CN107060120A - 一种注塑岩棉复合一体化外墙保温板制备方法 - Google Patents
一种注塑岩棉复合一体化外墙保温板制备方法 Download PDFInfo
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Abstract
本发明公开了一种注塑岩棉复合一体化外墙保温板制备方法,其步骤如下:1)清理、预埋金属锚固件;2)选择岩棉厚度;3)涂抹聚酯胶,将岩棉块密封粘接在饰面板上;4)对模具进行清理、预热、调整、涂刷脱模剂,将饰面板置入在模具内,进行合模;5)通过浇注机向模具内注入聚氨酯混合料;6)进行开模、脱模、取件;本发明通过使岩棉在聚氨酯发泡过程中被包裹在聚氨酯内侧,利用聚氨酯硬泡的吸水率在3%~5%,且吸水部分大都集中在泡沫表面,使岩棉避免被水浸入,解决了岩棉吸水保温性能下降的问题,同时当复合保温板燃烧时,聚氨酯发泡形成的碳化骨架与岩棉共同形成防火隔离带,阻碍火势蔓延,提高复合保温板的燃烧等级。
Description
技术领域
本发明属于由隔绝材料和混凝土、石料或石类材料组成的技术领域,具体是涉及一种用于新建建筑和旧房改造建筑的外墙外保温的注塑岩棉复合一体化外墙保温板制备方法。
背景技术
建筑节能是指通过采取合理的建筑设计和选用符合节能要求的墙体材料、屋面隔热材料、玻璃、门窗、空调等措施,这样所建造的房屋,与没有采取节能措施的房屋相比,在保证相同的室内热舒适环境条件下,它可以提高能源利用效率,减少建筑能耗;对于目前市场上纯聚氨酯硬泡保温复合一体化的外墙保温板燃烧等级为B2级,即使加入价格昂贵的阻燃剂可达到燃烧等级为B1级,少量可达到A级;岩棉作为外墙外保温材料虽然有饰面板材的遮挡保护但装饰面板接缝难于做到严丝合缝,当保温***受到外界雨水侵蚀后,岩棉吸水导致保温性能急剧下降,岩棉吸水冻胀引起装饰面层开裂、脱落。
发明内容
有鉴于此,本发明的目的在于提供注塑岩棉复合一体化外墙保温板制备方法,该注塑岩棉复合一体化外墙保温板制备方法通过使岩棉在聚氨酯发泡过程中被包裹在聚氨酯内侧,利用聚氨酯硬泡的吸水率在3%~5%,且吸水部分大都集中在泡沫表面,使岩棉避免被水浸入,解决了岩棉吸水保温性能下降的问题,同时当复合保温板燃烧时,聚氨酯发泡形成的碳化骨架与岩棉共同形成防火隔离带,阻碍火势蔓延,提高复合保温板的燃烧等级。
为了达到上述目的,本发明一种注塑岩棉复合一体化外墙保温板制备方法,其步骤如下:1)饰面板表面进行清理、预埋金属锚固件;
2)依据节能设计要求选择岩棉厚度,计算预留岩棉封边宽度以及聚氨酯发泡流动通道,切割岩棉块;
3)将岩棉块底部和饰面板背面涂抹聚酯胶,将岩棉块底部用聚酯胶密封粘接在饰面板上;
4)对聚氨酯基料进行预热,将模具进行清理、预热、调整、涂刷脱模剂,然后将粘接有岩棉块的饰面板置入在模具内,进行合模;
5)计算聚氨酯基料用量,通过浇注机向模具内进行加压并且按照一定比例注入聚氨酯混合料,聚氨酯混合料在模具内发泡塑化成型;
6)进行开模、脱模、取件,得到注塑岩棉复合一体化外墙保温板半成品,对半成品进行外观检测,切除毛刺和边角料。
进一步,在步骤6)中,在聚氨酯发泡塑化成型远离饰面板的表面粘接有水泥基背衬。
进一步,所述岩棉块设置为多块且呈矩阵布置粘接在饰面板上。
进一步,所述岩棉块与岩棉块之间以及岩棉块与水泥基背衬之间的距离大于10mm。
进一步,所述岩棉块的尺寸设置为:长度设置为220~250mm;宽度设置为140~160mm;高度设置为25~60mm。
本发明还公开了一种注塑岩棉复合一体化外墙保温板,包括外板、内板和设置在外板与内板之间的保温层,所述保温层包括多块岩棉保温芯块和包裹在岩棉保温芯块周围以及顶部的聚氨酯硬泡层,所述岩棉保温芯块底部通过密封连接在外板或内板上;所述聚氨酯硬泡包括聚氨酯硬泡框架和聚氨酯硬泡板,所述聚氨酯硬泡框架中设置有容纳岩棉保温芯块的容纳槽;所述聚氨酯硬泡框架和聚氨酯硬泡板设置为由聚氨酯材料注塑一体成型体。
进一步,所述饰面板上连接有设置有不少于2对连接件,所述2对连接件分别布置在聚氨酯硬泡层左右两侧。
本发明的有益效果在于:
1、结构安全可靠、质量稳定,与墙体间直接采用专用水泥砂浆粘接,同种材料界面相容性好,因而粘结强度高,另外还设置有金属锚固件作为辅助连接手段,两道连接防线,更进一步提高了外墙保温***的安全可靠性,因为采用了在工厂预制化加工的成品,减少了作业环境和操作人员带来的不确定性,使得产品质量稳定;
2、生产效益高:在市场需求量急剧上涨的情况下,工厂化生产线生产,提高生产效率节约了社会劳动力成本,带来了良好的经济性和竞争性;
3、保温节能效果好,减轻建筑自重:该保温层其特有的闭孔性和高抗气体扩散性具有优越的长期保温性,聚氨酯硬泡导热系数为0.02W/m.K~0.03W/m.K之间,为所有保温材料中导热系数最低的,岩棉导热系数为0.03W/m.K~0.04W/m.K之间。保温层厚度的减小,使***护结构变薄,利于减轻复合板的自重,提高了安全性,同时厚度小也利于减少建筑物的重量;
4、阻燃防火性能好,消防安全性高:采用聚氨酯硬泡、岩棉保温芯材,不会产生熔融滴落的燃烧火球,而且在燃烧过程中表面会形成炭化骨架层覆盖在表面,阻隔空气,抑制火势蔓延,在正面和背面分别采用不燃的装饰面层和水泥基背衬,安装时在四个边用防火阻燃的耐候粘结密封胶密封,使得产品的燃烧性能达到A级,完全能满足消防要求;
5、施工简单方便、缩短工期:聚氨酯硬泡岩棉复合装饰保温***将传统通过现场湿作业完成的保温和装饰两大工序中绝大部分工作在工厂的生产线一次预制成型,现场一次安装即可,形成了产品标准化,施工安装流程化,简化了施工工艺,大幅度降低劳动强度、提高工效,避免了由于大量现场湿作业,施工质量和进度易受现场施工环境、气候、人员素质影响的弊端;施工周期比薄抹灰***缩短一半以上;
6、抗变形、抗开裂能力强:由于注塑岩棉复合一体化外墙保温板制备方法是用聚氨酯与岩棉与饰面层和水泥基背衬利用聚氨酯的自粘性复合而成,复合后的板材强度增加抗变形能力增强。而且复合板粘锚施工时,板与板之间的缝隙采用弹性密封材料填缝,能有效地释放装饰面材因温度变化引起应力,不会因板材的变形产生裂缝。当建筑主体结构产生裂缝时,由于复合层采用了聚氨酯弹性材料有效的吸收了主体结构变形产生应力,因此其具有较强的抗裂性能;
7、尺寸稳定性好:聚氨酯硬泡岩棉与装饰面材料复合后,因聚氨酯尺寸稳定性优于其它保温材料,(聚氨酯硬泡尺寸稳定性≤1.0%)且聚氨酯硬泡有一定弹性,装饰面层不会因聚氨酯变形引起起鼓、脱落;
8、 性价比高:注塑岩棉复合一体化外墙保温***采用“粘贴+锚固”的方式安装,与传统建筑幕墙比较,不使用龙骨,降低造价。而且因工期的大幅度缩减,降低了施工措施成本和管理成本,综合成本更低;缩短施工工期,能提前将工程投入使用,加快投资回收;
9、丰富的外立面处理:装饰面材料丰富多样对既有建筑进行节能改造时,不仅使建筑获得更好的保温隔热效果,而且立面焕然一新;
10、边角料回收再利用,绿色环保:该产品在生产过程中产生的边角料主要成分为聚氨酯硬泡、水泥背衬,将边角料通过研磨工艺磨成微细颗粒,可作为生产透水砖的原料;该产品在生产过程不产生废水、废气、固体废弃物真正做到无三废,绿色环保;
11、有利于人文环境保护:由于实现了最大程度的工厂化加工,减少了施工现场建筑垃圾、建筑粉尘和噪音的产生,降低了扰民的程度,缩短了扰民的时间,对于旧房可边住人边改造。有利于人文环境保护。
附图说明
为了使本发明的目的、技术方案和有益效果更加清楚,本发明提供如下附图进行说明:
图1为本发明注塑岩棉复合一体化外墙保温板制备方法制备的产品结构示意图;
图2为本发明注塑岩棉复合一体化外墙保温板制备方法制备的产品中聚氨酯硬泡层结构示意图;
图3为本发明注塑岩棉复合一体化外墙保温板制备方法流程图。
附图说明:1-饰面板;2-岩棉保温芯块;3-聚氨酯硬泡框架;4-水泥基背衬;5-连接件;6-聚酯胶层;7-容纳槽;8-聚氨酯硬泡板。
具体实施方式
下面将结合附图,对本发明的优选实施例进行详细的描述。
如图1、图2、图3所示;本发明一种注塑岩棉复合一体化外墙保温板制备方法,其步骤如下:1)饰面板表面进行清理、预埋金属锚固件;
2)依据节能设计要求选择岩棉厚度,计算预留岩棉封边宽度以及聚氨酯发泡流动通道,切割岩棉块;
3)将岩棉块底部和饰面板背面涂抹聚酯胶,将岩棉块底部用聚酯胶密封粘接在饰面板上;
4)对聚氨酯基料进行预热,将模具进行清理、预热、调整、涂刷脱模剂,然后将粘接有岩棉块的饰面板置入在模具内,进行合模;
5)计算聚氨酯基料用量,通过浇注机向模具内进行加压并且按照一定比例注入聚氨酯混合料,聚氨酯混合料在模具内发泡塑化成型;
6)进行开模、脱模、取件,得到注塑岩棉复合一体化外墙保温板半成品,对半成品进行外观检测,切除毛刺和边角料。
本发明通过使岩棉在聚氨酯发泡过程中被包裹在聚氨酯内侧,利用聚氨酯硬泡的吸水率在3%~5%,且吸水部分大都集中在泡沫表面,使岩棉避免被水浸入,解决了岩棉吸水保温性能下降的问题,同时当复合保温板燃烧时,聚氨酯发泡形成的碳化骨架与岩棉共同形成防火隔离带,阻碍火势蔓延,提高复合保温板的燃烧等级。
进一步,在步骤6)中,在聚氨酯发泡塑化成型远离饰面板的表面粘接有水泥基背衬。
进一步,所述岩棉块设置为多块且呈矩阵布置粘接在饰面板上。
进一步,所述岩棉块与岩棉块之间以及岩棉块与水泥基背衬之间的距离大于10mm。
进一步,所述岩棉块的尺寸设置为:长度设置为220~250mm;宽度设置为140~160mm;高度设置为25~60mm。
本发明还公开了注塑岩棉复合一体化外墙保温板包括外板、内板和设置在外板与内板之间的保温层,所述保温层包括多块岩棉保温芯块2和包裹在岩棉保温芯块2周围以及顶部的聚氨酯硬泡层,所述岩棉保温芯块2底部通过密封连接在外板或内板上。
本实施例通过使岩棉在聚氨酯发泡过程中被包裹在聚氨酯内侧,利用聚氨酯硬泡的吸水率在3%~5%,且吸水部分大都集中在泡沫表面,使岩棉避免被水浸入,解决了岩棉吸水保温性能下降的问题,同时当复合保温板燃烧时,聚氨酯发泡形成的碳化骨架与岩棉共同形成防火隔离带,阻碍火势蔓延,提高复合保温板的燃烧等级。
进一步,优选的所述聚氨酯硬泡包括聚氨酯硬泡框架3和聚氨酯硬泡板8,所述聚氨酯硬泡框架3中设置有容纳岩棉保温芯块的容纳槽7,优选的所述聚氨酯硬泡框架3和聚氨酯硬泡板8设置为由聚氨酯材料注塑一体成型体,该结构有利于注塑一体成型,方便岩棉保温芯块线下成型操作。
进一步,优选的所述聚氨酯硬泡板的厚度设置为不少于10mm,该结构有利于保温板保温、阻燃效果。
进一步,优选的所述外板设置为饰面板1,所述饰面板1设置为超薄天然石材板、玻璃纤维水泥板、真石漆板、人造大理石板、硅酸钙板、铝塑板或金属彩板,该结构有利于保温板适用于新建建筑和旧房改造建筑的外墙外保温***。
进一步,优选的所述内板设置为水泥基背衬板4,优选的所述饰面板1上连接有设置有不少于2对连接件,所述2对连接件分别布置在聚氨酯硬泡层左右两侧,本实施例水泥基背衬板4与墙体间直接采用专用水泥砂浆粘接,同种材料界面相容性好,因而粘结强度高,另外还设置有金属锚固件作为辅助连接手段,两道连接防线,更进一步提高了外墙保温***的安全可靠性。
本发明600mmx600mmx55mm的注塑岩棉复合一体化外墙保温板的检测结果如下。
表1为注塑岩棉复合一体化外墙保温板的抗燃烧性检测。
序号 | 检测参数 | 计量单位 | 质量要求 | 检测结果 | 单项判定 |
1 | 单位面积质量 | Kg/㎡ | 实测值 | 49 | / |
2 | 保温材料导热系数 | W/(m.k) | ≦0.048 | 0.042 | 合格 |
3 | 拉伸粘接强度 | MPa | 实测值 | 0.20 | / |
表2为注塑岩棉复合一体化外墙保温板的质量检测结果。
最后说明的是,以上优选实施例仅用以说明本发明的技术方案而非限制,尽管通过
形式上和细节上对其作出各种各样的改变,而不偏离本发明权利要求书所限定的范围。
Claims (7)
1.一种注塑岩棉复合一体化外墙保温板制备方法,其特征在于:其步骤如下,
1)饰面板表面进行清理、预埋金属锚固件;
2)依据节能设计要求选择岩棉厚度,计算预留岩棉封边宽度以及聚氨酯发泡流动通道,切割岩棉块;
3)将岩棉块底部和饰面板背面涂抹聚酯胶,将岩棉块底部用聚酯胶密封粘接在饰面板上;
4)对聚氨酯基料进行预热,将模具进行清理、预热、调整、涂刷脱模剂,然后将粘接有岩棉块的饰面板置入在模具内,进行合模;
5)计算聚氨酯基料用量,通过浇注机向模具内进行加压并且按照一定比例注入聚氨酯混合料,聚氨酯混合料在模具内发泡塑化成型;
6)进行开模、脱模、取件,得到注塑岩棉复合一体化外墙保温板半成品,对半成品进行外观检测,切除毛刺和边角料。
2.根据权利要求1所述的注塑岩棉复合一体化外墙保温板制备方法,其特征在于:在步骤6)中,在聚氨酯发泡塑化成型远离饰面板的表面粘接有水泥基背衬。
3.根据权利要求2所述的注塑岩棉复合一体化外墙保温板制备方法,其特征在于:所述岩棉块设置为多块且呈矩阵布置粘接在饰面板上。
4.根据权利要求2所述的注塑岩棉复合一体化外墙保温板制备方法,其特征在于:所述岩棉块与岩棉块之间以及岩棉块与水泥基背衬之间的距离大于10mm。
5.根据权利要求2所述的注塑岩棉复合一体化外墙保温板制备方法,其特征在于:所述岩棉块的尺寸设置为:长度设置为220~250mm;宽度设置为140~160mm;高度设置为25~60mm。
6.一种权利要求1-5任一项注塑岩棉复合一体化外墙保温板制备方法制备的注塑岩棉复合一体化外墙保温板,其特征在于:包括外板、内板和设置在外板与内板之间的保温层,所述保温层包括多块岩棉保温芯块和包裹在岩棉保温芯块周围以及顶部的聚氨酯硬泡层,所述岩棉保温芯块底部通过密封连接在外板或内板上;所述聚氨酯硬泡包括聚氨酯硬泡框架和聚氨酯硬泡板,所述聚氨酯硬泡框架中设置有容纳岩棉保温芯块的容纳槽;所述聚氨酯硬泡框架和聚氨酯硬泡板设置为由聚氨酯材料注塑一体成型体。
7.根据权利要求6所述的注塑岩棉复合一体化外墙保温板,其特征在于:所述饰面板上连接有设置有不少于2对连接件,所述2对连接件分别布置在聚氨酯硬泡层左右两侧。
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