CN113968713B - 一种用于防排烟风管的无机硅晶材料及其制备方法 - Google Patents
一种用于防排烟风管的无机硅晶材料及其制备方法 Download PDFInfo
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- 239000000463 material Substances 0.000 title claims abstract description 40
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- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 title claims abstract description 22
- 229910052710 silicon Inorganic materials 0.000 title claims abstract description 22
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 24
- 239000000843 powder Substances 0.000 claims abstract description 24
- 235000008733 Citrus aurantifolia Nutrition 0.000 claims abstract description 12
- 235000011941 Tilia x europaea Nutrition 0.000 claims abstract description 12
- 239000004571 lime Substances 0.000 claims abstract description 12
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 10
- 238000007731 hot pressing Methods 0.000 claims abstract description 9
- 238000010793 Steam injection (oil industry) Methods 0.000 claims abstract description 5
- 239000000835 fiber Substances 0.000 claims description 37
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 16
- 238000010438 heat treatment Methods 0.000 claims description 15
- 238000001035 drying Methods 0.000 claims description 13
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 claims description 11
- DHAHRLDIUIPTCJ-UHFFFAOYSA-K aluminium metaphosphate Chemical compound [Al+3].[O-]P(=O)=O.[O-]P(=O)=O.[O-]P(=O)=O DHAHRLDIUIPTCJ-UHFFFAOYSA-K 0.000 claims description 10
- 229910052599 brucite Inorganic materials 0.000 claims description 8
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- 239000002002 slurry Substances 0.000 claims description 7
- 238000005303 weighing Methods 0.000 claims description 7
- OSMSIOKMMFKNIL-UHFFFAOYSA-N calcium;silicon Chemical compound [Ca]=[Si] OSMSIOKMMFKNIL-UHFFFAOYSA-N 0.000 claims description 6
- GUJOJGAPFQRJSV-UHFFFAOYSA-N dialuminum;dioxosilane;oxygen(2-);hydrate Chemical compound O.[O-2].[O-2].[O-2].[Al+3].[Al+3].O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O GUJOJGAPFQRJSV-UHFFFAOYSA-N 0.000 claims description 6
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 6
- 229910052622 kaolinite Inorganic materials 0.000 claims description 6
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- 239000000378 calcium silicate Substances 0.000 description 1
- 229910052918 calcium silicate Inorganic materials 0.000 description 1
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
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- ONCZQWJXONKSMM-UHFFFAOYSA-N dialuminum;disodium;oxygen(2-);silicon(4+);hydrate Chemical compound O.[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[Na+].[Na+].[Al+3].[Al+3].[Si+4].[Si+4].[Si+4].[Si+4] ONCZQWJXONKSMM-UHFFFAOYSA-N 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
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- 229910052742 iron Inorganic materials 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 239000004579 marble Substances 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 231100000956 nontoxicity Toxicity 0.000 description 1
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- 229940080314 sodium bentonite Drugs 0.000 description 1
- 229910000280 sodium bentonite Inorganic materials 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
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- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/34—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
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- B28B11/245—Curing concrete articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
- B28B17/02—Conditioning the material prior to shaping
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
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- B28B3/006—Pressing by atmospheric pressure, as a result of vacuum generation or by gas or liquid pressure acting directly upon the material, e.g. jets of compressed air
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/02—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
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- B28B3/02—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
- B28B3/04—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form with one ram per mould
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- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
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Abstract
本发明提供的一种用于防排烟风管的无机硅晶材料及其制备方法，所述无机硅晶材料包括以下重量份的组分：氧化硅粉1000份、石灰粉700‑900份、硅酸铝短纤维215‑240份、水镁石纤维90‑140份、偏磷酸铝45‑55份、蒙脱土10‑30份和高岭石50‑70份，均采用了无机防火原料。本发明提供了更为先进的“喷蒸预热压+蒸压养护”制备技术，具有更高的传热效率，板材受热均匀，成型时间短，其成品材料轻质高强，具有优秀的耐火性能和防渗透性能，在高温时不变形、线性膨胀率小。
Description
技术领域
本发明涉及无机防火板材料，尤其涉及一种用于防排烟风管的无机硅晶材料及其制备方法。
背景技术
在人员密集的建筑中，发生火灾时，高效的防烟排烟系统将火灾所产生的有毒有害浓烟向室外排除，保证人员安全疏散，防排烟风管是防烟排烟系统的重要组成部分，需要采用不燃材料制成，具有防火性能好、高温耐变形、使用寿命长等特点。建筑中常使用的防排烟风管主要有金属材料风管和无机玻璃钢材料风管两大类，具有良好的不燃性，但在火灾的高温作用下易发生扭曲变形，出现裂缝甚至坍塌的情况，失去输送烟气的功能。此外,金属材料风管制作成本高、不易安装，像常用的镀锌铁皮风管易不耐水气腐蚀，易生锈；而无机玻璃钢风管易受潮老化而变形损坏,导致使用期限短，就算是经改进后的新型玻镁风管，在空气湿度较大时，也会出现滴水、返卤和泛霜现象。
因此防排烟风管用材料应具有一定的力学强度、无毒无害、耐高温形变、防火和憎水防潮湿等性能。
发明内容
本发明提供了一种用于防排烟风管的无机硅晶材料及其制备方法，是一种防排烟风管用的新型无机纤维增强结晶板材料。该无机硅晶材料包括以下重量份的组分：氧化硅粉1000份、石灰粉700-900份、硅酸铝短纤维215-240份、水镁石纤维90-140份、偏磷酸铝45-55份、蒙脱土10-30份和高岭石50-70份。
优选地，所述氧化硅粉中SiO2含量大于95％，细度大于180目；所述石灰粉中CaO含量70-80％，细度大于120目；所述硅酸铝短纤维呈棉丝状，长度为0.4-0.8mm。
一种用于防排烟风管的无机硅晶材料的制备方法，包括以下步骤：
S1、将纤维称量后，加入纤维总重量的12倍的温水，用松解机在75-85℃下，将硅酸铝短纤维和水镁石纤维松解混合，松解时间为15min-30min。将氧化硅粉和石灰粉称重混合，加水湿磨20-30min，干燥后进行充分干磨得到钙硅粉。
S2、将S1中的钙硅粉和松解后的纤维加水混合，加水量为钙硅粉和纤维总重量的20％，再加入称好重量的偏磷酸铝、蒙脱土和高岭石，用打浆机打料，制成料浆，经真空脱水5-8次，辊压脱水2-3次得到料坯。
S3、模具框内预蒸压：将料坯在模具框内铺装，在喷蒸热压机5-7MPa压力下加压4min-7min，然后热压板喷加一定温度和压力的蒸汽使料坯成型，成型后抽真空停止蒸汽加热，再脱模得到成型的板坯。
S4、蒸压釜内进行水热反应：将S3中成型的板坯送入蒸压釜，蒸压釜抽真空后通入饱和水蒸气，缓慢升温至100-110℃，保温20-30min，再将釜内温度升温至175-185℃，恒温养护10-16h后，缓慢泄放蒸压釜内的蒸汽，待蒸压釜温度降至常温后再次真空脱水。
S5、将经过程S4蒸压养护后的板料，在120℃干燥室内干燥18-24h后，在干燥通风处陈放48-72h，最后板面砂光切边即得本发明所述的一种用于防排烟风管的无机硅晶材料。
优选地、过程S3中，所述热压板喷加的蒸汽压力为0.4-0.7Mpa，热压温度为160-170℃，热压时间为120s-170s；过程S4中，蒸压釜内水蒸气压力为0.8-1.2MPa。
本发明有益效果在于：
1、本发明提供的一种用于防排烟风管的无机硅晶材料，均采用无机防火原料，其成品材料轻质高强，具有优秀的耐火性能和防渗透性能，在高温时不变形、线性膨胀率小。本发明提供了更为先进的“喷蒸预热压+蒸压养护”制备技术，具有更高的传热效率，板材受热均匀，成型时间短，热压机压制时，通入高温蒸汽可以使板坯快速成型，预先蒸压，可以使得无机晶体预生长，形成更多的晶核，有助于提高后续蒸压的结晶度，使坯体在蒸养前具有一定的强度，避免后续蒸压釜内剧烈的水热反应产生裂纹。
2、本发明采用偏磷酸铝取代传统的水玻璃做胶粘剂，相比于传统的水玻璃或其他有机胶粘剂，其耐高温性能大大优于水玻璃，较有机胶粘剂，不会在烧失时产生有毒浓烟和刺激性气味。加入适量的偏磷酸铝的料浆，在蒸压过程中能够产生轻微膨胀，防止填料收缩，优化产品的结晶结构，使成品高温时膨胀率降低，强度得到有效提高。本发明所述的硅酸铝短纤维和水镁石纤维作为增强纤维，均为无机纤维，本身具有耐高温不燃性。相比早期使用的石棉纤维，水镁石纤维对人体无害，更适合作为建筑用防排烟风管材料，并且耐酸碱性，加入可以提高材料的耐蚀性和稳定性。硅酸铝短纤维能增加材料的内聚力，增加剪切强度，并且能提高材料的隔热保温性能。
具体实施方式
下面结合具体的实施例和对比例及其制品材料的性能对比来进一步阐述本发明。
实施例1：
该实施例是按本发明提供的内容，制得的一种用于防排烟风管的无机硅晶材料，生产的材料板材规格为规格为2440×1220×12mm。所用工业级原料包括：SiO2含量97％细度180目的氧化硅粉1000份、CaO含量75％细度120目的石灰粉800份、长度为0.6mm呈棉丝状的硅酸铝短纤维225份、水镁石纤维110份、偏磷酸铝50份、蒙脱土20份和高岭石60份。
S1、将225份硅酸铝短纤维和110份水镁石纤维称量后，加入4000份温水，用松解机在80℃下，将硅酸铝短纤维和水镁石纤维松解混合20min，将1000份氧化硅粉和800份石灰粉称重混合，用球磨机以240r/min，加水湿磨25min，干燥后进行充分干磨得到钙硅粉。
S2、将钙硅粉和松解后的纤维混合，再加入50份偏磷酸铝、20份蒙脱土和60份高岭石，加入450份水，用泵式打浆机打料15min，制成料浆，经真空脱水6次，辊压脱水2次得到料坯，装入储料罐。
S3、将储料罐的料坯在模具框内铺装，在喷蒸热压机6MPa压力下加压5min，然后热压板喷加165℃、0.5Mpa压力的蒸汽140s使料坯成型，成型后抽真空停止蒸汽加热，再脱模得到成型的板坯。
S4、成型的板坯送入蒸压釜，蒸压釜抽真空后通入1.0MPa饱和水蒸气，缓慢升温至105℃，保温25min，再将釜内温度升温至180℃，恒温养护12h后，缓慢泄放蒸压釜内的蒸汽，待蒸压釜温度降至常温后再次真空脱水。
S5、蒸压釜出料后，在120℃干燥室内干燥20h后，在干燥通风处陈放56h，最后板面用砂光机砂光，切边即得按本发明提供的内容制作的一种用于防排烟风管的无机硅晶材料。
实施例2：
本实施例是按本发明提供的内容，改变以下参数同实施例1制备的一种用于防排烟风管的无机硅晶材料：
所用工业级原料包括：SiO2含量95％细度200目的氧化硅粉1000份、CaO含量70％细度120目的石灰粉700份、长度为0.8mm呈棉丝状的硅酸铝短纤维215份、水镁石纤维100份、偏磷酸铝45份、蒙脱土15份和高岭石50份。
喷蒸热压机5MPa压力下加压7min，热压板喷加160℃、0.4Mpa压力的蒸汽160s。
蒸压釜抽真空后通入1.1MPa饱和水蒸气，缓慢升温至110℃，保温20min，再将釜内温度升温至185℃，恒温养护10h。
实施例3：
本实施例是按本发明提供的内容，改变以下参数同实施例1制备的一种用于防排烟风管的无机硅晶材料：
所用工业级原料包括：SiO2含量97％细度200目的氧化硅粉1000份、CaO含量80％细度140目的石灰粉900份、长度为0.4mm呈棉丝状的硅酸铝短纤维240份、水镁石纤维130份、偏磷酸铝55份、蒙脱土25份和高岭石70份。
喷蒸热压机7MPa压力下加压4min，热压板喷加170℃、0.7Mpa压力的蒸汽120s。
蒸压釜抽真空后通入0.9MPa饱和水蒸气，缓慢升温至100℃，保温30min，再将釜内温度升温至175℃，恒温养护14h。
对比例：
以传统的防排烟风管用硅酸钙板材料为对比例，原料及制造方法如下：
选用氧化硅含量大于75％的粉煤灰1000份作为硅质材料，CaO含量78-87％石灰浆800份作为钙质材料，纤维量80％的纸浆纤维120份和2mm直径的云母片450份作为增强材料，水玻璃80份和钠基膨润土10份作为胶粘助剂。
按纤维松解→各原料称重后碾压混合打浆→辊压脱水→模压成型→蒸压养护→脱模烘干→切边后处理的流程进行制造。
纤维松解：80℃松解30min；模板机模压成型：加压压力为9MPa,加压时间约为14min；蒸压养护：1MPa水蒸气压力，185℃，恒温17h。
现对同样大小规格的实施例1-3及对比例所制得的板材进行以下试验：
力学性能测试：将上述对比例和实施例中的制品，分切成长为80mm宽为20mm的试样，在万能试验机上测试其相关力学性能。
抗渗性试验：对试样板表面喷洒25L/h/m2的水流，连续48h，观察试样板背面渗水情况。
耐高温试验：将试样在恒温箱中加热到800℃，恒温4h后取出，待完全冷却后，观察试样表面开裂情况，测量试验前后尺寸变化情况计算线性收缩率，测试其力学性能变化情况。
参考GB/T17428-2009《通风管道耐火试验方法》、GB/T 5464-2010《建筑材料不燃性试验方法》和GB/8624-2012《建筑材料及制品燃烧性能分级》相关标准设计耐火试验方案。将上述对比例和实施例制得的材料板，用云石机切割机切割成规格为2440×1220×12mm的板材，用自攻螺钉作为紧固件，用内角钢龙骨固定，角钢法兰来连接，拼缝处均匀涂抹硅酮密封胶，吊装在风管支架上，安装成总共5段的风管。用风机保持风管内300-400Pa的压差，3-4m/s/m2的空气流速，用加热炉提供火源模拟火灾。除了GB/T17428-2009中第十条试验过程外，另外增加以下试验过程：炉子点火，打开阀门，当风管内温度达到80℃，打开风机，当风管内温度达到280℃，保持该温度60min，调节温度至400℃以上，关闭风机，保持该温度30min。
以上试验结果均为多个试样的平均值，相关结果见下表1。
表1：
由上表1可知，本发明提供的一种用于防排烟风管的无机硅晶材料具有优良的防渗水性，能够憎水防潮湿，在耐高温试验中，具有较低膨胀率，抗折强度下降不超5％，高温不变形。在耐火试验中，本发明提供的一种用于防排烟风管的无机硅晶材料制成的风管，较同类型传统的风管在试验过程中完整性保持的更好，具有更长的耐火极限。
Claims (4)
1.一种用于防排烟风管的无机硅晶材料的制备方法，其特征在于，包括以下步骤：
（1）将纤维称量后，加入纤维总重量的12倍的温水，用松解机在75-85℃下，将硅酸铝短纤维和水镁石纤维松解混合，松解时间为15 min-30 min；将氧化硅粉和石灰粉称重混合，加水湿磨20-30min，干燥后进行充分干磨得到钙硅粉；
（2）将（1）中的钙硅粉和松解后的纤维加水混合，加水量为钙硅粉和纤维总重量的20%，再加入称好重量的偏磷酸铝、蒙脱土和高岭石，用打浆机打料，制成料浆，经真空脱水5-8次，辊压脱水2-3次得到料坯；
（3）模具框内预蒸压：将料坯在模具框内铺装，在喷蒸热压机5-7MPa压力下加压4min-7min，然后热压板喷加一定温度和压力的蒸汽使料坯成型，成型后抽真空停止蒸汽加热，再脱模得到成型的板坯；
（4）蒸压釜内进行水热反应：将（3）中成型的板坯送入蒸压釜，蒸压釜抽真空后通入饱和水蒸气，缓慢升温至100-110℃，保温20-30min，再将釜内温度升温至175-185℃，恒温养护10-16h后，缓慢泄放蒸压釜内的蒸汽，待蒸压釜温度降至常温后再次真空脱水；
（5）将经过程（4）蒸压养护后的板料，在120℃干燥室内干燥18-24h后，在干燥通风处陈放48-72h，最后板面砂光切边即得一种用于防排烟风管的无机硅晶材料。
2.根据权利要求1所述的一种用于防排烟风管的无机硅晶材料的制备方法，其特征在于：过程（3）中，所述热压板喷加的蒸汽压力为0.4-0.7Mpa，热压温度为160-170℃，热压时间为120s-170s；过程（4）中，蒸压釜内水蒸气压力为0.8-1.2MPa。
3.一种用于防排烟风管的无机硅晶材料，其特征在于，由权利要求1或2所述的用于防排烟风管的无机硅晶材料的制备方法制得，包括以下重量份的组分：氧化硅粉1000份、石灰粉700-900份、硅酸铝短纤维215-240份、水镁石纤维90-140份、偏磷酸铝45-55份、蒙脱土10-30份和高岭石50-70份。
4.根据权利要求3所述的一种用于防排烟风管的无机硅晶材料，其特征在于：所述氧化硅粉中SiO2含量大于95%，细度大于180目；所述石灰粉中CaO含量70-80%，细度大于120目；所述硅酸铝短纤维呈棉丝状，长度为0.4-0.8mm。
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