TWI719872B - Production method of fire-resistant and heat-resistant phenolic foam material - Google Patents

Abstract

The present invention relates to a production method of fire-resistant and heat resistant phenolic foam material, comprises the steps below: mixing a foaming resin, a foaming agent, a curing agent and a surfactant to form a mixed flurry. The mixed flurry is transformed to a phenolic foam material through foaming reaction and curing reaction; then, crushing the phenolic foam material to form a plurality of phenolic grains. Finally, mix one of a silicate resin and a water-based acrylic resin with a plurality of the phenolic grains and water to form the phenolic foam coating and put the phenolic foam material on the coated object to form a phenolic foam plate. Therefore, the phenolic foam plate can be made without using any mold during the production process. The phenolic foam coating presented in fluent state has the effects of thermal insulation and forming convenience, so that the phenolic foam coating can be coated in objects of various shapes according to the requirement of production.

Description

Manufacturing method of phenolic foam fireproof and heat insulation material

The present invention relates to a manufacturing method capable of producing phenolic foam boards, in particular to a manufacturing method of phenolic foam fireproof and heat-insulating materials that do not need to use molds in the manufacturing process.

Phenolic resin undergoes a foaming reaction to obtain a foam called phenolic foam, and phenolic foam has the characteristics of flame retardancy, fire resistance and heat preservation, making phenolic foam widely used in electrical appliances, construction and petrochemical industries.

Among them, the current common production process of phenolic foam is to first mix and stir foamable resin, foaming agent, curing agent and surfactant to form a mixed slurry, and then pour the mixed slurry into the foaming mold. , And wait for 40 to 60 minutes for the mixed slurry to undergo foaming and curing reactions to form a solid phenolic foam board. However, when the phenolic foam board is to be applied to the coated object (or other products), the phenolic foam board The foam board needs to be cut according to the size of the coated object, so that the cut phenolic foam board can be attached to the coated object through adhesives or fixings. Therefore, the phenolic foam board is attached to the coated object It takes a long working time, and the process of attaching phenolic foam board to the coated object is complicated, which makes it impossible to increase the output and relatively unable to meet the needs of various industries.

The main purpose of the present invention is to make the phenolic foam board without using any molds, and the phenolic foam coating not only has the effect of heat preservation, but also because the phenolic foam coating is fluid and has the effect of convenient construction, making the phenolic foam coating It can be used for various shapes of coated objects according to the needs of use, so that the process of applying phenolic foam coating to the coated objects can be simplified to increase the output of phenolic foam board.

In order to achieve the foregoing objectives, the present invention relates to a method for manufacturing a phenolic foam fireproof and thermal insulation material, which comprises the following steps: a first mixing step: a foaming resin, a foaming agent, a curing agent and a surfactant are mixed Mixing to form a mixed slurry; a foaming and curing step: the above-mentioned mixed slurry undergoes a foaming reaction and a curing reaction to transform into a phenolic foam material; a pulverizing step: the phenolic foam material is pulverized to form a plurality of phenolic particles ; A second mixing step: mixing one of a silicate resin and an aqueous acrylic resin with the plurality of phenolic particles and an aqueous solution to form a phenolic foam coating; and a forming step: the above The aldehyde foam paint is applied to an object to be coated, and the phenolic foam paint is waited to dry so that the dried aldehyde foam paint and the object to be coated together form a phenolic foam board.

In a preferred embodiment, the above-mentioned phenolic foam fireproof and thermal insulation material manufacturing method further includes the following steps: a pre-mixing step: mixing a formaldehyde, a phenol and a catalyst to form a pre-mixed slurry; and The foaming resin generation step: heating, cooling, adjusting the pH value, and dehydrating under reduced pressure to the premixed slurry to form the foaming resin.

Wherein, in the pre-mixing step, the formaldehyde and phenol are first mixed, heated to a first temperature, and then mixed with the catalyst. In addition, in the foamable resin production step, the pre-mixing The slurry is first heated to a second temperature higher than the first temperature, and the temperature of the pre-mixed slurry is maintained at the second temperature for a first preset time, and then, the pre-mixed slurry The material is heated to a third temperature higher than the second temperature, and the temperature of the pre-mixed slurry is kept at the third temperature for a second preset time that is longer than the first preset time. temperature.

Furthermore, in the foamable resin generating step, the temperature of the premixed slurry is lowered from the third temperature to a temperature lower than a fourth temperature between the second temperature and the third temperature, wherein, when the When the temperature of the pre-mixed slurry drops below the fourth temperature, the pre-mixed slurry is mixed with a dilute acetic acid to adjust the pH of the pre-mixed slurry to 6.5-7.4.

In a preferred embodiment, the above-mentioned mixed slurry undergoes foaming reaction and solidification reaction in an operating environment with a temperature of 50-80°C. In the above-mentioned pulverizing step, a pulverizer is provided, and the pulverizer is a pulverizer. In the second mixing step, one of the silicate resin and the water-based acrylic resin, the plurality of phenolic particles and the aqueous solution are pulverized at a rotation speed lower than the pulverization. The mixing speed of the rotation speed is mixed.

Finally, in the second mixing step, one of the silicate resin and the aqueous acrylic resin is mixed with the aqueous solution to form a liquid material, and then the liquid material is combined with the plurality of phenolic resins. The particles are mixed to form the above-mentioned phenolic foam coating, wherein the weight ratio between the above-mentioned liquid material and the phenolic particles is 1:1-20, and the above-mentioned liquid material contains 1-30% by weight of the above-mentioned silicate resin and 70~99% by weight of the above-mentioned aqueous solution.

The feature of the present invention is that no mold is needed in the process of making phenolic foam board, and after the phenolic foam material is crushed, one of the phenolic foam material, silicate resin and water-based acrylic resin will be in a crushed state. Mix and stir with the aqueous solution to form a phenolic foam coating. The phenolic foam coating not only has the effect of heat preservation, but also because the phenolic foam coating is fluid and has the effect of convenient construction, so that the phenolic foam coating can be used in accordance with the needs of use. Various shapes of coated objects, and when the phenolic foam coating is applied to the insulation object, wait for the phenolic foam coating to dry naturally to form a phenolic foam board, thereby simplifying the process of applying the phenolic foam coating to the coated object to improve Production of phenolic foam board.

In order to facilitate a deeper, clear and detailed knowledge and understanding of the structure, use and characteristics of the present invention, a preferred embodiment is given, which is described in detail in conjunction with the drawings as follows:

1 and 2, the manufacturing method 1 of the phenolic foam fireproof insulation material of the present invention first performs a pre-mixing step 10. First, a three-neck equipped with a condenser 201, an electric stirrer 202 and a thermometer 203 is provided. The flask 20, then, pour a phenol 30 and a formaldehyde 31 into the inside of the three-necked flask 20. Next, the electric stirrer 202 stirs, mixes and heats the phenol 30 and the formaldehyde 31, and when the thermometer 203 senses the phenol When the temperature between 30 and formaldehyde 31 during the mixing process is as high as the first temperature set to 40°C, a catalyst 32 set as sodium hydroxide is poured into the inside of the three-neck flask 20, and the electric stirrer 202 The formaldehyde 31, the phenol 30, and the catalyst 32 are mixed to form a pre-mixed slurry 33, whereby the pre-mixing step 10 is completed.

Please refer to Figures 1 and 3, when the pre-mixing step 10 is completed, a foamable resin generation step 11 is started, and the pre-mixed slurry 33 is sequentially heated, cooled, pH adjusted, and decompressed Dehydrate to form a foamable resin 34.

In this embodiment, the electric stirrer 202 of the three-necked flask 20 stirs and heats the pre-mixed slurry 33, so that the pre-mixed slurry 33 is heated from a first temperature to a second temperature higher than the first temperature. Temperature (60°C). When the thermometer 203 of the three-necked flask 20 senses that the temperature of the pre-mixed slurry 33 is the above-mentioned second temperature set to 60°C, the electric stirrer 202 will make the pre-mixed slurry 33 The temperature is continuously maintained at the above second temperature for a first preset time set to 60 minutes. Next, the electric stirrer 202 stirs and reheats the pre-mixed slurry 33 again to make the pre-mixed slurry 33 33 is raised again from the above second temperature to a third temperature (90°C) higher than the second temperature, and when the thermometer 203 senses that the temperature of the pre-mixed slurry 33 is set to the above third temperature of 90°C At this time, the electric agitator 202 keeps the temperature of the pre-mixed slurry 33 at the third temperature for a second preset time (120 minutes) that is longer than the first preset time.

Next, the condenser 201 of the three-neck flask 20 cools the pre-mixed slurry 33, so that the temperature of the pre-mixed slurry 33 is lowered from the third temperature to a fourth temperature or lower. In this embodiment, the above The fourth temperature is between the aforementioned second temperature and the aforementioned third temperature, and is set to 70°C. When the thermometer 203 of the three-neck flask 20 senses that the temperature of the premixed slurry 33 is lower than the aforementioned fourth temperature At temperature, pour a dilute acetic acid 35 into the three-necked flask 20, mix the pre-mixed slurry 33 with a dilute acetic acid 35 to adjust the pH of the pre-mixed slurry 33 to 6.5~7.4, and finally, The premixed slurry 33 having a pH of 6.5 to 7.4 is dehydrated under pressure and reduced pressure to form a foamable resin 34.

1 and 4, the foaming resin 34, a foaming agent 36, a curing agent 37, and a surfactant 38 are poured into the inside of a first agitator 21, so that the first agitator 21. The foaming resin 34, the foaming agent 36, the curing agent 37 and the surfactant 38 are mixed and stirred to form a mixed slurry 39 in a fluid state, thereby completing a first mixing step 12. After the first mixing step 12, a foaming and curing step 13 is started, and the mixed slurry 39 undergoes a foaming reaction and a curing reaction in an operating environment with a temperature of 50-80° C. to transform into a phenolic foam material 40.

Please refer to FIG. 1 and FIG. 5, and then a pulverization step 14 is performed. A pulverizer 22 is provided. The pulverizer 22 pulverizes the phenolic foam material 40 at a pulverizing speed to form a plurality of phenolic particles 41 with a particle size of 50um~2mm. In this embodiment, the grinding speed is between 1000-25000 rpm.

Please refer to Figures 1 and 6, and finally a second mixing step 15 is started. First, the silicate resin 42 and the aqueous solution 43 are poured into the inside of a second stirrer 23, so that the second stirrer 23 first The acid salt resin 42 and the aqueous solution 43 are mixed and stirred to form a liquid material 44. In this embodiment, the liquid material 44 contains 1-30% by weight of silicate resin 42 and 70-99% by weight of aqueous solution 43. However, the liquid material 44 is composed of the silicate resin 42 and the aqueous solution 43 only for convenience of illustration, that is, the second agitator 23 can mix and stir the aqueous acrylic resin and the aqueous solution 43 to form the liquid material 44.

After that, a plurality of phenolic particles 41 are poured into the inside of the second agitator 23, and the second agitator 23 mixes the liquid material 44 with the plurality of phenolic particles 41 at a mixing speed that is less than the pulverizing speed to form a The phenolic foam paint 45 in a fluid state, in this embodiment, the mixing speed is between 5 and 850 rpm, and the weight ratio between the liquid material 44 and the phenolic particles 41 is 1:1-20.

Please refer to Table 1. Table 1 shows the disadvantages of conventional thermal insulation materials compared to phenolic foam coating 45.

Table I: Known insulation materials Disadvantage Rock wool, glass wool, expanded perlite 1. It has high water absorption and is not suitable for humid and low temperature areas. 2. Poor thermal insulation effect (the thermal conductivity of glass wool fort is 0.043~0.053W/mk, the thermal conductivity of expanded perlite is 0.043~0.053W/mk). 3. Harmful to the environment and people. 4. Molding is required. 5. Use an adhesive to bond with the wall, or fix it with a nail lock. Polychloroester, polystyrene 1. Poor fire safety and easy to age. 2. When burning and heated, it will decompose highly toxic gases such as hydrogen cyanide and carbon monoxide, which can easily cause death and increase the difficulty of extinguishing fire. 3. Poor thermal insulation effect (the thermal conductivity of glass wool fort is 0.033W/mk). 4. Molding is required. 5. Use an adhesive to bond with the wall, or fix it with a nail lock. Vermiculite Board 1. Relatively fragile and easily broken. 2. Molding is required. 3. Use adhesive to bond with the wall, or fix it with a nail lock. Phenolic foam 1. High brittleness and high degree of powdering. Phenolic foam board 1. Molding is required. 2. Use adhesive to bond with the wall, or fix it with a nail lock.

Please refer to Table 2. Table 2 shows the advantages of phenolic foam coating 45.

Table II: advantage The thermal conductivity is similar to that of chloramine foam (00.18~0.024W/mk), but its heat resistance and flame retardancy are far superior to polyurethane and other foam resins. Using fluorine-free foaming technology, fiber-free, in line with national and international environmental protection requirements. It is not limited by the appearance of the object, it can be used as a coating, or as a filler, plate, and the thickness and shape can be changed according to the needs. It does not burn or melt in the fire. Under the direct action of the flame, it has carbon formation, no dripping, no curling, and no melting. After the flame burns, a layer of "stone foam" is formed on the surface, which effectively protects the foam in the layer. structure. Anti-corrosion, anti-aging, long-term exposure to the sun, no obvious aging phenomenon, so it has good aging resistance. The construction is simple, fast, and can improve efficiency. The density is small and the weight is light. The density of the phenolic insulation board is ^{below 100kg/m 3} and can reach about 50kg/m ³ . It can be cured directly at room temperature. After curing and forming, the material is hard and not easy to be brittle. Micro closed cell structure, cell diameter 50~80um, good thermal insulation and sound insulation effect

Please refer to FIG. 7 and finally perform a forming step 16. Because the phenolic foam coating 45 is fluid and has the effect of convenient construction at the same time, the phenolic foam coating 45 can be applied to various shapes of coated objects according to the needs of use. 50 (such as metal door panels or thermal insulation objects), when the phenolic foam coating 45 is applied to the object 50 to be coated, wait for the phenolic foam coating 45 to dry naturally, so that the dried phenolic foam coating 45 and the object 50 to be coated together form a phenolic foam The board 60 can simplify the process of applying the phenolic foam coating 45 to the object 50 to be coated to increase the output of the phenolic foam board 60.

The above-mentioned embodiments are only used to facilitate the description of the present invention and are not intended to limit them. Without departing from the scope of the present invention, those skilled in the industry who are familiar with the scope of the invention’s patent application and the description of the invention make various simple modifications and modifications should still contain Included in the scope of the following patent applications.

1: Manufacturing method of phenolic foam fireproof insulation material 10: Pre-mixing steps 11: Steps for producing foamable resin 12: The first mixing step 13: Foam curing step 14: Crushing step 15: Second mixing step 16: forming steps 20: Three-necked flask 201: Condenser 202: electric mixer 203: Thermometer 21: The first agitator 22: Crusher 23: second agitator 30: Phenol 31: Formaldehyde 32: Catalyst 33: Pre-mixed slurry 34: Foaming resin 35: dilute acetic acid 36: foaming agent 37: curing agent 38: Surfactant 39: mixed slurry 40: Phenolic foam material 41: Phenolic particles 42: Silicate resin 43: Aqueous solution 44: Liquid material 45: Phenolic foam coating 50: painted object 60: Phenolic foam board

Figure 1 is a flow chart of the manufacturing method of the phenolic foam fireproof and thermal insulation material of the present invention; Fig. 2 is a schematic diagram of the pre-mixing step in Fig. 1; FIG. 3 is a schematic diagram of the steps of generating foamable resin in FIG. 1; FIG. 4 is a schematic diagram of the first mixing step and the foaming and curing step in FIG. 1; Figure 5 is a schematic diagram of the crushing step in Figure 1; Fig. 6 is a schematic diagram of the second mixing step in Fig. 1; and Fig. 7 is a schematic diagram of the forming step in Fig. 1.

1: Manufacturing method of phenolic foam fireproof insulation material

10: Pre-mixing steps

11: Steps for producing foamable resin

12: The first mixing step

13: Foam curing step

14: Crushing step

15: Second mixing step

16: forming steps

Claims (10)

A method for manufacturing a phenolic foam fireproof and thermal insulation material, comprising: a first mixing step: mixing a foaming resin, a foaming agent, a curing agent and a surfactant to form a mixed slurry; a foaming Curing step: the above-mentioned mixed slurry undergoes a foaming reaction and a curing reaction to transform into a phenolic foam material; a pulverization step: the phenolic foam material is pulverized to form a plurality of phenolic particles; a second mixing step: a silicic acid Salt resin, the plurality of phenolic particles and an aqueous solution are mixed to form a phenolic foam coating; and a forming step: apply the aldehyde foam coating to an object to be coated, and wait for the phenolic foam coating to dry naturally at room temperature So that the dried aldehyde foam paint and the object to be coated together form a phenolic foam board. The method for manufacturing a phenolic foam fireproof and thermal insulation material according to claim 1, wherein the above-mentioned mixed slurry undergoes a foaming reaction and a curing reaction in an operating environment with a temperature of 50-80°C. The method for manufacturing a phenolic foam fireproof and thermal insulation material according to claim 1, wherein, in the pulverizing step, a pulverizer is provided, and the pulverizer pulverizes the phenolic foam material at a pulverizing speed, and in the second mixing step The above-mentioned silicate resin, the above-mentioned plurality of phenolic particles and the above-mentioned aqueous solution are mixed at a mixing speed that is less than the above-mentioned grinding speed. The method for manufacturing a phenolic foam fireproof and thermal insulation material according to claim 1, wherein in the second mixing step, the silicate resin and the aqueous solution are first mixed to form a liquid material, and then the liquid material is mixed with The above-mentioned plural phenolic particles are mixed to form the above-mentioned phenolic foam coating. The method for manufacturing the phenolic foam fireproof and thermal insulation material according to claim 4, wherein the weight ratio between the liquid material and the phenolic particles is 1:1-20, and the liquid material contains 1-30% by weight of the above Silicate resin and 70~99% by weight of the above-mentioned aqueous solution. The method for manufacturing the phenolic foam fireproof and thermal insulation material according to claim 1, wherein the manufacturing method of the phenolic foam fireproof and thermal insulation material further comprises: a pre-mixing step: mixing a formaldehyde, a phenol and a catalyst to form a pre-mixing step Setting the mixed slurry; and a step of generating foamable resin: heating, cooling, adjusting the pH value, and decompressing and dehydrating the above-mentioned pre-mixed slurry to form the above-mentioned foaming resin. The method for manufacturing a phenolic foam fireproof and thermal insulation material according to claim 6, wherein in the pre-mixing step, the formaldehyde and phenol are mixed first, heated to a first temperature, and then mixed with the catalyst. The method for manufacturing a phenolic foam fireproof and thermal insulation material according to claim 7, wherein, in the foamable resin generation step, the pre-mixed slurry is first heated to a second temperature higher than the first temperature, and The temperature of the pre-mixed slurry is maintained at the second temperature for a first preset time. After that, the pre-mixed slurry is heated to a third temperature higher than the second temperature, and allowed to The temperature of the pre-mixed slurry is maintained at the third temperature for a second preset time that is longer than the first preset time. The method for manufacturing a phenolic foam fireproof and thermal insulation material according to claim 8, wherein, in the foamable resin generating step, the temperature of the premixed slurry is lowered from the third temperature to a temperature between the second temperature Below the fourth temperature with the third temperature. The method for manufacturing a phenolic foam fireproof and thermal insulation material according to claim 9, wherein when the temperature of the pre-mixed slurry drops below the fourth temperature, the pre-mixed slurry is mixed with a dilute acetic acid to mix The pH value of the aforementioned pre-mixed slurry is adjusted to 6.5~7.4.

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