CN114164984A - 一种由复合板材组成的墙面板及其制备方法 - Google Patents
一种由复合板材组成的墙面板及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种由复合板材组成的墙面板,属于建筑材料制备技术领域,包括由上至下依次排列的第一面板、第一增强层、聚氨酯泡沫板、第二增强层和第二面板,其中聚氨酯泡沫板由以下步骤制成:准备以下重量份原料:聚醚多元醇85‑160份、聚酯多元醇75‑180份、二异氰酸酯25‑55份、温控材料8‑10份、金属填料10‑15份、发泡剂4‑13份、扩链剂8‑18份;步骤A12、准备泡沫板框架模具,向模具中放入金属填料并摆放成圆形阵列形状,然后将聚氨酯预混料注入泡沫板框架模具中,发泡成型,得到聚氨酯泡沫板,本发明通过在聚氨酯泡沫板中加入金属填料和温控材料,使本发明制备的墙面板具有较好的保温、隔音性能。
Description
技术领域
本发明属于建筑材料制备技术领域,具体地,涉及一种由复合板材组成的墙面板及其制备方法。
背景技术
建筑外墙围护结构的保温性能直接影响到建筑物的采暖和能耗。随着地球资源的日渐紧缺,能源供应越来越紧张,节能型建筑设计也越来越受到人们的关注和重视,各个地区也推出了相应的推广标准,越来越多的人开始致力于建筑物特别是建筑物外墙的装饰保温隔热技术的研制和开发。
聚氨酯具有质轻、隔热保温、吸音抗震、耐水耐腐蚀等优良性能,是一种理想的轻质结构材料和能量吸收材料。然而,聚氨酯是一种有机高分子化合物,防火性能差,需要对其进行阻燃改性;并且聚氨酯强度较低,在很多强度要求高的特殊场合(例如,作为结构材料及其配套材料)达不到使用要求,需要通过各种手段提升材料的机械强度,以达到增强的目的。
因此,利用聚氨酯为芯材复合其他板材,制备出的墙板层出不穷,但是现有的聚氨酯板的保温、隔音性能较差,导致是使用效果一般,基于现有噪音污染严重这一现象,提供一种保温、隔音效果优越的由复合板材组成的墙面板是目前需要解决的技术问题。
发明内容
为了解决背景技术中提到的技术问题,本发明提供一种由复合板材组成的墙面板及其制备方法。
本发明的目的可以通过以下技术方案实现:
一种由复合板材组成的墙面板,包括由上至下依次排列的第一面板、第一增强层、聚氨酯泡沫板、第二增强层和第二面板;
该复合板材组成的墙面板由以下步骤制成:
由上而下依次铺设第一面板、第一增强层、聚氨酯泡沫板、第二增强层和第二面板,复合成预制墙板,经过切割成型,得到复合板材组成的墙面板。
进一步地,第一增强层和第二增强层分别选自玻璃纤维毡、玻璃纤维网格布、玻璃纤维布、钢丝网中的任意一种,
进一步地,第一面层和第二面层分别选自石膏板、混凝土板、水泥砂浆板、纤维水泥板、陶瓷板、陶土板、玻璃钢板、金属板、玻镁板、硅钙板中的任意一种。
进一步地,聚氨酯泡沫板由以下步骤制成:
步骤A11、准备以下重量份原料:聚醚多元醇85-160份、聚酯多元醇75-180份、二异氰酸酯25-55份、温控材料8-10份、金属填料10-15份、发泡剂4-13份、扩链剂8-18份;
步骤A12、准备泡沫板框架模具,向模具中放入金属填料,并将金属填料摆放成圆形阵列形状,将聚醚多元醇和聚酯多元醇混合均匀,然后加入发泡剂、扩链剂、温控材料,室温下搅拌均匀,最后加入二异氰酸酯,搅拌均匀得预混料,然后将预混料注入泡沫板框架模具中,注入压力为14MPa,注入时间10-20s,并在30-40℃下发泡熟化10min,修剪边角料,得到聚氨酯泡沫板;
进一步地,聚醚多元醇的相对分子质量为2000-3000,羟值为200-320mgKOH/g,官能度为7,所述聚酯多元醇的相对分子质量为1500-2500,羟值为280-400mgKOH/g,官能度2.4-2.9。
进一步地,二异氰酸酯为异佛尔酮二异氰酸酯、二苯基甲烷二异氰酸酯、二环己基甲烷二异氰酸酯中的一种。
进一步地,发泡剂为偶氮甲酰胺、偶氮二异丁腈按照质量比1-3:1.5-2混合组成,扩链剂为2,2-二羟甲基丁酸。
进一步,金属填料由以下步骤制成:
将不锈钢管材采用40#砂纸进行打磨,使其暴露出粗糙表面,然后将其加入反应釜中,再向反应釜中加入无水乙醇、去离子水和接枝剂,转速100-200r/min条件下,搅拌混合6-8h,反应结束后,过滤,滤饼于100℃烘箱中干燥12h,得到金属填料;
其中,不锈钢管材直径为0.5-1.0mm,长度1-3mm,不锈钢管材、无水乙醇、去离子水和接枝剂的用量比为10g:100mL:100mL:7.8-11.2g,利用接枝剂分子链上的硅氧链水解,然后与打磨后的不锈钢管材发生接枝反应,得到金属填料;
本发明首先对微细不锈钢管材用砂纸进行打磨,增加其表面粗糙度,然后利用接枝剂对其进行偶联剂改性处理,其中接枝剂含有氮磷六元杂环、刚性苯环、醇羟基、羧基和硅氧键,然后将金属填料加入聚氨酯泡沫板中,并布置成具有周期性特点的圆管阵列,构筑出相应的固-固二维二元声子晶体,进而借助于声子晶体本身带隙特征实现优异的隔声降噪性能,并且通过引入阻尼介质增加内部声波传输损耗实现优异的吸声性能,进而使聚氨酯泡沫板具有优异的隔音降噪性能,其中接枝剂在受热分解时产生的一些组分诸如CO2、CO、含磷化合物等气体,它们可以起到稀释火焰、降低燃烧区域温度的作用,且裂解时产生一些磷氧自由基等可捕获聚氨酯链段裂解产生的自由基,能够从酸源、碳酸、气源三个方面协同发挥阻燃作用,醇羟基、羧基的存在使金属填料能够参与聚氨酯的交联反应,硅氧键的存在能够提高聚氨酯材料的耐热性能,其次金属填料的加入能够提高聚氨酯泡沫板的抗冲击等力学性能。
进一步地,接枝剂由以下步骤制成:
步骤S11、将六氯环三磷腈、5-甲基-2-羟基苯甲醛、碳酸钾和四氢呋喃加入三口烧瓶中,升温至回流反应48h,反应结束后,将反应产物旋蒸至原体积的1/4,蒸馏产物转移至去离子水中,静置4-6h,得到白色沉淀,抽滤,滤饼用去离子水洗涤3-5次,最后于60℃烘箱中干燥12h,得到中间产物1;
其中,六氯环三磷腈、5-甲基-2-羟基苯甲醛、碳酸钾和四氢呋喃用量比为5g:11.4-12.2g:9.95g:200mL,在碱性条件下,使六氯环三磷腈的氯原子与5-甲基-2-羟基苯甲醛的酚羟基发生消去HCl反应,得到中间产物1;
步骤S12、将中间产物1和1,4-二氧六环加入三口烧瓶中,室温搅拌3-5min后,向三口烧瓶中加入KH-550,然后升温至回流反应24h,反应结束后,旋蒸去除1,4-二氧六环,得到中间产物2;
其中,中间产物1、1,4-二氧六环、KH-550的用量比为0.01mol:68.5-74.2mL:0.06mol;利用中间产物1的醛基与KH-550的氨基发生缩合反应得到中间产物2;
步骤S13、将中间产物2和DMF加入三口烧瓶中,加入高锰酸钾和质量分数17%的盐酸溶液,然后升温至65-68℃,搅拌反应4-5h,冷却至室温,过滤,用质量分数10%的碳酸钠溶液调节滤液pH至7-8,加入乙酸乙酯萃取,有机相减压蒸馏去除乙酸乙酯,得到中间产物3;
其中,中间产物2、DMF、高锰酸钾和盐酸溶液的用量比为0.01mol:70-80mL:0.7-1.1g:5-10mL,在酸性高锰酸钾的氧化下,使中间产物2的苯环上的甲基被氧化羧基,得到中间产物3;
步骤S14、将中间产物3和2,2-二羟甲基丁酸加入DMF中,搅拌条件下加入对甲苯磺酸,升温至80-90℃,搅拌反应2-3h,反应结束后,加入去离子水洗涤至中性,用乙酸乙酯萃取,再减压蒸馏去除乙酸乙酯,得到接枝剂;
其中,中间产物3、2,2-二羟甲基丁酸和DMF的用量比为0.01mol:0.01mol:95.7-103.2mL,对甲苯磺酸的用量为中间产物3质量的5-8%,在对甲苯磺酸的催化作用下,使中间产物3和2,2-二羟甲基丁酸发生酯化反应,得到接枝剂。
进一步,温控材料由以下步骤制成:
步骤B1、将高岭土置于马弗炉中800℃下保温2h,然后自然冷却至室温得到偏高龄土;将偏高龄土和质量分数2%的十六烷基三甲基溴化铵溶液搅拌混合20-30min后,加入质量分数40%的氢氧化钠溶液调节pH值为12.0,然后升温至90℃,频率40-50kHz下超声处理3h,然后抽滤,滤饼洗涤至洗涤液呈中性,100℃下干燥2h,540℃下焙烧5h,得到壁材,偏高龄土和十六烷基三甲基溴化铵溶液的用量比为3.5-4.2g:60mL;
步骤B2、将石蜡和硬脂酸加入三口烧瓶中,75℃恒温水浴中处理20min,然后加入壁材,90℃水浴加热下,磁力搅拌20-30min后,抽真空至0.01MPa,搅拌反应1h,反应结束后,得到温控材料,石蜡、硬脂酸和壁材的质量比为17:8:2.5-3.7。
本发明的有益效果:
本发明通过第一面板、第一增强层、聚氨酯泡沫板、第二增强层和第二面板复合,再经切割得到墙面板,该墙面板具有优异的抗震性能,较为突出的是,本发明制备的聚氨酯泡沫板隔音性能优异,并且具有较好的保温性能,经检测,其空气隔音性能在108dB以上,导热系数在0.023-0.026W/(m·K)之间,主要归因于,本发明以十六烷基三甲基溴化铵为模板剂,制备出多孔壁材,以石蜡和硬脂酸为芯材,制备出温控材料,克服单纯有机相变材料在固-液相变过程中出现液体泄漏,造成墙面板污染的问题,将温控材料加入聚氨酯泡沫板中使泡沫板的导热系数降低,对泡沫板的升温、降温产生迟滞作用,起到良好的温控效应,然后将金属填料加入聚氨酯泡沫板中,并布置成具有周期性特点的圆管阵列,构筑出相应的固-固二维二元声子晶体,进而借助于声子晶体本身带隙特征实现优异的隔声降噪性能,通过引入阻尼介质增加内部声波传输损耗实现优异的吸声性能,进而使聚氨酯泡沫板具有优异的隔音降噪性能,再者聚氨酯泡沫板基体具有许多细小的间隙和连续的泡孔,当声波入射到其表面时,发生透射,主要通过两种机理实现声波的衰减:其一是由于声波振动引起材料中间隙或泡孔内的空气运动,造成与孔壁的摩擦,在摩擦和粘滞力的作用,相当一部分声能以热能的形式释放,从而导致声波产生衰减,达到吸声降噪的目的:其二是孔隙中的空气和泡孔筋络之间的发生热交换导致的热损失,从而产生声能衰减,另外由于高频声波会使材料孔隙间的空气质点的振动速度加快,前述热交换也加快,所以多孔材料在高频段具有良好的吸声性能。
附图说明
下面结合附图对本发明作进一步的说明。
图1是本发明一种由复合板材组成的墙面板结构示意图。
图中:1、第一面板;2、第一增强层;3、聚氨酯泡沫板;4、第二增强层;5、第二面板。
具体实施方式
下面将结合本发明实施例,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作出创造性劳动前提下所获得的所有其它实施例,都属于本发明保护的范围。
实施例1
本实施例提供一种温控材料,由以下步骤制成:
步骤B1、将高岭土置于马弗炉中800℃下保温2h,然后自然冷却至室温得到偏高龄土;将偏高龄土和质量分数2%的十六烷基三甲基溴化铵溶液搅拌混合20min后,加入质量分数40%的氢氧化钠溶液调节pH值为12.0,然后升温至90℃,频率40kHz下超声处理3h,然后抽滤,滤饼洗涤至洗涤液呈中性,100℃下干燥2h,540℃下焙烧5h,得到壁材,偏高龄土和十六烷基三甲基溴化铵溶液的用量比为3.5g:60mL;
步骤B2、将石蜡和硬脂酸加入三口烧瓶中,75℃恒温水浴中处理20min,然后加入壁材,90℃水浴加热下,磁力搅拌20min后,抽真空至0.01MPa,搅拌反应1h,反应结束后,得到温控材料,石蜡、硬脂酸和壁材的质量比为17:8:2.5。
实施例2
本实施例提供一种温控材料,由以下步骤制成:
步骤B1、将高岭土置于马弗炉中800℃下保温2h,然后自然冷却至室温得到偏高龄土;将偏高龄土和质量分数2%的十六烷基三甲基溴化铵溶液搅拌混合30min后,加入质量分数40%的氢氧化钠溶液调节pH值为12.0,然后升温至90℃,频率50kHz下超声处理3h,然后抽滤,滤饼洗涤至洗涤液呈中性,100℃下干燥2h,540℃下焙烧5h,得到壁材,偏高龄土和十六烷基三甲基溴化铵溶液的用量比为4.2g:60mL;
步骤B2、将石蜡和硬脂酸加入三口烧瓶中,75℃恒温水浴中处理20min,然后加入壁材,90℃水浴加热下,磁力搅拌30min后,抽真空至0.01MPa,搅拌反应1h,反应结束后,得到温控材料,石蜡、硬脂酸和壁材的质量比为17:8:3.7。
实施例3
本实施例提供一种聚氨酯泡沫板,由以下步骤制成:
步骤A11、准备以下重量份原料:聚醚多元醇85份、聚酯多元醇75份、异佛尔酮二异氰酸酯25份、实施例1的温控材料8份、金属填料10份、发泡剂4份、2,2-二羟甲基丁酸8份;
步骤A12、准备泡沫板框架模具,向模具中放入金属填料,并将金属填料摆放成圆形阵列形状,将聚醚多元醇和聚酯多元醇混合均匀,然后加入发泡剂、扩链剂、温控材料,室温下搅拌均匀,最后加入异佛尔酮二异氰酸酯,搅拌均匀得预混料,然后将预混料注入泡沫板框架模具中,注入压力为14MPa,注入时间10s,并在40℃下发泡熟化10min,修剪边角料,得到聚氨酯泡沫板;
其中,聚醚多元醇的相对分子质量为2000-3000,羟值为200-320mgKOH/g,官能度为7,所述聚酯多元醇的相对分子质量为1500-2500,羟值为280-400mgKOH/g,官能度2.4-2.9,发泡剂为偶氮甲酰胺、偶氮二异丁腈按照质量比1:1.5混合组成。
其中,金属填料由以下步骤制成:
将10g不锈钢管材采用40#砂纸进行打磨,使其暴露出粗糙表面,然后将其加入反应釜中,再向反应釜中加入100mL无水乙醇、100mL去离子水和7.8g接枝剂,转速100r/min条件下,搅拌混合6h,反应结束后,过滤,滤饼于100℃烘箱中干燥12h,得到金属填料,不锈钢管材直径为0.5mm,长度3mm;
其中,接枝剂由以下步骤制成:
步骤S11、将5g六氯环三磷腈、11.4g 5-甲基-2-羟基苯甲醛、9.95g碳酸钾和200mL四氢呋喃加入三口烧瓶中,升温至回流反应48h,反应结束后,将反应产物旋蒸至原体积的1/4,蒸馏产物转移至去离子水中,静置4h,得到白色沉淀,抽滤,滤饼用去离子水洗涤3次,最后于60℃烘箱中干燥12h,得到中间产物1;
步骤S12、将0.01mol中间产物1和68.5mL 1,4-二氧六环加入三口烧瓶中,室温搅拌3min后,向三口烧瓶中加入0.06mol KH-550,然后升温至回流反应24h,旋蒸去除1,4-二氧六环,得到中间产物2;
步骤S13、将0.01mol中间产物2和70mL DMF加入三口烧瓶中,加入0.7g高锰酸钾和5mL质量分数17%的盐酸溶液,然后升温至65℃,搅拌反应4h,冷却至室温,过滤,用质量分数10%的碳酸钠溶液调节滤液pH至7,加入乙酸乙酯萃取,减压蒸馏去除乙酸乙酯,得到中间产物3;
步骤S14、将0.01mol中间产物3和0.01mol 2,2-二羟甲基丁酸加入95.7mL DMF中,搅拌条件下加入对甲苯磺酸,升温至80℃,搅拌反应2h,反应结束后,加入去离子水洗涤至中性,用乙酸乙酯萃取,再减压蒸馏去除乙酸乙酯,得到接枝剂,对甲苯磺酸的用量为中间产物3质量的5%。
实施例4
本实施例提供一种聚氨酯泡沫板,由以下步骤制成:
步骤A11、准备以下重量份原料:聚醚多元醇120份、聚酯多元醇100份、二苯基甲烷二异氰酸酯30份、实施例2的温控材料9份、金属填料12份、发泡剂8份、2,2-二羟甲基丁酸10份;
步骤A12、准备泡沫板框架模具,向模具中放入金属填料,并将金属填料摆放成圆形阵列形状,将聚醚多元醇和聚酯多元醇混合均匀,然后加入发泡剂、扩链剂、温控材料,室温下搅拌均匀,最后加入二苯基甲烷二异氰酸酯,搅拌均匀得预混料,然后将预混料注入泡沫板框架模具中,注入压力为14MPa,注入时间16s,并在36℃下发泡熟化10min,修剪边角料,得到聚氨酯泡沫板;
其中,聚醚多元醇的相对分子质量为2000-3000,羟值为200-320mgKOH/g,官能度为7,所述聚酯多元醇的相对分子质量为1500-2500,羟值为280-400mgKOH/g,官能度2.4-2.9,发泡剂为偶氮甲酰胺、偶氮二异丁腈按照质量比2:1.5混合组成。
其中,金属填料由以下步骤制成:
将10g不锈钢管材采用40#砂纸进行打磨,使其暴露出粗糙表面,然后将其加入反应釜中,再向反应釜中加入100mL无水乙醇、100mL去离子水和10.5g接枝剂,转速150r/min条件下,搅拌混合7h,反应结束后,过滤,滤饼于100℃烘箱中干燥12h,得到金属填料,不锈钢管材直径为1.0mm,长度1mm;
其中,接枝剂由以下步骤制成:
步骤S11、将5g六氯环三磷腈、13.8g 5-甲基-2-羟基苯甲醛、9.95g碳酸钾和200mL四氢呋喃加入三口烧瓶中,升温至回流反应48h,反应结束后,将反应产物旋蒸至原体积的1/4,蒸馏产物转移至去离子水中,静置5h,得到白色沉淀,抽滤,滤饼用去离子水洗涤4次,最后于60℃烘箱中干燥12h,得到中间产物1;
步骤S12、将0.01mol中间产物1和69.5mL 1,4-二氧六环加入三口烧瓶中,室温搅拌4min后,向三口烧瓶中加入0.06mol KH-550,然后升温至回流反应24h,旋蒸去除1,4-二氧六环,得到中间产物2;
步骤S13、将0.01mol中间产物2和75mL DMF加入三口烧瓶中,加入0.9g高锰酸钾和8mL质量分数17%的盐酸溶液,然后升温至68℃,搅拌反应4.5h,冷却至室温,过滤,用质量分数10%的碳酸钠溶液调节滤液pH至7,加入乙酸乙酯萃取,有机相减压蒸馏去除乙酸乙酯,得到中间产物3;
步骤S14、将0.01mol中间产物3和0.01mol 2,2-二羟甲基丁酸加入100.2mL DMF中,搅拌条件下加入对甲苯磺酸,升温至85℃,搅拌反应2.5h,加入去离子水洗涤至中性,用乙酸乙酯萃取,再减压蒸馏去除乙酸乙酯,得到接枝剂,对甲苯磺酸的用量为中间产物3质量的7%。
实施例5
本实施例提供一种聚氨酯泡沫板,由以下步骤制成:
步骤A11、准备以下重量份原料:聚醚多元醇160份、聚酯多元醇180份、二环己基甲烷二异氰酸酯55份、实施例1的温控材料10份、金属填料15份、发泡剂13份、2,2-二羟甲基丁酸18份;
步骤A12、准备泡沫板框架模具,向模具中放入金属填料,并将金属填料摆放成圆形阵列形状,将聚醚多元醇和聚酯多元醇混合均匀,然后加入发泡剂、扩链剂、温控材料,室温下搅拌均匀,最后加入二环己基甲烷二异氰酸酯,搅拌均匀得预混料,然后将预混料注入泡沫板框架模具中,注入压力为14MPa,注入时间20s,并在40℃下发泡熟化10min,修剪边角料,得到聚氨酯泡沫板;
其中,聚醚多元醇的相对分子质量为2000-3000,羟值为200-320mgKOH/g,官能度为7,所述聚酯多元醇的相对分子质量为1500-2500,羟值为280-400mgKOH/g,官能度2.4-2.9,发泡剂为偶氮甲酰胺、偶氮二异丁腈按照质量比3:2混合组成。
其中,金属填料由以下步骤制成:
将10g不锈钢管材采用40#砂纸进行打磨,使其暴露出粗糙表面,然后将其加入反应釜中,再向反应釜中加入100mL无水乙醇、100mL去离子水和11.2g接枝剂,转速200r/min条件下,搅拌混合8h,反应结束后,过滤,滤饼于100℃烘箱中干燥12h,得到金属填料,不锈钢管材直径为0.8mm,长度2mm;
其中,接枝剂由以下步骤制成:
步骤S11、将5g六氯环三磷腈、12.2g 5-甲基-2-羟基苯甲醛、9.95g碳酸钾和200mL四氢呋喃加入三口烧瓶中,升温至回流反应48h,反应结束后,将反应产物旋蒸至原体积的1/4,蒸馏产物转移至去离子水中,静置6h,得到白色沉淀,抽滤,滤饼用去离子水洗涤5次,最后于60℃烘箱中干燥12h,得到中间产物1;
步骤S12、将0.01mol中间产物1和74.2mL 1,4-二氧六环加入三口烧瓶中,室温搅拌5min后,向三口烧瓶中加入0.06mol KH-550,然后升温至回流反应24h,旋蒸去除1,4-二氧六环,得到中间产物2;
步骤S13、将0.01mol中间产物2和80mL DMF加入三口烧瓶中,加入1.1g高锰酸钾和10mL质量分数17%的盐酸溶液,然后升温至68℃,搅拌反应5h,冷却至室温,过滤,用质量分数10%的碳酸钠溶液调节滤液pH至8,加入乙酸乙酯萃取,有机相减压蒸馏去除乙酸乙酯,得到中间产物3;
步骤S14、将0.01mol中间产物3和0.01mol 2,2-二羟甲基丁酸加入103.2mL DMF中,搅拌条件下加入对甲苯磺酸,升温至90℃,搅拌反应3h,反应结束后,加入去离子水洗涤至中性,用乙酸乙酯萃取,再减压蒸馏去除乙酸乙酯,得到接枝剂,对甲苯磺酸的用量为中间产物3质量的8%。
对比例1
将实施例3中的金属填料去除,其余原料制备过程不变。
对比例2
将实施例4中的温控材料去除,其余原料制备过程不变。
实施例6
请参阅图1所示,一种由复合板材组成的墙面板,包括由上至下依次排列的第一面板1、第一增强层2、聚氨酯泡沫板3、第二增强层4和第二面板5;
该复合板材组成的墙面板由以下步骤制成:
由上而下依次铺设第一面板1、第一增强层2、聚氨酯泡沫板3、第二增强层4和第二面板5,复合成预制墙板,经过切割成型,得到复合板材组成的墙面板。
其中,第一增强层2为玻璃纤维毡,第二增强层4为钢丝网,第一面板1和第二面板5均为石膏板,聚氨酯泡沫板3为实施例1所得产品。
实施例7
一种由复合板材组成的墙面板,包括由上至下依次排列的第一面板1、第一增强层2、聚氨酯泡沫板3、第二增强层4和第二面板5;
该复合板材组成的墙面板由以下步骤制成:
由上而下依次铺设第一面板1、第一增强层2、聚氨酯泡沫板3、第二增强层4和第二面板5,复合成预制墙板,经过切割成型,得到复合板材组成的墙面板。
其中,第一增强层2和第二增强层4均为玻璃纤维网格布,第一面板1和第二面板5均为石膏板,聚氨酯泡沫板3为实施例2所得产品。
实施例8
一种由复合板材组成的墙面板,包括由上至下依次排列的第一面板1、第一增强层2、聚氨酯泡沫板3、第二增强层4和第二面板5;
该复合板材组成的墙面板由以下步骤制成:
由上而下依次铺设第一面板1、第一增强层2、聚氨酯泡沫板3、第二增强层4和第二面板5,复合成预制墙板,经过切割成型,得到复合板材组成的墙面板。
其中,第一增强层2为玻璃纤维布,第二增强层4为钢丝网,第一面板1和第二面板5均为陶瓷板,聚氨酯泡沫板3为实施例3所得产品。
对比例3
将实施例6中聚氨酯泡沫板3替换成对比例1所得材料,其余原料制备过程不变。
对比例4
将实施例7中聚氨酯泡沫板3替换成对比例2所得材料,其余原料制备过程不变。
对比例5
本对比例为公开号为CN101618611B的发明专利中实施例1制得的产品。
将实施例6-8和对比例3-5的墙板进行性能测试,测试过程如下:
抗压强度参照B/T 176693-199标准;隔音量检测参照《建筑门窗空气声隔声性能分级及检测方法》GB/T 8485-2008;冲击性能:参照标准GB/T 23451-2009检测;导热系数:参照DB44∕T 1700-2015建筑墙体传热系数试验规程,测试结果如表1所示:
表1
由表1可以看出,实施例6-8所制备的墙面板抗压强度在350MPa以上,空气隔音性能在108dB以上,5次冲击后无裂纹,导热系数在0.023-0.026W/(m·K),数据均优于对比例3-5,由对比例3和实施例6-8相比可知,将金属填料加入聚氨酯泡沫板中,并布置成具有周期性特点的圆管阵列,构筑出相应的固-固二维二元声子晶体,进而借助于声子晶体本身带隙特征实现优异的隔声降噪性能,并且通过引入阻尼介质增加内部声波传输损耗实现优异的吸声性能,进而使聚氨酯泡沫板具有优异的隔音降噪性能,由对比例4和实施例6-8相比可知,将温控材料加入聚氨酯泡沫板中使泡沫板的导热系数降低,对泡沫板的升温、降温产生迟滞作用,起到良好的温控效应,综上,本发明制备的墙面板具有优异的保温隔音性能。
需要说明的是,在本文中,诸如第一和第二等之类的关系术语仅仅用来将一个实体或者操作与另一个实体或操作区分开来,而不一定要求或者暗示这些实体或操作之间存在任何这种实际的关系或者顺序。而且,术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含,从而使得包括一系列要素的过程、方法、物品或者设备不仅包括那些要素,而且还包括没有明确列出的其他要素,或者是还包括为这种过程、方法、物品或者设备所固有的要素。
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 (8)
1.一种由复合板材组成的墙面板,其特征在于,包括由上至下依次排列的第一面板(1)、第一增强层(2)、聚氨酯泡沫板(3)、第二增强层(4)和第二面板(5);
其中,聚氨酯泡沫板(3)由以下步骤制成:
首先准备泡沫板框架模具,向模具中放入金属填料并摆放成圆形阵列形状,将聚醚多元醇和聚酯多元醇混合,然后加入发泡剂、扩链剂、温控材料,室温下搅拌均匀,最后加入二异氰酸酯,搅拌均匀得预混料,然后将预混料注入泡沫板框架模具中,发泡熟化,得到聚氨酯泡沫板(3)。
2.根据权利要求1所述的一种由复合板材组成的墙面板,其特征在于,金属填料由以下步骤制成:
将不锈钢管材打磨,然后将其加入反应釜中,再向反应釜中加入无水乙醇、去离子水和接枝剂,搅拌混合6-8h,过滤,干燥,得到金属填料。
3.根据权利要求2所述的一种由复合板材组成的墙面板,其特征在于,不锈钢管材直径为0.5-1.0mm,长度1-3mm。
4.根据权利要求1所述的一种由复合板材组成的墙面板,其特征在于,接枝剂由以下步骤制成:
步骤S11、将六氯环三磷腈、5-甲基-2-羟基苯甲醛、碳酸钾和四氢呋喃混合,回流反应48h,得到中间产物1;
步骤S12、将中间产物1和1,4-二氧六环加入三口烧瓶中,室温搅拌3-5min后,向三口烧瓶中加入KH-550,回流反应24h,得到中间产物2;
步骤S13、将中间产物2和DMF混合,加入高锰酸钾和盐酸溶液,升温至65-68℃,搅拌反应4-5h,冷却至室温,过滤,用碳酸钠溶液调节滤液pH至7-8,萃取,减压蒸馏,得到中间产物3;
步骤S14、将中间产物3和2,2-二羟甲基丁酸加入DMF中,搅拌下加入对甲苯磺酸,升温至80-90℃,反应2-3h,得到接枝剂。
5.根据权利要求4所述的一种由复合板材组成的墙面板,其特征在于,步骤S14中对甲苯磺酸的用量为中间产物3质量的5-8%。
6.根据权利要求1所述的一种由复合板材组成的墙面板,其特征在于,温控材料由以下步骤制成:
步骤B1、将偏高龄土和十六烷基三甲基溴化铵溶液混合,加入氢氧化钠溶液调节pH值为12.0,升温至90℃,超声处理3h,抽滤,滤饼涤液,干燥,540℃下焙烧,得到壁材;
步骤B2、将石蜡和硬脂酸混合,75℃恒温水浴中处理20min,然后加入壁材,90℃水浴加热下,磁力搅拌20-30min后,抽真空至0.01MPa,搅拌反应1h,得到温控材料。
7.根据权利要求6所述的一种由复合板材组成的墙面板,其特征在于,步骤B2中石蜡、硬脂酸和壁材的质量比为17:8:2.5-3.7。
8.根据权利要求1所述的一种由复合板材组成的墙面板的制备方法,其特征在于,包括以下步骤:
由上而下依次铺设第一面板(1)、第一增强层(2)、聚氨酯泡沫板(3)、第二增强层(4)和第二面板(5),复合成预制墙板,经过切割成型,得到复合板材组成的墙面板。
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