温防火材料的厚度为0.8~20cm。
2.如权利要求1所述的保温防火材料,其特征在于,以一层非织造层和一层纳米绝热材料层为一个循环单元,所述循环单元的个数为4~200。
3.如权利要求1所述的保温防火材料,其特征在于,所述无机短切纤维、纳米绝热材料层中的纳米绝热材料和树脂的质量比为180:(1~2):(8~20)。
4.如权利要求3所述的保温防火材料,其特征在于,所述无机短切纤维为石英纤维短切丝、陶瓷纤维短切丝、玄武岩纤维短切丝、莫来石纤维短切丝、矿棉纤维短切丝、碳纤维短切丝和玻璃纤维短切丝中的一种或几种;
所述纳米绝热材料层中的纳米绝热材料的导热系数≤0.018W/m·K;
所述树脂包括酚醛树脂、糠醛树脂、环氧树脂或双马树脂。
5.如权利要求4所述的保温防火材料,其特征在于,所述纳米绝热材料层中的纳米绝热材料包括疏水性二氧化硅气凝胶、Al2O3气凝胶、ZrO2气凝胶、TiO2气凝胶和稀土氧化物中的一种或几种;
所述酚醛树脂包括水溶性酚醛树脂或醇溶性酚醛树脂。
6.如权利要求1~5任一项所述的保温防火材料,其特征在于,所述层状结构的表层还浸渍有白炭黑;所述白炭黑均匀分散在所述树脂中;
所述无机短切纤维和白炭黑的质量比为180:(1~2)。
7.权利要求1~6任一项所述的保温防火材料的制备方法,其特征在于,包括以下步骤:
将无机短切纤维进行非织造,得到非织造预产物层;
按照“非织造层/纳米绝热材料层/非织造层/纳米绝热材料层…………/非织造层”的循环顺序进行铺网后,沿法向进行针刺处理,得到保温防火材料的骨架结构;
将所述保温防火材料的骨架结构在树脂溶液中进行浸渍后,进行固化,得到所述保温防火材料。
8.如权利要求7所述的制备方法,其特征在于,所述浸渍的方式为压浸或真空浸渍;
所述压浸包括依次循环进行的压缩和虹吸;
所述压缩在厚度方向上的变形量为8~12%;
所述循环的次数为3~5次。
9.如权利要求7所述的制备方法,其特征在于,所述固化包括依次进行的第一阶段、第二阶段和第三阶段;
所述第一阶段为在80~85℃保温15~120min;
所述第二阶段为在120~129℃保温20~50min;
所述第三阶段为在240~250℃保温10~30min;
所述第一阶段和第二阶段在微波加热的条件下进行,所述第三阶段在红外加热的条件下进行。
10.权利要求1~6任一项所述的保温防火材料或权利要求7~9任一项所述的制备方法制备得到的保温防火材料在建筑领域、航海领域、工业设备领域和航空航天烧蚀领域中的应用。
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