CN114382228A - 一种泡沫陶瓷复合墙板及其应用 - Google Patents
一种泡沫陶瓷复合墙板及其应用 Download PDFInfo
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Abstract
本发明提供一种泡沫陶瓷复合墙板及其应用,涉及建筑墙板技术领域。本发明的泡沫陶瓷复合墙板,包括外侧泡沫陶瓷板、发泡聚氨酯层和内侧泡沫陶瓷板,外侧泡沫陶瓷板和内侧泡沫陶瓷板内均设有加固网,发泡聚氨酯层内设有主龙骨;发泡聚氨酯层通过以下方法制备得到:将磷元素杂化聚醚多元醇、聚酯多元醇、交联剂、泡沫稳定剂、水和催化剂混合,得到组合聚醚;将组合聚醚和多亚甲基多苯基多异氰酸酯混合均匀,得到混合料A;将混合料A注入模具内,发泡完成即得;磷元素杂化聚酯多元醇通过含磷酸酐与多元酸、多元醇进行缩聚反应得到。本发明的泡沫陶瓷复合墙板,具有轻质高强、耐火、低导热、低成本的优点。
Description
技术领域
本发明涉及建筑墙板技术领域,特别是涉及一种泡沫陶瓷复合墙板及其应用。
背景技术
在建筑墙体上使用节能材料是实现建筑节能的有效措施,符合低碳经济的发展理念。常见的建筑节能材料分为有机保温材料和无机保温材料。有机保温材料导热系数低、保温效果好,但稳定性、耐火性、生态友好性较差,易造成安全隐患;传统的无机保温材料的耐火性能良好,但通常具有吸水率高、易开裂、强度低的问题,而且保温效果也有待提升。结合有机保温材料和无机保温材料的优势,研发新型有机-无机复合保温材料是目前的一个研究热点。
泡沫陶瓷以闭口气孔为主,除了具有耐火、耐温、耐腐蚀和其他传热陶瓷材料的优异性能外,泡沫陶瓷还具有低容重、高孔隙率、低吸水率等独特的性能。但是,现有的泡沫陶瓷板容易出现泡沫分散不均匀、板材强度不高等问题,保温和防水效果也有待提高,影响泡沫陶瓷的推广应用。
发明内容
基于此,有必要针对上述问题,提供一种泡沫陶瓷复合墙板,具有轻质、高强、耐火、低导热、低成本的优点。
本发明提供的一种泡沫陶瓷复合墙板,包括从外到内依次贴合设置的外侧泡沫陶瓷板、发泡聚氨酯层和内侧泡沫陶瓷板,所述外侧泡沫陶瓷板和内侧泡沫陶瓷板内均设有加固网,所述发泡聚氨酯层内设有主龙骨;
所述发泡聚氨酯层通过以下方法制备得到:将聚醚多元醇、磷元素杂化聚酯多元醇、交联剂、泡沫稳定剂、水和催化剂混合,得到组合聚醚;将组合聚醚和多亚甲基多苯基多异氰酸酯混合均匀,得到混合料A;将混合料A注入模具内,发泡完成后得到发泡聚氨酯层;
所述磷元素杂化聚酯多元醇通过以下方法制备得到:以9,10-二氢-9-氧杂-10-磷杂菲-10-氧化物(DOPO)和顺丁烯二酸酐为原料合成含磷酸酐,将含磷酸酐与多元酸、多元醇进行缩聚反应,得到磷元素杂化聚酯多元醇。
上述泡沫陶瓷复合墙板,通过引入发泡聚氨酯层,提高泡沫陶瓷复合墙板的保温性,通过外侧泡沫陶瓷板和内侧泡沫陶瓷板提高泡沫陶瓷复合墙板的强度和耐火性;而且,内侧泡沫陶瓷板和外侧泡沫陶瓷板均内置有加固网,发泡聚氨酯层内置有主龙骨,可提高墙板的强度和整体性;发泡聚氨酯层为磷元素杂化本征阻燃聚氨酯软泡材料,不需额外添加阻燃剂即可达到难燃级别。本发明的泡沫陶瓷复合墙板具有保温性好、强度高、耐火性好等优点。
在其中一个实施例中,所述聚醚多元醇、磷元素杂化聚酯多元醇、交联剂、泡沫稳定剂、水和催化剂的重量比为(60~80):(10~30):(5~10):(3~5):(3~5):(3~5)。
在其中一个实施例中,所述组合聚醚和多亚甲基多苯基多异氰酸酯的重量比为(35~40):(50~75)。
在其中一个实施例中,所述9,10-二氢-9-氧杂-10-磷杂菲-10-氧化物和顺丁烯二酸酐的重量比为(60~75):(30~45)。
在其中一个实施例中,所述含磷酸酐、多元酸和多元醇的重量比为(40~65):(20~40):(20~40)。
在其中一个实施例中,所述多元酸为均苯四甲酸;所述多元醇为季戊四醇。
在其中一个实施例中,所述外侧泡沫陶瓷板和内侧泡沫陶瓷板为材质相同的泡沫陶瓷板,所述泡沫陶瓷板通过以下方法制备得到:将陶瓷粉末、水泥、粘土和发泡剂混合均匀,得到混合料B,将混合料B注入模具内,加压成型,加热至120~150℃保温3~5小时,发泡和固化得到泡沫陶瓷生坯;将泡沫陶瓷生坯进行程序升温至350~450℃,升温速率为3~5℃/min,保温2~3小时,冷却后得到泡沫陶瓷板。
在其中一个实施例中,所述陶瓷粉末、水泥、粘土和发泡剂的重量比为(50~60):(10~15):(10~15):(10~20)。
在其中一个实施例中,所述陶瓷粉末为废弃陶瓷粉末。高温陶瓷废弃物是一种常用的绿色环保建筑材料,主要包括废弃陶瓷、玻璃、石粉等。废弃陶瓷粉末即将高温陶瓷废弃物碾碎得到的粉末,以废弃陶瓷粉末作为原料,在保证泡沫陶瓷板的保温性和强度的同时,降低生产成本。优选地,泡沫陶瓷板是以高温陶瓷废弃物为主要原材料,引入发泡剂低温烧制得到的轻质多孔材料。
在其中一个实施例中,发泡剂为蔗糖。
在其中一个实施例中,所述外侧泡沫陶瓷板远离发泡聚氨酯层的一面还覆盖有防水涂料层,所述防水涂料层由防水涂料制成,所述防水涂料通过以下方法制备得到:将重量比为(50~60):(5~10):(1~2):(1~2):(0.2~0.5):(0.2~0.5):(1~2):(30~40)的氟硅改性水性聚丙烯酸酯乳液、无机纳米粒子、成膜助剂、分散剂、湿润剂、消泡剂、pH调节剂和水混合,以400~600rad/min的速率分散20~30min,得到防水涂料。该防水涂料具有抗老化、耐沾污能力强的特点。
在其中一个实施例中,所述氟硅改性水性聚丙烯酸酯乳液通过以下方法制备得到:采用含氟单体和含硅单体与丙烯酸树脂单体进行乳液聚合反应,得到氟硅改性水性丙烯酸酯乳液。
在其中一个实施例中,所述无机纳米粒子为经硅烷偶联剂改性后的含有TiO2、SiO2和ZnO的无机纳米粒子。
在其中一个实施例中,所述内侧泡沫陶瓷板远离发泡聚氨酯层的一面还粘接有装饰层。
在其中一个实施例中,所述装饰层为石材面、实木面、喷墨面、砂岩板面或雕刻板面。装饰层可根据需要选择,以满足室内装饰需求。
在其中一个实施例中,所述加固网为钢筋网。
在其中一个实施例中,所述外侧泡沫陶瓷板和内侧泡沫陶瓷板朝向所述发泡聚氨酯层的一面均设有凹凸纹路,所述凹凸纹路的凹面和凸面的高度差为10~20mm。凹凸纹路的构造有助于提高发泡聚氨酯层与外侧泡沫陶瓷板和内侧泡沫陶瓷板的连接强度。
在其中一个实施例中,所述主龙骨为钢龙骨。
本发明还提供一种上述泡沫陶瓷复合墙板在制作建筑墙体中的应用。
与现有技术相比,本发明具有以下有益效果:
本发明的泡沫陶瓷复合墙板,通过引入发泡聚氨酯层,提高泡沫陶瓷复合墙板的保温性,通过外侧泡沫陶瓷板和内侧泡沫陶瓷板提高泡沫陶瓷复合墙板的强度和耐火性。本发明的泡沫陶瓷复合墙板具有保温性好、强度高、耐火性好等优点。
附图说明
图1为实施例1中的泡沫陶瓷复合墙板的结构示意图。
图中,1、防水涂料层,2、外侧泡沫陶瓷板,3、加固网,4、发泡聚氨酯层,5、主龙骨,6、固定件,7、凹凸纹路,8、内侧泡沫陶瓷板,9、装饰层。
具体实施方式
为了便于理解本发明,以下将给出较佳实施例对本发明进行更全面的描述。但是,本发明可以以许多不同的形式来实现,并不限于本文所描述的实施例。相反地,提供这些实施例的目的是使对本发明的公开内容的理解更加透彻全面。
除非另有定义,本文所使用的所有的技术和科学术语与属于本发明的技术领域的技术人员通常理解的含义相同。本文中在本发明的说明书中所使用的术语只是为了描述具体的实施例的目的,不是旨在于限制本发明。
实施例1
一种泡沫陶瓷复合墙板,如图1所示,包括从内到外依次层叠设置的外侧泡沫陶瓷板2、发泡聚氨酯层4和内侧泡沫陶瓷板8。
外侧泡沫陶瓷板2和内侧泡沫陶瓷板8内均内置有一层加固网3,优选为钢筋网片,钢筋网片做镀锌防腐处理,钢筋网片中的钢筋间距为150mm。钢筋网片延伸至泡沫陶瓷板左右两侧外沿,用于与建筑主体连接。发泡聚氨酯层4内设有主龙骨5,优选为钢龙骨。加固网3和主龙骨5为提供墙板支撑作用。外侧泡沫陶瓷板2和内侧泡沫陶瓷板8朝向发泡聚氨酯层4的一面设置为凹凸纹路7,凹凸纹路7的凹面和凸面的高度差为12mm,相应地,发泡聚氨酯层4的两侧面具有与凹凸纹路7相配合的纹路,以加强外侧泡沫陶瓷板2和发泡聚氨酯层4,以及内侧泡沫陶瓷板8和发泡聚氨酯层4的连接和固定。
发泡聚氨酯层4采用磷元素杂化本征阻燃聚氨酯软泡材料制备而成,具体通过以下方法制备得到:(1)将61份聚醚多元醇、21份磷元素杂化聚酯多元醇、6份交联剂季戊四醇、4份泡沫稳定剂软泡硅油、4份水和4份催化剂月桂酸有机锡化合物混合,得到组合聚醚;(2)将38份组合聚醚,按异氰酸酯指数1.4加入62份多亚甲基多苯基多异氰酸酯混合均匀,得到混合料A;(3)在带有喷头的搅拌器中将混合料A快速拌匀,迅速注入外侧墙板和外侧墙板之间的空隙,待发泡完成后修理边缝,得到发泡聚氨酯层4。
其中,磷元素杂化聚酯多元醇通过以下方法制备得到:以重量比为68:32的9,10-二氢-9-氧杂-10-磷杂菲-10-氧化物和顺丁烯二酸酐为原料合成含磷酸酐,将重量比为52:24:24的含磷酸酐、多元酸均苯四甲酸、多元醇季戊四醇进行缩聚反应,得到侧链含磷的聚酯多元醇。
外侧泡沫陶瓷板2和内侧泡沫陶瓷板8为材质相同的泡沫陶瓷板,泡沫陶瓷板通过以下方法制备得到:(1)将58份废弃高温陶瓷粉末、12份P.C42.5级复合硅酸盐水泥、12份粘土和18份发泡剂蔗糖混合,高速球磨使原料和发泡剂混合均匀,加热并继续搅拌使蔗糖完全熔化,得到混合料B;(2)将混合料B注入内置有单层双向钢筋网片、具有凹凸纹路构造面的模板中,加压成型;(3)将模板加热至发泡温度130℃,保温4小时,发泡和固化得到泡沫陶瓷生坯;(4)对泡沫陶瓷生坯以3℃/min的升温速率进行加热,升温至400℃保温2小时,自然冷却后得到内置双向钢筋网片的泡沫陶瓷板。
为提高泡沫陶瓷复合墙板的耐候性,在外侧泡沫陶瓷板2的外表面涂覆防水涂料,形成防水涂料层1。防水涂料的制备方法如下:(1)取5份甲基丙烯酸三氟乙酯、5份γ-甲基丙烯酰氧基丙基三甲氧基硅烷、30份甲基丙烯酸甲酯、14份丙烯酸丁酯、3份乳化剂十二烷基硫酸钠、1份引发剂过硫酸铵、42份水混合,经乳液聚合法得到氟硅改性水性丙烯酸酯乳液,备用;(2)以硅烷偶联剂改性市售的含TiO2、SiO2、ZnO的无机纳米粒子,备用;(3)将54份氟硅改性水性聚丙烯酸酯乳液、8份无机纳米粒子、2份成膜助剂醇酯十二、0.5份湿润剂炔二醇、0.5份有机硅消泡剂、1份pH调节剂链烷醇胺、32份水加入反应釜中,以500rad/min的速率分散25min,调节黏度至22S(涂-4杯),得到防水涂料。
为满足室内装修要求,在内侧泡沫陶瓷板8的内表面粘接天然石材面板作为装饰层9,利用环氧AB胶将装饰层9与内侧泡沫陶瓷板8粘合。
在实际组装过程中,可以利用螺栓、背栓、托架或挂件等固定件6,通过背栓点支撑的方式将外侧泡沫陶瓷板2、内侧泡沫陶瓷板8与钢龙骨5固定组成整体墙板。
本实施例的泡沫陶瓷复合墙板,具有轻质、隔热、隔声、防水、耐火、高强的特点,其容重为0.95g/cm3,导热系数为0.19W(m·K),空气声隔音量为48dB,吸水率为0.76%,防火等级为A2级,抗压强度为6.7MPa。
以上所述实施例的各技术特征可以进行任意的组合,为使描述简洁,未对上述实施例中的各个技术特征所有可能的组合都进行描述,然而,只要这些技术特征的组合不存在矛盾,都应当认为是本说明书记载的范围。
以上所述实施例仅表达了本发明的几种实施方式,其描述较为具体和详细,但并不能因此而理解为对发明专利范围的限制。应当指出的是,对于本领域的普通技术人员来说,在不脱离本发明构思的前提下,还可以做出若干变形和改进,这些都属于本发明的保护范围。因此,本发明专利的保护范围应以所附权利要求为准。
Claims (10)
1.一种泡沫陶瓷复合墙板,其特征在于,包括从外到内依次贴合设置的外侧泡沫陶瓷板、发泡聚氨酯层和内侧泡沫陶瓷板,所述外侧泡沫陶瓷板和内侧泡沫陶瓷板内均设有加固网,所述发泡聚氨酯层内设有主龙骨;
所述发泡聚氨酯层通过以下方法制备得到:将聚醚多元醇、磷元素杂化聚酯多元醇、交联剂、泡沫稳定剂、水和催化剂混合,得到组合聚醚;将组合聚醚和多亚甲基多苯基多异氰酸酯混合均匀,得到混合料A;将混合料A注入模具内,发泡完成后得到发泡聚氨酯层;
所述磷元素杂化聚酯多元醇通过以下方法制备得到:以9,10-二氢-9-氧杂-10-磷杂菲-10-氧化物和顺丁烯二酸酐为原料合成含磷酸酐,将含磷酸酐与多元酸、多元醇进行缩聚反应,得到磷元素杂化聚酯多元醇。
2.根据权利要求1所述的泡沫陶瓷复合墙板,其特征在于,所述聚醚多元醇、磷元素杂化聚酯多元醇、交联剂、泡沫稳定剂、水和催化剂的重量比为(60~80):(10~30):(5~10):(3~5):(3~5):(3~5),所述组合聚醚和多亚甲基多苯基多异氰酸酯的重量比为(35~40):(50~75);所述9,10-二氢-9-氧杂-10-磷杂菲-10-氧化物和顺丁烯二酸酐的重量比为(60~75):(30~45),所述含磷酸酐、多元酸和多元醇的重量比为(40~65):(20~40):(20~40)。
3.根据权利要求1所述的泡沫陶瓷复合墙板,其特征在于,所述外侧泡沫陶瓷板和内侧泡沫陶瓷板为材质相同的泡沫陶瓷板,所述泡沫陶瓷板通过以下方法制备得到:将陶瓷粉末、水泥、粘土和发泡剂混合均匀,得到混合料B,将混合料B注入模具内,加压成型,加热至120~150℃保温3~5小时,发泡和固化得到泡沫陶瓷生坯;将泡沫陶瓷生坯进行程序升温至350~450℃,升温速率为3~5℃/min,保温2~3小时,冷却后得到泡沫陶瓷板。
4.根据权利要求3所述的泡沫陶瓷复合墙板,其特征在于,所述陶瓷粉末、水泥、粘土和发泡剂的重量比为(50~60):(10~15):(10~15):(10~20)。
5.根据权利要求3所述的泡沫陶瓷复合墙板,其特征在于,所述陶瓷粉末为废弃陶瓷粉末,发泡剂为蔗糖。
6.根据权利要求1所述的泡沫陶瓷复合墙板,其特征在于,所述外侧泡沫陶瓷板远离发泡聚氨酯层的一面还覆盖有防水涂料层,所述防水涂料层由防水涂料制成,所述防水涂料通过以下方法制备得到:将重量比为(50~60):(5~10):(1~2):(1~2):(0.2~0.5):(0.2~0.5):(1~2):(30~40)的氟硅改性水性聚丙烯酸酯乳液、无机纳米粒子、成膜助剂、分散剂、湿润剂、消泡剂、pH调节剂和水混合,以400~600rad/min的速率分散20~30min,得到防水涂料。
7.根据权利要求6所述的泡沫陶瓷复合墙板,其特征在于,所述氟硅改性水性聚丙烯酸酯乳液通过以下方法制备得到:采用含氟单体和含硅单体与丙烯酸树脂单体进行乳液聚合反应,得到氟硅改性水性丙烯酸酯乳液;所述无机纳米粒子为经硅烷偶联剂改性后的含有TiO2、SiO2和ZnO的无机纳米粒子。
8.根据权利要求1所述的泡沫陶瓷复合墙板,其特征在于,所述内侧泡沫陶瓷板远离发泡聚氨酯层的一面还粘接有装饰层,所述装饰层为石材面、实木面、喷墨面、砂岩板面或雕刻板面。
9.根据权利要求1~8任一项所述的泡沫陶瓷复合墙板,其特征在于,所述加固网为钢筋网;所述外侧泡沫陶瓷板和内侧泡沫陶瓷板朝向所述发泡聚氨酯层的一面均设有凹凸纹路,所述凹凸纹路的凹面和凸面的高度差为10~20mm;所述主龙骨为钢龙骨。
10.一种权利要求1~9任一项所述的泡沫陶瓷复合墙板在制作建筑墙体中的应用。
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