CN114213058B - 一种改性无机粉体材料及其制备方法 - Google Patents
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Abstract
本发明公开了一种改性无机粉体材料，包括质量份数为75～85的无机粉体、质量份数为3～5的表面处理剂，质量份数为10～15的热塑性酚醛树脂；所述表面处理剂包覆在无机粉体表面，形成改性层；所述热塑性酚醛树脂包覆在改性层外面，形成热塑层；所述无机粉体含有质量分数为10～15％的可膨胀石墨，其余组分为碳酸钙以及含硅化合物的混合物；所述表面处理剂由质量份数为30～50％的分散剂和质量份数50～70％的偶联剂组成。解决了现有技术中无机粉体加入热固性胶粘剂制成的防火板材成型工艺复杂、力学性能低、耐火性差，难以回收利用的技术问题。
Description
本发明要求中国专利申请CN202111454815.3的优先权，该优先权文件的说明书、说明书附图和权利要求书所记载的内容全文引入本发明的说明书并被作为本发明说明书原始记载的一部分。申请人进一步声明，申请人拥有基于该优先权文件修改本发明的说明书和权利要求书的权利。
技术领域
本发明涉及功能性材料技术领域，特别涉及一种改性无机粉体材料及其制备方法。
背景技术
目前市场上的铝塑板一般为三明治结构，其两面为铝质金属面板，起到装饰和防火的作用；中间为芯材，起到支撑增强的作用。根据其阻燃性能，又分为普通铝塑板和阻燃铝塑板。普通铝塑板芯材主要由聚乙烯制成，由于成型容易，价格便宜，是目前国内市场的主流，但其不阻燃，氧指数仅为16～18，燃烧后易滴落，容易引发火灾蔓延。阻燃铝塑板的芯材一般由无机粉体加入热固性胶粘剂后，进行加压加热，固化制得，但是芯材成型工艺复杂，难以回收利用，且机械性能较差。
发明内容
针对现有技术的不足，本发明的目的在于，提供一种改性无机粉体材料及其制备方法，以期至少部分解决现有技术中无机粉体加入热固性胶粘剂制成的防火板材成型工艺复杂、力学性能低、耐火性差，难以回收利用的技术问题。
为达到此发明目的，本发明采用以下技术方案：
一方面，本发明提供一种改性无机粉体材料，其特征在于，包括质量份数为75～85的无机粉体、质量份数为3～5的表面处理剂，质量份数为10～25的热塑性酚醛树脂；
所述表面处理剂包覆在无机粉体表面，形成改性层，用于增强无机粉体的分散性，防止团聚，更容易与热塑性酚醛树脂浸渍，并增强与热塑性酚醛树脂的界面强度；
所述热塑性酚醛树脂包覆在改性层外面，形成热塑层，由于热塑性酚醛树脂在加热时能够熔化，因此在铝塑板生产时不需要再加入热固性胶粘剂，在热压下即能形成芯材并与上下铝面板复合在一起，生产工艺简单；
所述无机粉体含有质量分数为10～15％的可膨胀石墨，其余组分为碳酸钙以及含硅化合物的混合物，可膨胀石墨在高温下能够膨胀形成泡沫焦炭，能够进行隔热，防止热塑性酚醛树脂的软化滴落；
所述表面处理剂由质量份数为30～50％的分散剂和质量份数50～70％的偶联剂组成。
进一步地，所述热塑性酚醛树脂的软化点为92～95℃，在加工温度下能够保持较低的粘度，与无机粉体能够充分浸渍，形成均匀的热塑层。
进一步地，所述分散剂为硅酸钠、三聚磷酸钠、六偏磷酸钠、羧甲基纤维素、脂肪酸聚乙二醇酯中的一种或多种的组合。
进一步地，所述的偶联剂为乙烯基三乙氧基硅烷、乙烯基三甲氧基硅烷、甲基丙烯酸氯化铬络合物、三异硬脂酰基钛酸异丙酯中的一种或多种的组合。
进一步地，所述无机粉体的粒径为80-800目。
另一方面，本发明提供一种如上述所述的改性无机粉体材料的制备方法，所述方法包括以下步骤：
S1：将配方比例的可膨胀石墨、碳酸钙以及含硅化合物进行共混搅拌，得到预混后的无机粉体；
S2：将配方比例的表面处理剂溶于水中，加入预混后的无机粉体，充分搅拌后烘干，得到具有表面处理剂包裹的改性层无机粉体。
S3：将热塑性酚醛树脂加热熔化后，加入改性层无机粉体进行搅拌共混，然后涂覆到传送带上，冷却后粉碎，过筛，得到具有热塑层的改性无机粉体材料。
进一步地，所述S2中采用的搅拌过程中还加入超声波作用，超声波通过对无机粉体的震荡作用，能够进一步避免团聚。
进一步地，所述S2中采用的烘干方式为流化床烘干，使无机粉体在烘干的同时得到了分散。
进一步地，所述S3中热塑性酚醛树脂的加热温度为130～150℃，使热塑性酚醛树脂保持在低粘度状态，便于与无机粉体浸渍包裹。
本发明还提供一种如上述所述的改性无机粉体材料的用途，所述用途为：用作铝塑板芯材。
相对于现有技术，本发明具有以下有益效果：
(1)本发明提供的改性无机粉体材料，外部由热塑性酚醛树脂包覆形成热塑层，此在铝塑板生产时不需要再加入热固性胶粘剂，在热压下即能形成芯材并与上下铝面板复合在一起，生产工艺简单，力学性能，且防火板在粉碎后还能再次加热成型，能够进行多次回收利用；
(2)本发明提供的改性无机粉体材料含有可膨胀石墨，在高温下能够膨胀形成泡沫焦炭，能够进行隔热，耐火性能高。
具体实施方式
下面通过具体实施方式来进一步说明本发明的技术方案。本领域技术人员应该明了，所述实施例仅仅是帮助理解本发明，不应视为对本发明的具体限制。
实施例1
一种改性无机粉体材料，包括质量份数为75的无机粉体、质量份数为5的表面处理剂，质量份数为20的热塑性酚醛树脂；表面处理剂包覆在无机粉体表面，形成改性层；热塑性酚醛树脂的软化点为92℃，包覆在改性层外面，形成热塑层；无机粉体的粒径为80目，含有质量分数为10％的可膨胀石墨，其余组分为碳酸钙以及含硅化合物的混合物；表面处理剂由质量份数为30％的硅酸钠分散剂和质量份数70％的乙烯基三乙氧基硅烷偶联剂组成。
在该实施例1中，用于制备如上所述的改性无机粉体材料的制备方法包括以下步骤：
S1：将配方比例的可膨胀石墨、碳酸钙以及含硅化合物进行共混搅拌，得到预混后的无机粉体；
S2：将配方比例的表面处理剂溶于水中，加入预混后的无机粉体，在超声波的作用下充分搅拌，然后通过流化床的方式烘干，得到具有表面处理剂包裹的改性层无机粉体。
S3：将热塑性酚醛树脂加热到130℃熔化后，加入改性层无机粉体进行搅拌共混，然后涂覆到传送带上，冷却后粉碎，过筛，得到具有热塑层的改性无机粉体材料。
实施例2
在实施例2中，一种改性无机粉体材料，包括质量份数为78的无机粉体、质量份数为5的表面处理剂，质量份数为17的热塑性酚醛树脂；表面处理剂包覆在无机粉体表面，形成改性层；热塑性酚醛树脂的软化点为93℃，包覆在改性层外面，形成热塑层；无机粉体的粒径为200目，含有质量分数为12％的可膨胀石墨，其余组分为碳酸钙以及含硅化合物的混合物；表面处理剂由质量份数为40％的三聚磷酸钠分散剂和质量份数60％的乙烯基三甲氧基硅烷偶联剂组成。
实施例2的改性无机粉体材料的制备方法请参考实施例1，与实施例1不同的是，S3中热塑性酚醛树脂加热温度为135℃。
实施例3
在实施例3中，一种改性无机粉体材料，包括质量份数为80的无机粉体、质量份数为5的表面处理剂，质量份数为15的热塑性酚醛树脂；表面处理剂包覆在无机粉体表面，形成改性层；热塑性酚醛树脂的软化点为94℃，包覆在改性层外面，形成热塑层；无机粉体的粒径为400目，含有质量分数为14％的可膨胀石墨，其余组分为碳酸钙以及含硅化合物的混合物；表面处理剂由质量份数为45％的六偏磷酸钠分散剂和质量份数55％的甲基丙烯酸氯化铬络合物组成。
实施例3的改性无机粉体材料的制备方法请参考实施例1，与实施例1不同的是，S3中热塑性酚醛树脂加热温度为140℃。
实施例4
在实施例4中，一种改性无机粉体材料，包括质量份数为85的无机粉体、质量份数为5的表面处理剂，质量份数为10的热塑性酚醛树脂；表面处理剂包覆在无机粉体表面，形成改性层；热塑性酚醛树脂的软化点为95℃，包覆在改性层外面，形成热塑层；无机粉体的粒径为800目，含有质量分数为15％的可膨胀石墨，其余组分为碳酸钙以及含硅化合物的混合物；表面处理剂由质量份数为50％的羧甲基纤维素分散剂和质量份数50％的三异硬脂酰基钛酸异丙酯偶联剂组成。
实施例4的改性无机粉体材料的制备方法请参考实施例1，与实施例1不同的是，S3中热塑性酚醛树脂加热温度为150℃。
对比例1
对比例1中，改性无机粉体材料的配方组分请参考实施例1，不同的是，改性无机粉体材料包括质量份数为90的无机粉体、质量份数为5的表面处理剂，质量份数为5的热塑性酚醛树脂。
对比例1的改性无机粉体材料的制备方法同实施例1。
对比例2
对比例2中，改性无机粉体材料的配方组分请参考实施例1，不同的是，热塑性酚醛树脂的软化点位96℃。
对比例2的改性无机粉体材料的制备方法同实施例1。
对比例3
对比例3中，改性无机粉体材料的配方组分请参考实施例1，不同的是，无机粉体中可膨胀石墨的含量为8％。
对比例3的改性无机粉体材料的制备方法同实施例1。
对比例4
对比例4中，改性无机粉体材料的配方组分请参考实施例1，不同的是，表面处理剂由质量份数为40％的硅酸钠分散剂和质量份数60％的乙烯基三乙氧基硅烷偶联剂组成。
对比例4的改性无机粉体材料的制备方法同实施例1。
将实施例1～4以及对比例1～4中制得的改性无机粉体材料通过热压的方法制得厚度为3mm的铝塑板芯材，并测试铝塑板芯材的拉伸断裂强度；将3mm的铝塑板芯材与两个厚度为1mm的铝面板复合，制成规格为200mm×300mm的铝塑板，并测试所述铝塑板的剥离强度；对铝塑板进行1000～1200℃，持续时间为5min的火烧试验，对铝塑板芯材的碳化层厚度进行测量。并对市场上通过将未改性的无机粉体加入热固性不饱和树脂制得的芯材以及铝塑板进行了对比试验。试验结果如下所示：
表1评价测试结果
由表1的结果可以看出，本发明实施例1-4所提供的改性无机粉体材料制备的铝塑板芯材的拉伸断裂强度和剥离强度，以及铝塑板的耐火性均显著高于对比例1～4以及未改性无机粉体加入热固性不饱和树脂制得的铝塑板及芯材。
申请人声明，本发明通过上述实施例来说明本发明的技术方案，但本发明并不局限于上述实施例，即不意味着本发明必须依赖上述实施例才能实施。所属技术领域的技术人员应该明了，对本发明的任何改进，对本发明产品各原料的等效替换及辅助成分的添加、具体方式的选择等，均落在本发明的保护范围和公开范围之内。
以上详细描述了本发明的优选实施方式，但是，本发明并不限于上述实施方式中的具体细节，在本发明的技术构思范围内，可以对本发明的技术方案进行多种简单变型，这些简单变型均属于本发明的保护范围。
另外需要说明的是，在上述具体实施方式中所描述的各个具体技术特征，在不矛盾的情况下，可以通过任何合适的方式进行组合，为了避免不必要的重复，本发明对各种可能的组合方式不再另行说明。
Claims (7)
1.一种改性无机粉体材料，其特征在于，包括质量份数为75~85的无机粉体、质量份数为3~5的表面处理剂，质量份数为10~25的热塑性酚醛树脂；
所述表面处理剂包覆在无机粉体表面，形成改性层；
所述热塑性酚醛树脂包覆在改性层外面，形成热塑层；
所述无机粉体含有质量分数为10~15%的可膨胀石墨，其余组分为碳酸钙以及含硅化合物的混合物；
所述表面处理剂由质量份数为30%的硅酸钠分散剂和质量份数70%的乙烯基三乙氧基硅烷偶联剂组成，或者由质量份数为40%的三聚磷酸钠分散剂和质量份数60%的乙烯基三甲氧基硅烷偶联剂组成，或者由质量份数为45%的六偏磷酸钠分散剂和质量份数55%的甲基丙烯酸氯化铬络合物组成，或者由质量份数为50%的羧甲基纤维素分散剂和质量份数50%的三异硬脂酰基钛酸异丙酯偶联剂组成；
所述热塑性酚醛树脂的软化点为92~95℃。
2.根据权利要求1所述的改性无机粉体材料，其特征在于，所述无机粉体的粒径为80-800目。
3.一种权利要求1或2所述的改性无机粉体材料的制备方法，其特征在于，所述方法包括以下步骤：
S1：将配方比例的可膨胀石墨、碳酸钙以及含硅化合物进行共混搅拌，得到预混后的无机粉体；
S2：将配方比例的表面处理剂溶于水中，加入预混后的无机粉体，充分搅拌后烘干，得到具有表面处理剂包裹的改性层无机粉体；
S3：将热塑性酚醛树脂加热熔化后，加入改性层无机粉体进行搅拌共混，然后涂覆到传送带上，冷却后粉碎，过筛，得到具有热塑层的改性无机粉体材料。
4.根据权利要求3所述的改性无机粉体材料的制备方法，其特征在于，所述S2中采用的搅拌过程中还加入超声波作用。
5.根据权利要求3所述的改性无机粉体材料的制备方法，其特征在于，所述S2中采用的烘干方式为流化床烘干。
6.根据权利要求3所述的改性无机粉体材料的制备方法，其特征在于，所述S3中热塑性酚醛树脂的加热温度为130~150℃。
7.一种权利要求1或2所述的改性无机粉体材料的用途，所述用途为：用作铝塑板芯材。
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