CN106433016B - 一种改性增强型保温隔声酚醛泡沫板的制备方法 - Google Patents
一种改性增强型保温隔声酚醛泡沫板的制备方法 Download PDFInfo
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Abstract
本发明公开了一种改性增强型保温隔声酚醛泡沫板及其制备方法，其组分及质量份数为：改性酚醛树脂100份，改性粘土10‑30份，增韧剂1‑10份，稳定剂1‑5份，发泡剂10‑20份，表面活性剂2‑10份，阻燃剂5‑10，固化剂5‑20份。一种改性增强型保温隔声酚醛泡沫板制备方法包括如下步骤：1）制备改性酚醛树脂；2）将改性酚醛树脂、改性粘土、增韧剂用计量泵输送到浇注发泡机的混合头内，再依次加入稳定剂、发泡剂、表面活性剂、阻燃剂,搅拌均匀后再加入固化剂进行搅拌；3）膜腔中发泡、固化。本发明通过对复合生产工艺的改进，大大的提高了酚醛泡沫的韧性、阻燃性、隔声性能。
Description
技术领域
本发明涉及一种改性增强型保温隔声酚醛泡沫板的制备方法，属于建筑保温隔声材料制备领域。
背景技术
酚醛泡沫和传统的聚乙烯泡沫和聚氨酯泡沫板相比，酚醛泡沫除了导热系数低以外，还具有这两种泡沫不具备的难燃性，且其燃烧等级达到了B1级，具有优异的阻燃性能性能，是一种理想的阻燃材料，现广泛应用于保温阻火场合。同时，酚醛泡沫板作为轻质泡沫板，由于其特有的泡孔结构，使得这种材料在保温性能和隔声性能方面都适用。因此，将酚醛泡沫板的保温隔声阻燃性能应用于建筑墙体、楼板中进行推广，有很好的市场前景。
市面上也已有性能有所提高的隔音泡沫板，但是一般泡沫隔音板仅仅是通过铝箔表面的花纹与酚醛泡沫板结合形成凹槽进行隔音，或者是通过已制备好的酚醛泡沫板进行二次加工形成波浪线的凹槽进行隔音，这种隔音效果较单纯的泡孔隔声相比有所改进，但是还有很大的提升空间。而且酚醛泡沫板其脆性以及成本问题也限制了其作为保温材料的推广应用。
为了在保持酚醛泡沫优异阻燃性能的基础上，提高泡沫的韧性，抗冲击性，隔声效果，制备价格低廉，综合性能优异的酚醛泡沫，本文选用不同的改性剂以及生产工艺对酚醛泡沫进行了改性研究。
发明内容
本发明为了克服现有市场中酚醛泡沫板的韧性差、内聚能低、掉渣率高、力学强度低、隔声效果一般的缺陷提供一种在原有生产工艺上进行改进的工艺简单、操作容易，能够提高隔声效果、阻燃性、抗冲击性、防掉渣率的一种改性增强型保温隔声酚醛泡沫板及其制备方法。
本发明是通过以下技术方案实现的：
一种改性增强型保温隔声酚醛泡沫板的组分及质量份数为：改性酚醛树脂100份，改性粘土10-30份，增韧剂1-10份，稳定剂1-5份，发泡剂10-20份，表面活性剂2-10份，阻燃剂5-10，固化剂5-20份。
一种改性增强型保温隔声酚醛泡沫板制备方法包括如下步骤：
1）制备改性酚醛树脂：准备苯酚、多聚甲醛、NaOH、氨水，苯酚、多聚甲醛的比例为1: (1.5-2.0)，NaOH的用量为苯酚的3%-6%，氨水的用量为苯酚的1%-3%； 先将NaOH和氨水混合，向苯酚中加入NaOH、氨水混合溶液总量的80%进行混合，在40-60℃下保温20-40min，加入多聚甲醛总量的80%，在60-70℃保温20-40min，然后加入剩余的NaOH和氨水混合液，保温10-20min，再加入剩余的多聚甲醛，调节pH值为8-9，加入改性剂，升温到70-80℃保温10-20min，在85-95℃回流30-60min，减压脱水出料；步骤1）中的改性剂为环氧树脂E51；
2）将步骤1）制成的改性酚醛树脂、改性粘土、增韧剂用计量泵输送到浇注发泡机的混合头内，再依次加入稳定剂、发泡剂、表面活性剂、 阻燃剂,搅拌均匀后再加入固化剂进行搅拌；步骤2）中使用的增韧剂为乙二醇、邻苯二甲酸二辛酯、磷酸三甲苯酯中的任意一种；
3）将搅拌后的物料从浇注发泡机上部迅速浇注在内部覆有保护层的模具膜腔中，通过机械手将模具盖上盖板进行模压，所述盖板的底部设有规则有序排列的圆柱型凸台，将模具连盖板一起送入层压输送机，物料在模具内的底层面材和上层盖板之间发泡固化成形，并随着层压输送机向前输送，输送过程中模具内的温度控制在65-70℃，输送时长15-20分钟，所述模具的深度为20mm-30mm,模具上的凸台高3-4mm，所述模具内的底层面材为高强度无纺布；
4）将固化后的酚醛泡沫板冷却脱模。
本发明的进一步改进在于，所述发泡剂为无氟发泡剂二亚硝基五次甲基四胺。
本发明的进一步改进在于，所述表面活性剂为脂肪醇聚氧乙烯、聚氧丙烯醚、壬基酚与环氧乙烷的加成物，或聚硅氧烷、聚氧乙烯、聚氧丙烯的嵌段共聚物。
本发明的进一步改进在于，固化剂为无机酸和有机酸的混合物加入制成的浓度为40-60%的水溶液，所述无机酸可选用硫酸、盐酸、磷酸中的一种，所述有机酸为草酸、已二酸、苯硝酸、酚硝酸、甲苯磺酸,苯磺酸、石油磺酸中的一种。
本发明的进一步改进在于，所述稳定剂为吐温-80和甲基硅油的混合物。
本发明的进一步改进在于，所述阻燃剂为无机阻燃剂硼酸锌。
本发明具有以下有益效果：
对传统的酚醛泡沫保温板生产线进行工装改进，使酚醛树脂在模具的膜腔内进行发泡，使生产的酚醛泡沫板一面复合保护膜，另一面经模具上的盖板膜压后形成圆形空腔，复合的保护膜降低了酚醛泡沫板的掉渣率，提高了酚醛泡沫板的拉伸性能，而醛泡沫板表面的圆形空腔，与以往的压纹和波浪式凹槽减震式隔音相比，隔声性能得到了大幅度的提高；泡沫板加工厚度为30 mm和20 mm，空腔深度仅为3~4 mm，不会对酚醛泡沫板的承重抗压能力产生任何的影响。
改性酚醛树脂在回流前加入改性剂，有利于环氧的溶解，与反应体系充分接触，反应完全，使溶液均匀，环氧树脂与酚醛树脂反应，接枝到酚醛树脂分子中，使产品枝化，分子量增大，拉剪强度增加，提高了任性；表面活性剂选用的是脂肪醇聚氧乙烯、聚氧丙烯醚、壬基酚与环氧乙烷的加成物，或聚硅氧烷、聚氧乙烯、聚氧丙烯的嵌段共聚物中的一种，不仅有良好的泡沫稳定性能，而且有极强的乳化作用。本发明的通过材料的复合以及生产工艺的改进，酚醛泡沫板泡孔细腻，密度均匀，强度及隔热性能可靠，大大的提高了酚醛泡沫的韧性、阻燃性、隔声性能。
具体实施方式
下面结合实例对本发明做进一步说明。
实施例1
一种改性增强型保温隔声酚醛泡沫板制备方法包括如下步骤：
1）制备改性酚醛树脂：准备苯酚、多聚甲醛、NaOH、氨水，苯酚、多聚甲醛的比例为1: (1.5-2.0)，NaOH的用量为苯酚的3%-6%，氨水的用量为苯酚的1%-3%； 先将NaOH和氨水混合，向苯酚中加入NaOH、氨水混合溶液总量的80%进行混合，在40-60℃下保温20-40min，加入多聚甲醛总量的80%，在60-70℃保温20-40min，然后加入剩余的NaOH和氨水混合液，保温10-20min，再加入剩余的多聚甲醛，调节pH值为8-9，加入改性剂，升温到70-80℃保温10-20min，在85-95℃回流30-60min，减压脱水出料；步骤1）中的改性剂为环氧树脂E51；
2）将步骤1）制成的改性酚醛树脂、改性粘土、增韧剂用计量泵输送到浇注发泡机的混合头内，再依次加入稳定剂、发泡剂、表面活性剂、 阻燃剂,搅拌均匀后再加入固化剂进行搅拌；步骤2）中使用的增韧剂为乙二醇、邻苯二甲酸二辛酯、磷酸三甲苯酯中的任意一种；
3）将搅拌后的物料从浇注发泡机上部迅速浇注在内部覆有保护层的模具膜腔中，通过机械手将模具盖上盖板进行模压，所述盖板的底部设有规则有序排列的圆柱型凸台，将模具连盖板一起送入层压输送机，物料在模具内的底层面材和上层盖板之间发泡固化成形，并随着层压输送机向前输送，输送过程中模具内的温度控制在65-70℃，输送时长15-20分钟，所述模具的深度为20mm-30mm,模具上的凸台高3-4mm，所述模具内的底层面材为高强度无纺布；
4）将固化后的酚醛泡沫板冷却脱模。
上述步骤中的原料质量分数如下：
步骤1制成的改性酚醛树脂100份，改性粘土10份，增韧剂1份，稳定剂1份，发泡剂10份，表面活性剂2份，阻燃剂5，固化剂5份。
实施例2
制备方法如实施例1，各组分质量份数如下：改性酚醛树脂100份，改性粘土30份，增韧剂10份，稳定剂5份，发泡剂20份，表面活性剂10份，阻燃剂10，固化剂20份。
实施例3
制备方法如实施例1，各组分质量份数如下：改性酚醛树脂100份，改性粘土20份，增韧剂1份，稳定剂5份，发泡剂10份，表面活性剂2份，阻燃剂10，固化剂5份。
实施例4
制备方法如实施例1，各组分质量份数如下：改性酚醛树脂100份，改性粘土15份，增韧剂10份，稳定剂1份，发泡剂20份，表面活性剂10份，阻燃剂5，固化剂10份。
实施例5
制备方法如实施例1，各组分质量份数如下：改性酚醛树脂100份，改性粘土25份，增韧剂7份，稳定剂3份，发泡剂15份，表面活性剂5份，阻燃剂7，固化剂18份。
实施例6
制备方法如实施例1，各组分质量份数如下：改性酚醛树脂100份，改性粘土20份，增韧剂3份，稳定剂5份，发泡剂15份，表面活性剂10份，阻燃剂6，固化剂15份。
实施例1~6所得的改性增强型保温隔声酚醛泡沫板的性能见表1。
表1 酚醛泡沫板的性能
由表1可以看出，本发明制备的改性增强型保温隔声酚醛泡沫板，保温和抗压效果都很好，韧性也有很大的提高。通过隔声效果的检测，结构表面，本发明的降噪效果也有明显的提高。
以上所述仅为说明本发明的实施方式，并不用于限制本发明，对于本领域的技术人员来说，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。
Claims (3)
1.一种改性增强型保温隔声酚醛泡沫板制备方法，其特征在于，改性增强型保温隔声酚醛泡沫板的组分及质量份数为：改性酚醛树脂100份，改性粘土10-30份，增韧剂1-10份，稳定剂1-5份，发泡剂10-20份，表面活性剂2-10份，阻燃剂5-10，固化剂5-20份；
制备方法包括如下步骤：
1）制备改性酚醛树脂：准备苯酚、多聚甲醛、NaOH、氨水，苯酚、多聚甲醛的比例为1:(1.5-2.0)，NaOH的用量为苯酚的3%-6%，氨水的用量为苯酚的1%-3%； 先将NaOH和氨水混合，向苯酚、改性剂中加入NaOH、氨水混合溶液总量的80%进行混合，在40-60℃下保温20-40min，加入多聚甲醛总量的80%，在60-70℃保温20-40min，然后加入剩余的NaOH和氨水混合液，保温10-20min，再加入剩余的多聚甲醛，调节pH值为8-9，加入改性剂，升温到70-80℃保温10-20min，在85-95℃回流30-60min，减压脱水出料；步骤1）中的改性剂为环氧树脂E51；
2）将步骤1）制成的改性酚醛树脂、改性粘土、增韧剂用计量泵输送到浇注发泡机的混合头内，再依次加入稳定剂、发泡剂、表面活性剂、 阻燃剂,搅拌均匀后再加入固化剂进行搅拌； 其中，增韧剂为乙二醇；
3）将搅拌后的物料从浇注发泡机上部迅速浇注在内部覆有保护层的模具膜腔中，通过机械手将模具盖上盖板进行模压，所述盖板的底部设有规则有序排列的圆柱型凸台，将模具连盖板一起送入层压输送机，物料在模具内的底层面材和上层盖板之间发泡固化成形，并随着层压输送机向前输送，输送过程中模具内的温度控制在65-70℃，输送时长15-20分钟，所述模具的深度为20mm-30mm,模具上的凸台高3-4mm，所述模具内的底层面材为高强度无纺布；
4）将固化后的酚醛泡沫板冷却脱模；
所述发泡剂为无氟发泡剂二亚硝基五次甲基四胺；
所述表面活性剂为壬基酚与环氧乙烷的加成物，或聚硅氧烷、聚氧乙烯、聚氧丙烯的嵌段共聚；
固化剂为无机酸和有机酸的混合物加入制成的浓度为40-60%的水溶液，所述无机酸可选用硫酸、盐酸、磷酸中的一种，所述有机酸为草酸、己二酸、苯硝酸、酚硝酸、甲苯磺酸,苯磺酸、石油磺酸中的一种。
2.根据权利要求1所述的一种改性增强型保温隔声酚醛泡沫板，其特征在于，所述稳定剂为吐温-80和甲基硅油的混合物。
3.根据权利要求1所述的一种改性增强型保温隔声酚醛泡沫板，所述阻燃剂为无机阻燃剂硼酸锌。
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