CN116161911B - 一种隔音泡沫墙板及其制备方法 - Google Patents
一种隔音泡沫墙板及其制备方法 Download PDFInfo
- Publication number
- CN116161911B CN116161911B CN202310189728.2A CN202310189728A CN116161911B CN 116161911 B CN116161911 B CN 116161911B CN 202310189728 A CN202310189728 A CN 202310189728A CN 116161911 B CN116161911 B CN 116161911B
- Authority
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- China
- Prior art keywords
- parts
- foam
- wallboard
- silicon dioxide
- sound insulation
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
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- SCPWMSBAGXEGPW-UHFFFAOYSA-N dodecyl(trimethoxy)silane Chemical compound CCCCCCCCCCCC[Si](OC)(OC)OC SCPWMSBAGXEGPW-UHFFFAOYSA-N 0.000 claims description 8
- 239000012065 filter cake Substances 0.000 claims description 8
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- YUYCVXFAYWRXLS-UHFFFAOYSA-N trimethoxysilane Chemical compound CO[SiH](OC)OC YUYCVXFAYWRXLS-UHFFFAOYSA-N 0.000 claims description 7
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- LNOPIUAQISRISI-UHFFFAOYSA-N n'-hydroxy-2-propan-2-ylsulfonylethanimidamide Chemical compound CC(C)S(=O)(=O)CC(N)=NO LNOPIUAQISRISI-UHFFFAOYSA-N 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims description 4
- 229940051841 polyoxyethylene ether Drugs 0.000 claims description 4
- 229920000056 polyoxyethylene ether Polymers 0.000 claims description 4
- 239000012745 toughening agent Substances 0.000 claims description 4
- IXPNQXFRVYWDDI-UHFFFAOYSA-N 1-methyl-2,4-dioxo-1,3-diazinane-5-carboximidamide Chemical compound CN1CC(C(N)=N)C(=O)NC1=O IXPNQXFRVYWDDI-UHFFFAOYSA-N 0.000 claims description 2
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- DBMJMQXJHONAFJ-UHFFFAOYSA-M Sodium laurylsulphate Chemical compound [Na+].CCCCCCCCCCCCOS([O-])(=O)=O DBMJMQXJHONAFJ-UHFFFAOYSA-M 0.000 claims description 2
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 claims description 2
- DPXJVFZANSGRMM-UHFFFAOYSA-N acetic acid;2,3,4,5,6-pentahydroxyhexanal;sodium Chemical compound [Na].CC(O)=O.OCC(O)C(O)C(O)C(O)C=O DPXJVFZANSGRMM-UHFFFAOYSA-N 0.000 claims description 2
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- 125000003438 dodecyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 claims description 2
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- BDHFUVZGWQCTTF-UHFFFAOYSA-M sulfonate Chemical compound [O-]S(=O)=O BDHFUVZGWQCTTF-UHFFFAOYSA-M 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 claims 3
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- 239000000126 substance Substances 0.000 description 4
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- 241001391944 Commicarpus scandens Species 0.000 description 3
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- 230000002776 aggregation Effects 0.000 description 3
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0875—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having a basic insulating layer and at least one covering layer
-
- 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
- B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
- B28B19/0092—Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
- B28C5/38—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions wherein the mixing is effected both by the action of a fluid and by directly-acting driven mechanical means, e.g. stirring means ; Producing cellular concrete
- B28C5/381—Producing cellular concrete
- B28C5/386—Plants; Systems; Methods
- B28C5/388—Methods
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
- B32B9/005—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
- B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B9/046—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B22/00—Use of inorganic materials as active ingredients for mortars, concrete or artificial stone, e.g. accelerators, shrinkage compensating agents
- C04B22/06—Oxides, Hydroxides
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
- C04B24/02—Alcohols; Phenols; Ethers
- C04B24/026—Fatty alcohols
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
- C04B38/106—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam by adding preformed foams
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/04—Inorganic
- B32B2266/049—Water-setting material, e.g. concrete, plaster or asbestos cement
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/10—Properties of the layers or laminate having particular acoustical properties
- B32B2307/102—Insulating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/304—Insulating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
- B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
-
- B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract
本发明公开了一种隔音泡沫墙板及其制备方法,该隔音泡沫墙板由陶瓷板、胶粘剂、发泡混凝土板层组成;发泡混凝土板层包括以下质量份的原料:400~500份水泥、10~100份细沙、100~300份水、1~20份减水剂、1~20份促凝剂、1~20份增稠剂、1~10份乳胶粉、1~10份增韧剂、1~5份发泡剂、1~5份稳泡剂。本发明制备得到的隔音泡沫墙板具有良好的隔热、隔音以及抗压强度,且使用的都是天然无机材料,具备良好的抵抗虫蛀和避免霉变和细菌滋生的性能;燃烧性能等级为A级,能够满足所有的室内安装使用要求。
Description
技术领域
本发明涉及装修技术领域,尤其涉及一种隔音泡沫墙板及其制备方法。
背景技术
由于使用传统材料存在较大的浪费,还存在工期长、工艺繁琐、工作量大、成本高、很难进行后期保养与维修等问题,与现代都市人倡导的实用、环保、节能观念不符,传统建筑装修材料已逐渐不再满足客户的需求。隔音泡沫墙板作为建筑节能与结构一体化技术的一种应用产品,是集结构功能和装饰功能为一体的新型墙体材料,结构上代替传统的砖混结构墙,装饰上代替单纯使用石膏板、密度板、涂料油漆等装饰的建筑装饰材料。
隔音泡沫墙板采用绿色环保可回收的原材料生产,无甲醛等有害物质,从源头上杜绝装修材料中甲醛、苯、DMF等有害化学物质的危害。现场作业过程中采用全干法施工,不使用任何涂料、溶剂、胶粘剂,而且施工过程不产生建筑垃圾。同时,隔音泡沫墙板产品工业化标准定制,让传统装修80%以上的工作量在工厂内完成,现场只需要简单的装配,即可快速实现装修效果,缩短工期。由于按统一标准定制,可以使得所有同款产品的应用效果和质量标准一致,完美解决质量与形象标准执行难题,实现高品质装修。此外,相比传统材料,在综合成本上,隔音泡沫墙板低于传统材料。
专利CN109555262B公开了一种保温陶粒轻质墙板,包括墙板本体,墙板本体包括两侧的墙面层、位于两侧的墙面层之间的保温墙芯和位于墙面内的网架;墙面层由混凝土填充;两侧的墙面层包覆保温墙芯和网架;保温墙芯上开设有若干通孔;通孔呈V形,包括两个开口端和一个连接端;两个开口端分别位于保温墙芯的两侧,连接端位于保温墙芯内部,连接端处放置有碳酸氢钠;保温墙芯表面开设有若干细槽;网架包括若干平行于墙面层的竖向钢丝;其中,墙面层混凝土的填充成分包括水泥、拌合水、河砂、陶粒、减水剂、粉煤灰、纤维素、减水剂和早强剂。该发明的技术方案能使墙板具有较强的抗压能力,但其缺点在于自重较大,保温效果以及隔音效果有待提高,同时墙芯与墙面层之间仅通过水泥粘接,由于水泥韧性不高,可能会发生脱落的风险,存在隐患。
专利CN108393997B公开了一种以杨木废弃木屑制备的集成墙板及其制备方法,集成墙板包括主料和辅料,所述主料按照重量百分比计包括:杨木木粉35~55%、竹粉40~50%、轻质钙粉5~25%;所述辅料中各成分按照重量百分比计包括:粘合剂70~85%和助剂15~30%;其中主料占总成分75~85%;该发明所制备的集成墙板具有较高的冲击强度和拉伸强度,且韧性也较好。其缺点在于并没有很好的装饰效果,且不具备保温和隔音效果,此外,该发明制备的集成墙板阻燃性较差,在现实中应用场景有限。
发明内容
有鉴于上述现有技术的缺陷,本发明提供一种具有良好保温、隔热、隔音、阻燃性能同时具有装饰效果的隔音泡沫墙板及其制备方法。
为了实现上述发明目的,本发明提供以下技术方案:
一种隔音泡沫墙板,由陶瓷板、胶粘剂、发泡混凝土板层组成。
优选的,所述陶瓷板厚度为1~6mm。
陶瓷板是具有极强的耐候性,无论日照、雨淋(甚至酸雨),还是潮气都对表面和基材没有任何影响。耐紫外线照射和色彩稳定性完全达到国际灰度级4-5级。同样,大幅或快速的温度变化也不会影响材料的特性和外观。抗弯强度和弹性的合理组合,使陶瓷板具有很高的耐冲击强度。致密的材料表面使灰尘不易粘附,使其清洁更为容易。陶瓷板具有极好的耐火特性,它不会融化、滴落或爆炸,并能长时间保持稳定。陶瓷板易于维护,表面和切割边缘都无需油漆或加保护陶瓷板。
相比传统材料,陶瓷板具有抗撞击、耐客刮。耐磨、易清洗、防潮、防火、防静电以及耐化学腐蚀等优点。能够与食物直接接触,100%可回收,无毒害无辐射的同时,满足可持续发展的要求,由于陶瓷板优越的特性,及丰富多彩的颜色,主要用于室外幕墙和室内的装饰。
而本发明中将陶瓷板作为隔音泡沫墙板的装饰层,除了具备陶瓷板自生的优良特性外,还从根本解决了薄型陶瓷板的难运输、难安装等应用问题,具有灵活便捷的装配式建筑应用构造。
优选的,所述发泡混凝土板层包括以下质量份的原料:400~500份水泥、10~100份细沙、100~300份水、1~20份减水剂、1~20份促凝剂、1~20份增稠剂、1~10份乳胶粉、1~10份增韧剂、1~5份发泡剂、1~5份稳泡剂。
优选的,所述促凝剂为氯化钙、硅酸钠、硅酸钾其中任意一种。
在发泡混凝土板层在制备过程中,气泡能否在料浆中稳定存在的必要条件是气泡在料浆中的寿命与料浆的凝结时间必须相匹配,气泡在料浆中的寿命较料浆的凝结时间更长时,气泡能够稳定存在。为了加快料浆的凝结,因此需要添加促凝剂提高气泡的稳定性。
优选的,所述增稠剂为甲基纤维素、黄原胶、羧甲基纤维素钠、海藻酸钠其中一种或两种及两种以上的混合。
增稠剂主要作用是增加泡沫混凝土砂浆的黏度,提高泡沫气泡的稳定性和寿命,从而提高泡沫混凝土砂浆的稳定性。
进一步优选的,所述增稠剂为黄原胶。
黄原胶拥有大分子的特殊结构和胶体的特性,可以作为乳化剂、稳定剂、增稠剂、浸润剂等。故黄原胶在泡沫混凝土砂浆中既能增加泡沫混凝土料浆的粘度,提高泡沫气泡的稳定性,又能起到保水作用,在一定程度上避免粉化。
乳胶粉具有良好的粘结强度,在本发明中可以增强发泡混凝土板层与陶瓷板之间的粘结性能,同时乳胶粉可以大大减小发泡混凝土板层的收缩性,避免陶瓷板的剥离和发泡混凝土板层的开裂。
优选的,所述增韧剂为聚丙烯纤维、聚乙烯纤维、聚乙烯醇纤维其中一种或两种及两种以上的混合。
在混凝土中添加适量的纤维可以提高发泡混凝土板层的抗压强度、抗拉强度、抗折强度以及减少干缩现象。适量的纤维掺量可以形成较稳定的三维网状结构,提高发泡混凝土板层的力学性能,混凝土是非匀质材料。当泡沫混凝土受到拉应力作用时,各区域受力不均匀,应力较为集中区域容易出现开裂现象。纤维的掺入能充当连接、传递应力的作用,很好地分散拉应力,避免某一区域出现过大拉应力的情况。因此纤维能够吸收胶凝剂收缩干燥时产生的应力,对发泡混凝土板层的收缩开裂问题以及与陶瓷板剥离的问题有很好的改良效果。
优选的,所述发泡剂为十二烷基硫酸钠、α-烯烃磺酸钠、脂肪酸聚氧乙烯醚硫酸钠、十二烷基聚氧乙烯醚其中一种或两种及两种以上的混合。
本发明所使用的发泡剂为阴离子型发泡剂,其特点在与发泡能力强、发泡体积更大,亲水基一段为阴离子,所带电荷与水泥中的钙离子的电荷电性一致,在水泥浆体中不会产生电荷相斥的作用,从而相比阳离子型发泡剂来说,泡沫稳定性更好。
优选的,所述稳泡剂为纳米二氧化硅、改性纳米二氧化硅、十二醇其中一种或两种及两种以上的混合。
由于泡沫在自然状态下是不稳定结构,因此泡沫不会稳定存在于空气中,一般指挥存在较短时间就会破裂消失,而对于泡沫混凝土来说,一般需要制备出的泡沫可以长时间稳定存在,因此需要添加稳泡剂来提高泡沫的寿命。
纳米二氧化硅可以分散在发泡剂中与发泡剂发生协同作用,在砂浆中形成特殊的囊泡结构,增强泡沫的稳定性,其原因在于纳米二氧化硅与发泡剂之间形成一层韧性的刚性膜,阻止泡沫的破裂和并聚。另一方面,泡沫表面的二氧化硅可以通过与水泥水化产生的氢氧化钙反应,生产的水化产物可以填充混凝土中的孔隙,从而降低吸水率并提高发泡混凝土板层的力学性能。
优选的,所述改性纳米二氧化硅的制备方法,包括以下步骤:
N1将纳米二氧化硅分散在甲苯溶液中,加入十二烷基三甲氧基硅烷反应,反应结束后再加入γ-聚环氧基三甲氧基硅烷反应,去除溶剂收集产物得到疏水化纳米二氧化硅;
N2将疏水化纳米二氧化硅分散在乙醇中,加入氨基磺酸反应,去除溶剂收集产物得到改性纳米二氧化硅。
进一步优选的,所述改性纳米二氧化硅的制备方法,包括以下步骤:
N1将5~10g纳米二氧化硅分散在100~200mL甲苯中,超声分散5~10min,加入1~5mL十二烷基三甲氧基硅烷,在60~100℃下,搅拌反应10~16h,反应结束后再加入1~5mLγ-聚环氧基三甲氧基硅烷,在0~100℃下,搅拌反应8~14h,抽滤去除溶剂,收集沉淀,将沉淀用乙醇洗涤2~3次后,置于烘箱中40~100℃干燥12~24h得到疏水化纳米二氧化硅;
N2将所述步骤N1得到的疏水化纳米二氧化硅分散在40~100mL乙醇中,超声分散5~10min,加热至60~80℃,将0.1~2g/mL氨基磺酸水溶液滴加至反应体系pH=2~5,再继续反应6~12h,反应结束后抽滤收集滤饼,将滤饼用水洗涤2~3次,置于烘箱中40~100℃干燥12~24h得到改性纳米二氧化硅。
纳米二氧化硅虽然具有一定的稳泡作用,但是单独使用纳米二氧化硅其团聚现象十分严重,同时其亲水性过强,很难稳定地吸附在泡沫界面上,为了达到更好地稳泡效果,故对纳米二氧化硅表面进行了改性,使其具有合适地分散性和润湿性。
本发明同时使用十二烷基三甲氧基硅烷和γ-聚环氧基三甲氧基硅烷同时对二氧化硅表面进行改性,由于十二烷基三甲氧基硅烷具有长链烷基,具有较强地疏水性,γ-聚环氧基三甲氧基硅烷的烷基链较短,疏水性较弱,且同时具有环氧基团,可以继续在其一端枝连亲水基团,本发明加入氨基磺酸,在二氧化硅表面枝连磺酸基,得到的改性二氧化硅表面同时具有了疏水端和亲水端,类似于表面活性剂的结构,因此得到的改性纳米二氧化硅相比单独的纳米二氧化硅更易吸附至泡沫界面,且更不易发生团聚现象,同时一部分发泡剂直接吸附在泡沫界面上,一部分先吸附在改性纳米二氧化硅表面,再随着纳米二氧化硅吸附于泡沫界面,这样单独的发泡剂可以插入改性纳米二氧化硅之间的孔隙之中,协同的泡沫稳定性最强。
进一步优选的,所述稳泡剂为质量比为1~3:1的改性纳米二氧化硅和十二醇的混合。
改性纳米二氧化硅虽然有着良好的泡沫稳定性,但是由于改性纳米二氧化硅的加入使得泡沫液膜强度较大而使其发泡较为困难,同时改性纳米二氧化硅使得溶液黏度增大导致在搅拌中空气难以进入溶液,因此会导致发泡体积降低;另一方面,当改性纳米二氧化硅添加量过高时,大量的发泡剂分子被吸附在颗粒表面,溶液中起泡剂的有效溶度很低,反而会降低泡沫的稳定性。因此,本发明将改性纳米二氧化硅与十二醇分子复配作为稳泡剂,十二醇分子相比改性纳米二氧化硅可以降低发泡所需克服的功,从而使得发泡体积变大,且由于改性纳米二氧化硅和阴离子型发泡剂都带负电,在泡沫界面上具有静电斥力作用,可能导致排水量增加,泡沫稳定性变弱,而十二醇分子可以被吸附于泡沫液膜内并插入发泡剂分子和改性纳米二氧化硅之间,而且十二醇分子的羟基可以它们之间形成氢键,在泡沫界面上,十二醇能穿插在改性纳米二氧化硅和起泡剂分子之间的孔隙中,克服了两者之间静电斥力的作用,从而显著的加强液膜的强度,提高液膜弹性即泡沫稳定性。
优选的,所述胶粘剂为瓷砖胶。
本发明还提供了上述隔音泡沫墙板的制备方法,包括以下步骤:
S1在陶瓷板的粗糙面涂刷胶粘剂,晾干;
S2将陶瓷板涂刷胶粘剂的一边向内,固定在模具架上,陶瓷板与模具架形成一个空间;
S3将泡沫混凝土浆料浇注入步骤S2所述的空间中;
S4待泡沫混凝土凝结硬化以后,从模具架中取出养护即得到隔音泡沫墙板。
优选的,所述步骤S1中胶粘剂厚度为0.1~1cm。
本发明制备方法先将胶粘剂涂刷在陶瓷板上晾干再与发泡混凝土板层结合,这是为了防止陶瓷板吸收泡沫混凝土砂浆中气泡液膜中的水分,导致与陶瓷板接触处的气泡消泡破裂,出现塌模的现象。
优选的,所述泡沫混凝土浆料的制备方法为:将1~5份发泡剂、1~5份稳泡剂与30~150份水混合用搅拌机1000~2000rpm搅拌3~10min制备泡沫;将400~500份水泥、10~100份细沙、70~270份水、1~20份减水剂、1~20份促凝剂、1~20份增稠剂、1~10份乳胶粉、1~10份增韧剂混匀得到砂浆;再将砂浆与泡沫混匀得到泡沫混凝土浆料。
与现有技术相比,本发明的有益效果:
1、隔音泡沫墙板具有良好的隔热、隔音效果,同时保证了板块的稳定和美观。
2、隔音泡沫墙板所使用的均为无机环保材料,具有良好的抗虫蛀和避免霉变和细菌滋生的性能。
3、本发明发泡混凝土板层所使用的稳泡剂可以使得泡沫混凝土中泡沫微小且稳定,使得发泡混凝土板层具有优良的隔热隔音以及抗干缩的效果,改性纳米二氧化硅还能与水泥水化产生的氢氧化钙反应得到的水化产物使其在重量轻的条件下具备良好的抗冲击性。
具体实施方式
下述实施例中所使用的实验方法如无特殊说明,均为常规方法。
下述实施例中所用的材料、试剂等,如无特殊说明,均可从商业途径得到。
本发明实施例中部分物质和仪器的具体参数如下:
水泥,普通硅酸盐水泥42.5,购自于浙江红狮水泥股份有限公司。
减水剂,聚羧酸减水剂,型号:SPC-100,减水率≥25%,购自于辽宁科隆精细化工股份有限公司。
乳胶粉,可再分散乳胶粉,型号:6070N,工业级,固含量≥98%,平均粒径≥80μm,购自于山东戈麦斯化工有限公司。
纳米二氧化硅,粒径约为20nm,购自于安徽科润纳米科技有限公司。
瓷砖胶,瓷砖背胶J-100,购自于京帝科技新材料有限公司。
实施例1
一种隔音泡沫墙板的制备方法,包括以下步骤:
S1在陶瓷板的粗糙面涂刷0.2cm厚的胶粘剂,晾干;
S2将陶瓷板涂刷胶粘剂的一边向内,固定在模具架上,陶瓷板与模具架形成一个空间;
S3将泡沫混凝土浆料浇注入步骤S2所述的空间中;
S4待泡沫混凝土凝结硬化以后,从模具架中取出养护即得到隔音泡沫墙板。
所述陶瓷板厚度为3mm。
所述泡沫混凝土浆料的制备方法为:将1.5份α-烯烃磺酸钠、3份稳泡剂与75份水混合用搅拌机1500rpm搅拌4min制备泡沫;将430份水泥、20份细沙、100份水、5份减水剂、10份氯化钙、2份黄原胶、5份乳胶粉、2份聚丙烯纤维混匀得到砂浆;再将砂浆与泡沫混匀得到泡沫混凝土浆料。
所述稳泡剂为质量比为3:1的改性纳米二氧化硅和十二醇的混合。
所述改性纳米二氧化硅的制备方法,包括以下步骤:
N1将5g纳米二氧化硅分散在100mL甲苯中,超声分散5min,加入2mL十二烷基三甲氧基硅烷,在80℃下,搅拌反应13h,反应结束后再加入2mLγ-聚环氧基三甲氧基硅烷,在80℃下,搅拌反应10h,抽滤去除溶剂,收集沉淀,将沉淀用乙醇洗涤3次后,置于烘箱中50℃干燥12h得到疏水化纳米二氧化硅;
N2将所述步骤N1得到的疏水化纳米二氧化硅分散在50mL乙醇中,超声分散5min,加热至70℃,将0.5g/mL氨基磺酸水溶液滴加至反应体系pH=3,再继续反应7h,反应结束后抽滤收集滤饼,将滤饼用水洗涤3次,置于烘箱中50℃干燥12h得到改性纳米二氧化硅。
实施例2
一种隔音泡沫墙板的制备方法,包括以下步骤:
S1在陶瓷板的粗糙面涂刷0.2cm厚的胶粘剂,晾干;
S2将陶瓷板涂刷胶粘剂的一边向内,固定在模具架上,陶瓷板与模具架形成一个空间;
S3将泡沫混凝土浆料浇注入步骤S2所述的空间中;
S4待泡沫混凝土凝结硬化以后,从模具架中取出养护即得到隔音泡沫墙板。
所述陶瓷板厚度为3mm。
所述泡沫混凝土浆料的制备方法为:将1.5份α-烯烃磺酸钠、3份稳泡剂与75份水混合用搅拌机1500rpm搅拌4min制备泡沫;;将430份水泥、20份细沙、100份水、5份减水剂、10份氯化钙、2份黄原胶、5份乳胶粉、2份聚丙烯纤维混匀得到砂浆;再将砂浆与泡沫混匀得到泡沫混凝土浆料。
所述稳泡剂为纳米二氧化硅。
实施例3
一种隔音泡沫墙板的制备方法,包括以下步骤:
S1在陶瓷板的粗糙面涂刷0.2cm厚的胶粘剂,晾干;
S2将陶瓷板涂刷胶粘剂的一边向内,固定在模具架上,陶瓷板与模具架形成一个空间;
S3将泡沫混凝土浆料浇注入步骤S2所述的空间中;
S4待泡沫混凝土凝结硬化以后,从模具架中取出养护即得到隔音泡沫墙板。
所述陶瓷板厚度为3mm。
所述泡沫混凝土浆料的制备方法为:将1.5份α-烯烃磺酸钠、3份稳泡剂与75份水混合用搅拌机1500rpm搅拌4min制备泡沫;;将430份水泥、20份细沙、100份水、5份减水剂、10份氯化钙、2份黄原胶、5份乳胶粉、2份聚丙烯纤维混匀得到砂浆;再将砂浆与泡沫混匀得到泡沫混凝土浆料。
所述稳泡剂为改性纳米二氧化硅。
所述改性纳米二氧化硅的制备方法,包括以下步骤:
N1将5g纳米二氧化硅分散在100mL甲苯中,超声分散5min,加入2mL十二烷基三甲氧基硅烷,在80℃下,搅拌反应13h,反应结束后再加入2mLγ-聚环氧基三甲氧基硅烷,在80℃下,搅拌反应10h,抽滤去除溶剂,收集沉淀,将沉淀用乙醇洗涤3次后,置于烘箱中50℃干燥12h得到疏水化纳米二氧化硅;
N2将所述步骤N1得到的疏水化纳米二氧化硅分散在50mL乙醇中,超声分散5min,加热至70℃,将0.5g/mL氨基磺酸水溶液滴加至反应体系pH=3,再继续反应7h,反应结束后抽滤收集滤饼,将滤饼用水洗涤3次,置于烘箱中50℃干燥12h得到改性纳米二氧化硅。
实施例4
一种隔音泡沫墙板的制备方法,包括以下步骤:
S1在陶瓷板的粗糙面涂刷0.2cm厚的胶粘剂,晾干;
S2将陶瓷板涂刷胶粘剂的一边向内,固定在模具架上,陶瓷板与模具架形成一个空间;
S3将泡沫混凝土浆料浇注入步骤S2所述的空间中;
S4待泡沫混凝土凝结硬化以后,从模具架中取出养护即得到隔音泡沫墙板。
所述陶瓷板厚度为3mm。
所述泡沫混凝土浆料的制备方法为:将1.5份α-烯烃磺酸钠、3份稳泡剂与75份水混合用搅拌机1500rpm搅拌4min制备泡沫;;将430份水泥、20份细沙、100份水、5份减水剂、10份氯化钙、2份黄原胶、5份乳胶粉、2份聚丙烯纤维混匀得到砂浆;再将砂浆与泡沫混匀得到泡沫混凝土浆料。
所述稳泡剂为十二醇。
测试例1
传热系数测试:使用标准GB/T 13475-2008《绝热稳态传热性质的测定标定和防护热箱法》的方法对实施例1~4制备的隔音泡沫墙板进行传热系数测试,结果如表1所示。
表1传热系数测试结果
传热系数(W/m2·K) | |
实施例1 | 0.95 |
实施例2 | 1.86 |
实施例3 | 1.39 |
实施例4 | 1.76 |
良好隔热性是墙板最重要的性质之一,传热系数越小说明墙板的隔热性越好,根据《建筑隔墙用保温条板》的标准传热系数≤2W/m2·K即满足该标准的要求。
根据表1的结果可知,上述4个实施例都满足了相关标准,其中实施例1的传热系数最小,说明期隔热性最好。其中可能的原因是,墙板的发泡混凝土板层由泡沫混凝土制成,其中存在大量的气孔,封闭气体在不流动时导热性能极低,温度在泡沫混凝土传递中逐层大幅度减弱达到隔热的效果,其中发泡混凝土板层中泡沫的封闭和量化影响其隔热效果。实施例1中使用改性纳米二氧化硅和十二醇作为稳泡剂,在混凝土凝结过程中能够保证泡沫不易破裂,使得制备出的发泡混凝土板层中封闭气孔率高,且由于稳泡剂的存在,在凝结过程中,相邻的气泡也不易合并成大气泡,大量的封闭小气孔使得墙板具有良好的隔热性,而实施例2的纳米二氧化硅不易吸附在泡沫界面上,同时自身容易发生聚集,导致稳泡效果不加,实施例3使用的改性纳米二氧化硅虽然具有一定的表面活性剂,但是其与阴离子型起泡剂具有相同的电荷,在静电斥力的作用小,导致排液量增加,气泡容易破裂和合并,实施例4使用的十二醇具有一定的稳泡作用,但是其效果有限,在泡沫界面形成的膜弹性较小,也比较容易破裂。
测试例2
抗压强度测试:使用标准GB/T 23450-2009《建筑隔墙用保温条板》的方法对实施例1~4制备的隔音泡沫墙板进行抗压强度测试,结果如表2所示。
表2抗压强度测试结果
抗压强度(MPa) | |
实施例1 | 5.2 |
实施例2 | 4.1 |
实施例3 | 4.5 |
实施例4 | 3.8 |
隔音泡沫墙板的抗压强度需要达到一定的要求,根据《建筑隔墙用保温条板》的标准≥3.5MPa即达到该标准要求。
根据表2的结果可知,实施例1~4制备的墙板都满足了相关标准,其中实施例1的抗压强度最好。其原因可能在于,泡沫混凝土内部的气孔结构可以显著影响墙板的抗压强度,当发泡混凝土板层内部气孔的结构为直径小且大小一致、气孔保持圆形时,墙板的抗压强度就越高,实施例1中使用改性纳米二氧化硅和十二醇作为稳泡剂,稳定泡沫的效果最好,改性纳米二氧化硅、十二醇与发泡剂分子形成的泡沫界面具有很好的弹性,在凝结过程中不易与相邻的泡沫合并,能够保持微小的气孔结构,另外界面上的改性纳米二氧化硅可以与水泥水化产生的氢氧化钙反应生成水化产物,因此抗压强度最高;实施例2~4的泡沫稳定性不如实施例1,因此其抗压强度均低于实施例1,且实施例4使用的十二醇并不能参与水泥的水化过程,因此其抗压强度最低。
综上所述,本发明制备的隔音泡沫墙板具有良好的隔热、隔音以及抗压强度,满足相关标准,另外制备过程中无污染,且都使用的天然无机材料,具备良好的抵抗虫蛀和避免霉变和细菌滋生的性能;燃烧性能等级为A级,能够满足所有的室内安装使用。
Claims (6)
1.一种隔音泡沫墙板,其特征在于:由陶瓷板、胶粘剂、发泡混凝土板层组成,所述发泡混凝土板层包括以下质量份的原料:400~500份水泥、10~100份细沙、100~300份水、1~20份减水剂、1~20份促凝剂、1~20份增稠剂、1~10份乳胶粉、1~10份增韧剂、1~5份发泡剂、1~5份稳泡剂;
其中,所述稳泡剂为质量比为1~3:1的改性纳米二氧化硅和十二醇的混合,
所述改性纳米二氧化硅的制备方法,包括以下步骤:
N1将5~10g纳米二氧化硅分散在100~200mL甲苯中,超声分散5~10min,加入1~5mL十二烷基三甲氧基硅烷,在60~100℃下,搅拌反应10~16h,反应结束后再加入1~5mLγ-聚环氧基三甲氧基硅烷,在0~100℃下,搅拌反应8~14h,抽滤去除溶剂,收集沉淀,将沉淀用乙醇洗涤2~3次后,置于烘箱中40~100℃干燥12~24h得到疏水化纳米二氧化硅;
N2将所述步骤N1得到的疏水化纳米二氧化硅分散在40~100mL乙醇中,超声分散5~10min,加热至60~80℃,将0.1~2g/mL氨基磺酸水溶液滴加至反应体系pH=2~5,再继续反应6~12h,反应结束后抽滤收集滤饼,将滤饼用水洗涤2~3次,置于烘箱中40~100℃干燥12~24h得到改性纳米二氧化硅。
2.如权利要求1所述的隔音泡沫墙板,其特征在于:所述增稠剂为甲基纤维素、黄原胶、羧甲基纤维素钠、海藻酸钠其中一种或两种及两种以上的混合。
3.如权利要求1所述的隔音泡沫墙板,其特征在于:所述增韧剂为聚丙烯纤维、聚乙烯纤维、聚乙烯醇纤维其中一种或两种及两种以上的混合。
4.如权利要求1所述的隔音泡沫墙板,其特征在于:所述发泡剂为十二烷基硫酸钠、α-烯烃磺酸钠、脂肪酸聚氧乙烯醚硫酸钠、十二烷基聚氧乙烯醚其中一种或两种及两种以上的混合。
5.一种如权利要求1-4任一项权利要求所述的隔音泡沫墙板的制备方法,其特征在于,包括以下步骤:
S1在陶瓷板的粗糙面涂刷胶粘剂,晾干;
S2将陶瓷板涂刷胶粘剂的一边向内,固定在模具架上,陶瓷板与模具架形成一个空间;
S3将泡沫混凝土浆料浇注入步骤S2所述的空间中;
S4待泡沫混凝土凝结硬化以后,从模具架中取出养护即得到隔音泡沫墙板。
6.如权利要求5所述的隔音泡沫墙板的制备方法,其特征在于,所述泡沫混凝土浆料的制备方法为:将1~5份发泡剂、1~5份稳泡剂与30~150份水混合用搅拌机1000~2000rpm搅拌3~10min制备泡沫;将400~500份水泥、10~100份细沙、70~270份水、1~20份减水剂、1~20份促凝剂、1~20份增稠剂、1~10份乳胶粉、1~10份增韧剂混匀得到砂浆;再将砂浆与泡沫混匀得到泡沫混凝土浆料。
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