Nano-photo catalytic phenol formaldehyde foam ceiling board and manufacture method
(1) technical field
The present invention relates to a kind of ornament materials, the inorganic modified phenol formaldehyde foam of especially a kind of employing is a base material, and nano-photocatalyst material is the ceiling board and the manufacture method thereof of decorative layer.
(2) background technology
Ceiling board belongs to the ceiling decoration material, and product category is various, and function also has nothing in common with each other.The ceiling board of light thermal-insulation has the mineral wool class, also organic expanded material.The former has sound absorption qualities and heat insulation effect preferably, and surface density is about 4-5kg/m
2, but humidity resistance is poor, and water-swellable distortion even mouldy does not have due decoration function; The latter has the polyvinyl chloride foam decoration acoustic absorption, the expanded polystyrene (EPS) ceiling, and polyurethane foam board, these quality of materials are light, good heat-insulation effect, and moisture resistance is wet, but fire protecting performance is all very poor, can only be used in fire-protection rating and require place lower and that self-saving ability is stronger.
The CN02108279 patent application discloses a kind of aluminium foil-phenolic foam sandwich composite plate and production technology thereof, and its used resistance incendiary agent is less, and flame retardant effect is not obvious, and the aluminium foil-phenolic foam sandwich composite plate of being produced can only reach difficult combustion B1 level.US4,681, No. 902 patents are made fire retardant with halogenated diphenyl ether (70%W/W) and organic phosphorus compound (30%W/W) mixing, and addition is the per 100 parts of resins of 0.5-20 part, and this organic fire-retardant can be emitted poisonous and hazardous hydrogen halide when high-temp combustion.US4,419, No. 460 patents improve the rate of closed hole of phenol formaldehyde foam with hydrated alumina, and its addition is 2%-15%, and more preferably 5%-10% facts have proved, and the anti-flammability of gained foam is not ideal enough, does not reach not fire the A grade standard.
(3) summary of the invention
The present invention aims to provide a kind of light thermal-insulation, the amount of deflection of making moist is low, sound absorbing capabilities good, fire-protection rating is high, the self-cleaning phenol formaldehyde foam ceiling board of photocatalysis and manufacture method thereof.
The said nano-photo catalytic phenol formaldehyde foam of the present invention ceiling board is to be base material with inorganic modified phenol formaldehyde foam, the two-sided compound fiber surface felt of going up of base material, and surperficial felt surface is outer decorative paint layer, outer decorative paint laminar surface is the nano-photo catalytic dope layer.
The component of said inorganic modified phenol formaldehyde foam and content by weight are:
Expandable phenolic resin is 100, and the aluminium hydroxide of powder-type is 100~300, and the foam glass microballon is 10~50,5~10 parts of blowing promotors, 10~30 parts in curing agent, foam density 60~200Kg/m
3
Said nano-photo catalytic coating is water-soluble emulsion, and its component and content by weight are: 100 parts in water, 1~3 part of dispersant, 0.5~3 part of photocatalyst agent nano particle.
The surface of the two-sided fiber surface felt on compound of said ceiling board base material can be required shape.
Said fiber surface felt can be selected fiberglass surfacing mat for use, ceramic fibre surface felt, and fibrous paper or alumina silicate fibre surface felt etc., material weight is 20~200g/m
2
Said outer decorative paint layer can be selected inorganic silicate coating for use, emulsion paint coating or water cement lacquer etc.
The manufacture method of the said nano-photo catalytic phenol formaldehyde foam of the present invention ceiling board is:
1, the preparation of inorganic modified phenol formaldehyde foam base material:
Expandable phenolic resin and blowing agent are mixed, add aluminium hydroxide, foam glass microballon, stir, add curing agent at last, stir 10s~120s, pour in the foaming mould, and be heated to 65~75 ℃, behind the foamed solidification, demoulding cool to room temperature cuts or is processed into the foam board of required size.
2, be coated with interior coating:
Coating in foam surface applied covers fully, fills and leads up and as the adhesive linkage of composite surface felt, coating is selected inorganic silicate coating or emulsion paint coating etc. for use.Coating processes can be with spraying roller coat or blade coating.
3, oven dry:
Adopt hot-air seasoning, temperature is 40~100 ℃, makes the moisture content volatilization and makes the coating primary solidification.
4, embossing:
Adopt stationary press compacting or the roll-in of hard flower strand roller, play surface decoration effect.
5, be coated with outer layer coating:
Coating adopts spraying, and roller coating or wire mark are covered with paint, lacquer, colour wash, etc., and coating layer thickness is 0.1~0.5mm.
6, be coated with photocatalytic nanometer coating:
Adopt spraying to cover with paint, lacquer, colour wash, etc., then in 40~100 ℃ of oven dry, dry-coated material thickness is 1~10 μ m.Coating should be dried by the fire to surface drying before covering with paint, lacquer, colour wash, etc.
Said inorganic modified phenol formaldehyde foam can adopt the mould foaming, or with box foaming excision forming, density is processed its stock board as requested at 60~200kg/m3.Overall dimensions are generally: 500mm * 500mm * (6~20) mm or 600mm * 600mm * (8~20) mm.
Outer layer coating is selected high-quality high-grade coating for use, as latex paint, and water cement lacquer etc., and can be mixed with various light colors according to customer requirements, as lemon yellow, light blue or light green color etc.There is the sheet material of embossing can only adopt spraying to cover with paint, lacquer, colour wash, etc. for the surface.
The present invention is a base material with inorganic modified phenol formaldehyde foam, and two-sided compound upward fiber surface felt also is pressed into the certain surface shape, coats outer decorative paint and photocatalytic nanometer coating then, promptly becomes the phenolic aldehyde ceiling board of nano-photo catalytic after the oven dry.Product has following function:
1, lightweight, insulation: surface density≤1.5kg/m
2, heat insulating coefficient≤0.04w/m.k.
2, the amount of deflection of making moist is low: foam and dope layer water absorption rate are low, and are thermosets, and vertical creep is little, under wet condition long-term use indeformable.
3, sound absorbing capabilities is good: foam is half-open permeability phenolic foam, and percent opening is 30%~40%, and acoustically effective is preferably arranged.
4, fire-protection rating height: inorganic modified phenol formaldehyde foam do not fire, smokeless, nontoxic, two-sidedly can reach the A level composite material standard of not firing after glass fibre and inorganic coating are compound, is fit to the building that various fire-protection ratings require.
5, photocatalysis, automatically cleaning: material outermost layer (decorative cover) scribbles nano-photo catalytic coating, but under the irradiation of visible light and ultraviolet organic molecule materials such as the formaldehyde in the autocatalysis decomposition chamber, benzene and oil smoke, air hygiene in the holding chamber, safety.
(4) specific embodiment
Following examples will the present invention is further illustrated.
Embodiment 1
Nano-photo catalytic phenol formaldehyde foam ceiling board is a base material with inorganic modified phenol formaldehyde foam, the two-sided compound fiber surface felt of going up of base material, and surperficial felt surface is outer decorative paint layer, outer decorative paint laminar surface is the nano-catalytic dope layer.
The component of inorganic modified phenol formaldehyde foam and content by weight are
Phenolic resins is 100, and the aluminium hydroxide of powder-type is 200, and the foam glass microballon is 20, blowing promotor 6, and curing agent 20, foam density is 150Kg/m
3
Said nano-photo catalytic coating is water-soluble nano coating, and its component and content by weight are:
100 parts in water, 1.5 parts of dispersants, 0.5 part on photo-catalytic nano particle.
The two-sided compound upper glass fiber surface felt of ceiling board base material, the surface can be required shape, and material weight is 30g/m
2
Outer decorative paint layer is selected inorganic silicate coating for use.
In the middle of preparation process, carry out the preparation of inorganic modified phenol formaldehyde foam base material earlier: expandable phenolic resin and blowing agent high-speed stirred are mixed, add aluminium hydroxide, foam glass microballon, stir, add curing agent at last, stir 10s~120s fast, pour in the foaming mould, and be heated to 65~75 ℃, behind the foamed solidification, demoulding cool to room temperature cuts or is processed into the foam board of required size.
Inorganic modified phenol formaldehyde foam can adopt box foaming excision forming, and density is processed its stock board as requested at 60~200kg/m3.Overall dimensions are: 600mm * 600mm * (8~20) mm.
In being coated with during coating, coating in foam surface applied covers fully, fills and leads up and as the adhesive linkage of composite surface felt, coating is selected inorganic silicate coating or emulsion paint coating etc. for use.Coating processes can be with spraying roller coat or blade coating.
Can adopt hot-air seasoning, temperature is 40~100 ℃, makes the moisture content volatilization and makes the coating primary solidification.And adopt stationary press compacting or hard flower strand roller roll-in embossing, play surface decoration effect.
Outer layer coating is selected high-quality high-grade coating for use, as latex paint, and water cement lacquer etc., and can be mixed with various light colors according to customer requirements, and light blue as lemon yellow, light green color etc.Coating takes spraying, roller coating or wire mark to cover with paint, lacquer, colour wash, etc.There is the sheet material of embossing can only adopt spraying to cover with paint, lacquer, colour wash, etc. for the surface.Coating layer thickness is at 0.1~0.5mm.
When being coated with photocatalytic nanometer coating, adopt spraying to cover with paint, lacquer, colour wash, etc., then in 40~100 ℃ of oven dry, dry-coated material thickness is between 1~10 μ m.Coating should be dried by the fire to surface drying before covering with paint, lacquer, colour wash, etc.
Embodiment 2
Inorganic modified phenol formaldehyde foam can adopt the mould foaming, and density is processed its stock board as requested at 60~200kg/m3.Overall dimensions are 500mm * 500mm * (6~20) mm.
Select for use inorganic silicate coating with coating in the foam surface spraying, cover fully, fill and lead up and as the adhesive linkage of composite surface felt.Adopt hot-air seasoning, temperature is 40~100 ℃, makes the moisture content volatilization and makes the coating primary solidification.
Certain surface decoration effect is played in the compacting of employing stationary press.
Outer layer coating is selected the high-quality high-grade latex paint for use, and can be mixed with various light colors according to customer requirements, and is light blue as lemon yellow, light green color etc.Coating layer thickness is at 0.1~0.5mm.
Behind the nano-catalytic paint finishing, in 40~50 ℃ of oven dry, coating is water white transparency, and dry-coated material thickness is between 1~10 μ m.For preventing that coating from spreading to internal layer,, coating should be dried by the fire to surface drying before covering with paint, lacquer, colour wash, etc.
Embodiment 3
Nano-photo catalytic phenol formaldehyde foam ceiling board is a base material with inorganic modified phenol formaldehyde foam, the two-sided compound fiber surface felt of going up of base material, and surperficial felt surface is outer decorative paint layer, outer decorative paint laminar surface is the nano-catalytic dope layer.
The component of inorganic modified phenol formaldehyde foam and content by weight are
Phenolic resins is 100, and the aluminium hydroxide of powder-type is 150, and the foam glass microballon is 30, blowing promotor 8, and curing agent 18, foam density is 100Kg/m
3
Said nano-photo catalytic coating is water-soluble nano coating, and its component and content by weight are:
100 parts in water, 2 parts of dispersants, 1 part on photo-catalytic nano particle.
The two-sided compound ceramic fibre surface felt of going up of ceiling board base material, the surface can be pressed into required shape.Material weight is 20~100g/m
2
Outer decorative paint layer is selected emulsion paint coating for use.
Inorganic modified phenol formaldehyde foam can adopt box foaming excision forming, and density is processed its stock board as requested at 60~200kg/m3.Overall dimensions are 600mm * 600mm * (8~20) mm.
Select for use emulsion paint with coating in the foam surface spraying, cover fully, fill and lead up and as the adhesive linkage of composite surface felt.Adopt hot-air seasoning, temperature is 90~100 ℃, makes the moisture content volatilization and makes the coating primary solidification.
Adopt the roll-in of hard flower strand roller, play certain surface decoration effect.
Outer layer coating is selected the high-quality water cement lacquer for use, and can be mixed with various light colors according to customer requirements, and is light blue as lemon yellow, light green color etc.Coating layer thickness is at 0.1~0.5mm.
Behind the spraying nano-catalytic coating, in 60~80 ℃ of oven dry, coating is water white transparency, and dry-coated material thickness is between 1~10 μ m.For preventing that coating from spreading to internal layer,, coating should be dried by the fire to surface drying before covering with paint, lacquer, colour wash, etc.