CN113968693A - Fireproof core material and manufacturing method thereof - Google Patents
Fireproof core material and manufacturing method thereof Download PDFInfo
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- CN113968693A CN113968693A CN202111265421.3A CN202111265421A CN113968693A CN 113968693 A CN113968693 A CN 113968693A CN 202111265421 A CN202111265421 A CN 202111265421A CN 113968693 A CN113968693 A CN 113968693A
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- 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
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
- C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/80—Component parts, details or accessories; Auxiliary operations
- B29B7/84—Venting or degassing ; Removing liquids, e.g. by evaporating components
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/26—Carbonates
- C04B14/28—Carbonates of calcium
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- 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
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
- C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- C04B26/06—Acrylates
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- 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
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- 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
- C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
- C04B2201/50—Mortars, concrete or artificial stone characterised by specific physical values for the mechanical strength
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- Fireproofing Substances (AREA)
- Compounds Of Alkaline-Earth Elements, Aluminum Or Rare-Earth Metals (AREA)
Abstract
The application provides a fireproof core material and a manufacturing method. The fireproof core material utilizes the water-based emulsion to mix powder such as calcium carbonate and flame retardant, reduces the using amount of the emulsion by reasonably matching the ratio of the particle size of inorganic powder, ensures the strength, and simultaneously ensures that the heat value of the material reaches the standard requirement of A2 to realize the fireproof effect. Meanwhile, as the flame-retardant components are selected from inorganic powder particles, the flame-retardant components can be softened along with the heating of the aqueous emulsion condensate and synchronously extend along with the emulsion, and provide corresponding toughness to realize bending into coils. The fireproof core material can meet the A2-grade fireproof requirement, and can be continuously bent into a roll shape for packaging and transportation, so that the transportation and subsequent processing cost is effectively reduced.
Description
Technical Field
The application relates to the technical field of fireproof materials, in particular to a fireproof core material and a manufacturing method thereof.
Background
The existing fireproof core material is mostly manufactured by adopting calcium carbonate, glass fiber, polypropylene short fiber, flame retardant and other components. However, due to the characteristics of the material and the limitation of the processing technology, the toughness and the strength of the existing fireproof core material finished product are poor. In addition, the existing fireproof core material is low in compactness and high in water absorption rate, and the existing fireproof core material cannot be bent into a roll shape for packaging and transportation, so that the transportation cost and the processing cost are high.
A large amount of adhesives are required to be mixed with flame-retardant components in the conventional fireproof core material, so that the strength of the core material is ensured to reach the standard. However, organic matters in the adhesive have high calorific value per unit weight, and flame is easily generated after the organic matters are heated, so that the calorific value of the existing fireproof core material using the organic matters cannot meet the requirement of A2-grade fireproof standard.
Disclosure of Invention
The utility model provides a to prior art's not enough, provide a fire prevention core and manufacturing method, this application adopts inorganic hydroxide as the fire retardant, calcium carbonate is as the filler, utilize inorganic fire retardant pyrolysis oxidation to realize fire-retardant and to the absorption cooling of environmental heat value, utilize high packing, the high proportion characteristic of calcium carbonate to reduce the calorific value of organic matter unit weight, proportion between inorganic powder granule thickness through reasonable collocation, reduce the use amount of emulsion, when guaranteeing intensity, make the material calorific value reach A2 level fire prevention requirement. The technical scheme is specifically adopted in the application.
Firstly, in order to achieve the purpose, a fireproof core material is provided, which comprises 17.5 to 22.5 parts of aqueous emulsion condensate and 200 parts of powder material in parts by weight; wherein the powder material comprises calcium carbonate powder particles.
Optionally, the fireproof core material is prepared by mixing the above components, wherein the aqueous emulsion cured product is any one or a combination of styrene-acrylic acid, vinyl acetate-ethylene copolymer, acrylic acid and vinyl acetate-acrylic acid; the calcium carbonate powder particles are heavy calcium carbonate powder or calcite mineral powder.
Optionally, the fireproof core material according to any one of the above claims, wherein the powder further comprises: any one or more powder particles of aluminum hydroxide, magnesium hydroxide, titanium dioxide, quartz sand and silicon dioxide.
Optionally, the fireproof core material is as described in any one of the above, wherein in the powder material, the particle size of D50 of aluminum hydroxide and magnesium hydroxide is in the range of 5-50 μm, and the weight of the D50 accounts for 0-90% of the total mass of the powder material; the maximum range of the rest of the powder particles is not more than 1000 μm; and the powder particles with the D50 particle size range of 5-50 mu m account for 20-90% of the total mass of the powder.
Optionally, the fireproof core material is prepared by mixing the calcium carbonate powder particles with the fireproof core material, wherein the fireproof core material comprises coarse-particle-size calcium carbonate powder and fine-particle-size calcium carbonate powder; wherein the D50 particle size range of the fine particle size calcium carbonate powder is between 5 and 50 mu m, and the weight of the fine particle size calcium carbonate powder accounts for 20 to 90 percent of the total weight of the powder; the D50 particle size range of the coarse particle size calcium carbonate powder is between 100 and 400 mu m, and the weight of the coarse particle size calcium carbonate powder accounts for 10 to 80 percent of the total weight of the powder.
Optionally, the fireproof core material according to any of the above, wherein the fluff comprises coarse-particle fluff and fine-particle fluff; the fine particle powder is any one or a plurality of powder particles of aluminum hydroxide, magnesium hydroxide, quartz sand, silicon dioxide and calcium carbonate, the D50 particle size range is between 5 and 50 mu m, and the weight of the D50 particle accounts for 20 to 90 percent of the total weight of the powder; the coarse powder is any one or more powder particles of calcium carbonate, aluminum hydroxide, magnesium hydroxide, quartz sand and silicon dioxide, the D50 particle size range is between 100 and 400 mu m, and the weight of the D50 particle size range accounts for 10 to 80 percent of the total weight of the powder.
Optionally, the fireproof core material comprises, by weight, 17.5-22.5 parts of aqueous emulsion condensate, 60 parts of aluminum hydroxide powder particles, 40 parts of magnesium hydroxide powder particles and 100 parts of calcium carbonate powder particles, wherein the D50 particle size of the 40 parts of calcium carbonate powder particles is in the range of 5-50 μm.
Optionally, the fireproof core material as described in any of the above, wherein the aluminum hydroxide powder particles have a D50 particle size of 10-15 μm; the D50 particle size of the magnesium hydroxide powder particles is 10-20 μm; the maximum particle size of the calcium carbonate powder particles does not exceed 1000 μm.
Meanwhile, in order to achieve the purpose, the application also provides a manufacturing method of the fireproof core material, which comprises the following steps: mixing 35-45 parts of aqueous emulsion and 200 parts of powder in parts by weight under a vacuum condition, and stirring to prepare slurry; putting the slurry into extrusion molding equipment to prepare a sheet; heating and baking the sheet material, applying pressure, and evaporating water contained in the sheet material to obtain the fireproof core material; wherein the powder material comprises heavy calcium carbonate powder.
Optionally, the method for manufacturing a fireproof core material includes that the aqueous emulsion is any one of or a mixture of styrene-acrylic emulsion, VAE emulsion, vinyl acetate emulsion and acrylic emulsion.
Optionally, in the method for manufacturing a fireproof core material, no more than 100 parts of any one or a combination of the following powder particles is added during the process of mixing and stirring under vacuum condition to form a slurry: aluminum hydroxide, magnesium hydroxide, titanium dioxide, quartz sand, silicon dioxide and quartz sand.
Optionally, the method of manufacturing a fire retardant core material as described in any one of the above, wherein the aluminium hydroxide powder particles have a D50 particle size of 14 μm; the D50 particle size of the magnesium hydroxide powder particles is 15 μm; the maximum particle size of the calcium carbonate powder particles does not exceed 1000 μm.
Optionally, the method for manufacturing a fireproof core material as described in any one of the above, wherein the step of baking the sheet material with heating and pressing includes: the sheets are sequentially fed into a plurality of ovens set at a temperature between 120 ℃ and 330 ℃, and between the ovens, the sheets are flattened and compacted to the required size of the fireproof core material by using at least 2 rolling mills.
Advantageous effects
The fireproof core material utilizes the water-based emulsion to mix the calcium carbonate powder and the inorganic flame retardant, reduces the usage amount of the emulsion by 20-30 percent through reasonable matching of thick and thin powder particles, further reduces the cost, can reduce the heat value of the unit weight of organic matters through the high specific gravity characteristic of the calcium carbonate, ensures that the heat value of the material is less than or equal to 3.0MJ/kg, and meets the standard requirement of A2 level. Meanwhile, the peeling strength of the composite rear roller of the fireproof core material provided by the application reaches more than 110 N.mm/mm, and the basic strength requirement of the core material can be met. The fireproof core material can further utilize the characteristic that inorganic flame retardant can be decomposed and oxidized when being heated in a high-temperature environment to absorb the heat of organic matters and the heat of the environment, thereby providing the flame retardant effect and providing necessary strength while meeting the heat value index of the fireproof material. Meanwhile, because the flame-retardant components are selected from inorganic powder particles, the flame-retardant components can be softened along with the heating of the aqueous emulsion condensate and synchronously extend along with the emulsion, and provide corresponding toughness to realize bending and coiling into a roll shape. The fireproof core material can meet the A2-grade fireproof requirement, and can be continuously produced, bent and rolled for packaging and transportation, so that the transportation and subsequent processing cost is effectively reduced, and meanwhile, the enough core material strength is provided. In addition, the magnesium hydroxide and the aluminum hydroxide powder can be added into the powder, the heat value of the organic matter and the heat value of the environment can be further absorbed by utilizing the moisture obtained by the endothermic reaction of the magnesium hydroxide and the aluminum hydroxide, and the magnesium oxide and the aluminum oxide obtained by pyrolysis can be used for inhibiting the generation of flame at high temperature, so that better flame-retardant and smoke-inhibiting effects can be further obtained.
The present application may further employ VAE emulsions to produce the above-described fire-retardant core material by mixing inorganic fire-retardant powder particles under vacuum conditions. Compared with other aqueous emulsions, the VAE emulsion has the characteristics of no peculiar smell, strong fluidity and good compatibility with powder. The processing process is green and environment-friendly, and the inorganic flame retardant powder can be bonded through the solidification after the moisture is evaporated, so that the strength of the core material is improved, and the sheet can be more easily prepared through extrusion molding equipment. In the heating and pressing baking forming process of the VAE emulsion, the compatibility of the VAE emulsion with a large amount of inorganic powder in the VAE emulsion can be ensured, the toughness required by processing is provided, the VAE emulsion is convenient to wind, and the peeling strength of the compounded core material is ensured. Compared with styrene-acrylic aqueous emulsion and acrylic aqueous emulsion, the VAE emulsion further has the advantages of good self-extinguishing property and low heat value, and the VAE emulsion can further reduce the heat value generated by the combustion of a fireproof structure and reduce the flame generated by the heated combustion of a fireproof material prepared from the VAE emulsion.
The application obtains the preferred proportion scope of calcium carbonate powder through a large amount of experiments, can be through the selection and the combination to heavy calcium carbonate powder granule D50 particle size and the corresponding calcium carbonate quality that fuses in the increase unit volume emulsion to provide stronger fire behaviour, thereby reduce the heat value of organic matter proportion further reduction fire prevention core material unit weight itself, improve fire prevention effect.
This application is in the course of working, mixes preparation thick liquids under the vacuum condition through vacuum mixer, can eliminate the bubble that produces because of the stirring in the thick liquids at the stirring in-process to improve the closely knit degree of the inside powder of core after the thick liquids toast, improve the off-the-shelf cohesive strength of core. In addition, the core material can be further compacted by rolling through the front and rear 2 rolling mills, particularly continuous rolling through the 2 nd double-group roller rolling mill, and the material of the finished core material is compact through the processing technology, so that the water absorption rate of the core material is obviously lower than that of the existing product, the hidden troubles of plate delamination, falling off and the like caused by water absorption can be solved, and sufficient process strength is provided to facilitate the processing of various fireproof plate finished products.
Additional features and advantages of the application will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the application.
Detailed Description
In order to make the purpose and technical solutions of the embodiments of the present application clearer, the technical solutions of the embodiments of the present application will be clearly and completely described below. It should be apparent that the described embodiments are only some of the embodiments of the present application, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the described embodiments of the application without any inventive step, are within the scope of protection of the application.
It will be understood by those skilled in the art that, unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the prior art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Example 1
Firstly, taking 35 parts by weight of aqueous emulsion obtained by mixing styrene-acrylic and vinyl acetate-acrylic, and 200 parts by weight of inorganic flame-retardant powder consisting of calcium carbonate powder particles with the maximum particle size not more than 1000 mu m, mixing and stirring the aqueous emulsion and the inorganic flame-retardant powder under vacuum condition to prepare slurry, wherein the calcium carbonate powder particles used in the slurry are heavy calcium carbonate powder or calcite powder, and the D50 particle size ratio of the powder particles is adjusted to ensure that the powder particles with the D50 particle size range of 5 mu m to 50 mu m account for 90 percent of the total mass of the inorganic flame-retardant powder, and the D50 particle size ranges of the rest powder particles can be distributed between 100 and 400 mu m;
secondly, putting the slurry obtained in the first step into extrusion molding equipment to prepare a sheet;
thirdly, the sheet obtained in the second step is placed on a transmission mesh belt with the linear speed of 2 m/min, the sheet is sequentially passed through 9 ovens with the following temperatures by the transmission of the transmission mesh belt, the sheet is sequentially heated and baked by the 9 ovens respectively, the moisture contained in the aqueous emulsion in the sheet is evaporated, the sheet is pressed by rolling mills between the ovens No. 4 and No. 5 and between the ovens No. 8 and No. 9 respectively, and the sheet is rolled into the size required by the fireproof core material of the finished product:
the oven set temperature of 1 st oven was 170 c,
the oven set temperature of 2 nd oven was 235 c,
the oven set temperature of No. 3 was 160 c,
the oven set temperature of 4 th was 220 c,
the oven set temperature of No. 5 was 160 c,
the oven set temperature of 6 th oven was 200 c,
the oven set temperature of 7 th was 210 c,
the oven set at temperature of 150 c 8 th,
the oven set point temperature of 9 th oven was 260 ℃.
The fireproof core material obtained by the method is placed in a furnace to be tested for the combustion performance of the building material according to GB/T14402 and GB/T20284 test methods, and the following performances can be achieved by the test results:
the performance data measured by the above experiment meet the judgment condition of A2-grade fire-retardant rating specified by GB 8624-2012 standard: the total heat value of the product is less than or equal to 3.0MJ/kg, the burning growth rate index is less than or equal to 120W/S, the heat release amount in 600S is less than or equal to 7.5MJ, and the transverse flame spread length is less than the edge of the sample. The peel strength reaches the industrial standard, and the processing fluidity meets the requirements of a continuous production process.
Example 2
Taking 40 parts by weight of vinyl acetate-ethylene copolymer aqueous emulsion (VAE emulsion) and 200 parts by weight of inorganic flame-retardant powder consisting of calcium carbonate powder particles with the maximum particle size not more than 1000 mu m, mixing and stirring the aqueous emulsion and the inorganic flame-retardant powder under vacuum condition to prepare slurry, wherein the calcium carbonate powder particles used in the slurry are heavy calcium carbonate powder or calcite powder, and the D50 particle size ratio of the powder particles is adjusted to ensure that the powder particles with the D50 particle size interval ranging from 5 mu m to 50 mu m account for 20 percent of the total mass of the inorganic flame-retardant powder, and the D50 particle size interval of the rest powder particles can be distributed between 100 and 400 mu m;
secondly, putting the slurry obtained in the first step into extrusion molding equipment to prepare a sheet;
thirdly, the sheet obtained in the second step is placed on a transmission mesh belt with the linear speed of 1.5 m/min, the sheet sequentially passes through 9 ovens with the following temperatures by the transmission of the transmission mesh belt, the sheet is sequentially heated and baked by the 9 ovens respectively, the moisture contained in the aqueous emulsion in the sheet is evaporated, the sheet is pressed by rolling mills between the ovens No. 4 and No. 5 and between the ovens No. 8 and No. 9 respectively, and the sheet is rolled into the size required by the fireproof core material of the finished product:
the oven set temperature of 1 st oven was 250 c,
the oven setting temperature of 2 nd oven was 170 c,
the oven setting temperature of the 3 rd oven was 190 c,
the oven set temperature of No. 4 was 175 c,
the oven set temperature of 5 th oven was 140 c,
the oven setting temperature of 6 th oven was 130 c,
the oven set temperature of 7 th was 140 c,
the 8 th oven was set to a temperature of 185 c,
setting the temperature of a 9 th oven to be 205 ℃;
and fourthly, carrying out surface film pasting on the finished fireproof core material with the surface temperature of 120 plus materials and 130 degrees output from the 9 th oven through a film pasting machine, trimming and leveling two side edges of the fireproof core material, maintaining the surface temperature of the fireproof core material at more than 50 ℃, and synchronously rolling the finished fireproof core material after being leveled by a constant tension rolling machine so as to conveniently load, unload and transport the rolled core material.
In the baking process, the aqueous emulsion is heated and baked, water is evaporated to generate a curing effect, the effect of bonding inorganic flame retardant powder is achieved, the basic strength of the core material is formed, and after the core material is cured, the pressure is applied through a double-group rolling machine positioned between rear section baking ovens, so that the core material is further compacted to ensure the peeling strength after compounding. Meanwhile, under the heating action, the cured emulsion has good flexibility, and the inorganic core material can be bent and rolled.
The fireproof core material obtained by the method is placed in a furnace to be tested for the combustion performance of the building material according to GB/T14402 and GB/T20284 test methods, and the following performances can be achieved by the test results:
the performance data measured by the above experiment meet the judgment condition of A2-grade fire-retardant rating specified by GB 8624-2012 standard: the total heat value of the product is less than or equal to 3.0MJ/kg, the burning growth rate index is less than or equal to 120W/S, the heat release amount in 600S is less than or equal to 7.5MJ, and the transverse flame spread length is less than the edge of the sample. The peel strength reaches the industrial standard, and the processing fluidity meets the requirements of a continuous production process.
Example 3
Taking 45 parts by weight of acrylic acid aqueous emulsion, and 200 parts by weight of inorganic flame retardant consisting of 100 parts by weight of fine-particle-size calcium carbonate powder with the D50 particle size range of 5-50 mu m, 10 parts by weight of a mixture of aluminum hydroxide powder and magnesium hydroxide powder with the D50 particle size range of 5-400 mu m and 90 parts by weight of coarse-particle-size calcium carbonate powder with the D50 particle size range of 100-400 mu m, mixing and stirring the mixture under vacuum condition to prepare slurry, wherein the powder particles of the aluminum hydroxide and the magnesium hydroxide used in the slurry can be selected from the following powder particles: coarse-grained aluminum hydroxide powder produced by the Bayer process, having a D50 particle size range between 100 and 400 μm; fine aluminum hydroxide powder produced by a sintering process, having a D50 particle size range between 5 and 50 μm; a fine particulate magnesium hydroxide powder produced by an ore process having a D50 particle size range between 5 μm and 15 μm;
secondly, putting the slurry obtained in the first step into extrusion molding equipment to prepare a sheet;
thirdly, the sheet obtained in the second step is placed on a transmission mesh belt with the linear speed of 3 m/min, the sheet is sequentially passed through 9 ovens with the following temperatures by the transmission of the transmission mesh belt, the sheet is sequentially heated and baked by the 9 ovens respectively, the moisture contained in the aqueous emulsion in the sheet is evaporated, the sheet is pressed by rolling mills between the ovens No. 4 and No. 5 and between the ovens No. 8 and No. 9 respectively, and the sheet is rolled into the size required by the fireproof core material of the finished product:
the oven set temperature of 1 st oven was 330 c,
the oven setting temperature of 2 nd oven was 300 c,
the oven set temperature of 3 rd was 220 c,
the oven set temperature of item 4 was 135 c,
the oven set temperature of 5 th oven was 120 c,
the oven setting temperature of 6 th oven was 165 c,
the oven set temperature of 7 th was 175 c,
the oven setting temperature of 8 th was 220 c,
the 9 th oven is set to be at 150 ℃;
and fourthly, trimming and leveling two side edges of the finished fireproof core material with the surface temperature of 120-130 ℃ output from the 9 th oven, and then synchronously rolling the finished fireproof core material after being leveled by using the waste heat of the fireproof core material through a constant tension rolling machine in the period that the surface temperature of the fireproof core material is maintained above 50 ℃ so as to conveniently load, unload and transport the rolled core material.
The fireproof core material obtained by the method is placed in a furnace to be tested for the combustion performance of the building material according to GB/T14402 and GB/T20284 test methods, and the following performances can be achieved by the test results:
the performance data measured by the above experiment meet the judgment condition of A2-grade fire-retardant rating specified by GB 8624-2012 standard: the total heat value of the product is less than or equal to 3.0MJ/kg, the burning growth rate index is less than or equal to 120W/S, the heat release amount in 600S is less than or equal to 7.5MJ, and the transverse flame spread length is less than the edge of the sample. The peel strength reaches the industrial standard, and the processing fluidity meets the requirements of a continuous production process.
Example 4
Taking 40 parts of VAE emulsion and 200 parts of inorganic flame-retardant powder consisting of 40 parts of fine quartz sand or silicon dioxide powder with the D50 particle size range of 5-50 mu m, 40 parts of fine calcium carbonate powder with the D50 particle size range of 5-50 mu m and 120 parts of coarse heavy calcium carbonate powder with the D50 particle size range of 100-400 mu m, mixing and stirring the materials under vacuum condition to prepare slurry, and adding a small amount of aluminum hydroxide or magnesium hydroxide powder into the slurry, wherein the used powder particles of the aluminum hydroxide and the magnesium hydroxide comprise: the coarse aluminum hydroxide powder can be prepared by a sintering process, and the D50 particle size is 90 mu m; fine aluminum hydroxide powder may be produced by the bayer process, having a D50 particle size of 15 μm, fine magnesium hydroxide powder may be produced by the chemical process, having a D50 particle size of 10 μm;
secondly, putting the slurry obtained in the first step into extrusion molding equipment to prepare a sheet;
thirdly, the sheet obtained in the second step is placed on a transmission mesh belt with the linear speed of 2.8 m/min, the sheet sequentially passes through 9 ovens with the following temperatures by the transmission of the transmission mesh belt, the sheet is sequentially heated and baked by the 9 ovens respectively, the moisture contained in the aqueous emulsion in the sheet is evaporated, the sheet is pressed by rolling mills between the ovens No. 4 and No. 5 and between the ovens No. 8 and No. 9 respectively, and the sheet is rolled into a finished fireproof core material with the thickness of 3.0 mm:
the oven set at temperature 275 c was oven 1,
the oven set temperature of 2 nd oven was 265 c,
the oven set temperature of 3 rd was 203 c,
the oven set temperature of 4 th was 204 c,
the oven set temperature of 5 th oven was 145 c,
the oven setting temperature of 6 th oven was 191 c,
the oven set temperature of 7 th was 198 deg.c,
the oven set temperature of 8 th oven was 213 c,
the 9 th oven is set to be 160 ℃;
and fourthly, trimming and leveling the two side edges of the finished fireproof core material with the surface temperature of 120-130 ℃ output from the 9 th oven to enable the width of the finished fireproof core material to be trimmed to 660mm, and synchronously rolling the finished fireproof core material after being repaired and leveled by a constant tension rolling machine during the period that the residual temperature of the surface of the fireproof core material is maintained to be more than 50 ℃ so as to facilitate loading, unloading and transporting the rolled core material.
The fireproof core material obtained by the method is placed in a furnace to be tested for the combustion performance of the building material according to GB/T14402 and GB/T20284 test methods, and the following performances can be achieved by the test results:
the performance data measured by the above experiment meet the judgment condition of A2-grade fire-retardant rating specified by GB 8624-2012 standard: the total heat value of the product is less than or equal to 3.0MJ/kg, the burning growth rate index is less than or equal to 120W/S, the heat release amount in 600S is less than or equal to 7.5MJ, and the transverse flame spread length is less than the edge of the sample. The peel strength reaches the industrial standard, and the processing fluidity meets the requirements of a continuous production process.
Compared with the previous examples 1 and 3, the VAE emulsion selected in the present example has better compatibility with powder, good processing fluency, stable quality performance, environmental protection in the production process, and environmental protection. Is the emulsion with better use effect.
Example 5
Firstly, taking 40 parts of VAE emulsion and 200 parts of inorganic flame retardant powder consisting of 60 parts of fine-particle titanium dioxide powder with the D50 particle size range of 1-200 mu m, 40 parts of aluminum hydroxide or magnesium hydroxide powder with the D50 particle size range of 5-50 mu m, 40 parts of fine-particle calcium carbonate powder, 60 parts of coarse-particle heavy calcium carbonate with the D50 particle size range of 100-400 mu m and quartz sand mixed powder, mixing and stirring the materials under vacuum condition to prepare slurry, wherein the slurry can be added in a small amount, wherein the used powder particles of aluminum hydroxide and magnesium hydroxide comprise: the aluminum hydroxide is prepared by a Bayer process, and D50 coarse-particle aluminum hydroxide powder with the particle size of 90 mu m; the powder is prepared by a sintering process, fine-particle aluminum hydroxide powder with the D50 particle size of 14 mu m is prepared by an ore method, and fine-particle magnesium hydroxide powder with the D50 particle size of 15 mu m is prepared by an ore method;
secondly, putting the slurry obtained in the first step into extrusion molding equipment to prepare a sheet;
thirdly, the sheet obtained in the second step is placed on a transmission mesh belt with the linear speed of 2.7 m/min, the sheet sequentially passes through 9 ovens with the following temperatures by the transmission of the transmission mesh belt, the sheet is sequentially heated and baked by the 9 ovens respectively, the moisture contained in the aqueous emulsion in the sheet is evaporated, the sheet is pressed by rolling mills between the ovens No. 4 and No. 5 and between the ovens No. 8 and No. 9 respectively, and the sheet is rolled into a finished fireproof core material with the thickness of 3.0 mm:
the oven set temperature of 1 st oven was 225 c,
the 2 nd oven was set to a temperature of 215 c,
the oven set temperature of No. 3 was 176 c,
the oven set temperature of 4 th oven was 146 c,
the oven set temperature of 5 th oven was 145 c,
the oven set point temperature of 6 th oven was 142 c,
the oven set point temperature of 7 th was 158 c,
the oven set temperature of 8 th oven was 163 c,
the 9 th oven is set to be 160 ℃;
fourthly, trimming and leveling the two side edges of the finished fireproof core material with the surface temperature of 120-130 ℃ output from the 9 th oven to enable the width of the finished fireproof core material to be trimmed to 1020 mm.
The fireproof core material obtained by the method is placed in a furnace to be tested for the combustion performance of the building material according to GB/T14402 and GB/T20284 test methods, and the following performances can be achieved by the test results:
the performance data measured by the above experiment meet the judgment condition of A2-grade fire-retardant rating specified by GB 8624-2012 standard: the total heat value of the product is less than or equal to 3.0MJ/kg, the burning growth rate index is less than or equal to 120W/S, the heat release amount in 600S is less than or equal to 7.5MJ, and the transverse flame spread length is less than the edge of the sample. The peel strength reaches the industrial standard, and the processing fluidity meets the requirements of a continuous production process.
Example 6
Firstly, taking 40 parts of VAE emulsion and 200 parts of inorganic flame-retardant powder consisting of 60 parts of fine-particle aluminum hydroxide powder, 40 parts of fine-particle magnesium hydroxide powder, 40 parts of coarse-particle calcium carbonate powder and 60 parts of coarse-particle aluminum hydroxide powder, mixing and stirring the materials under vacuum condition to prepare slurry, wherein the powder particles of aluminum hydroxide and magnesium hydroxide used in the slurry comprise: the coarse aluminum hydroxide powder is prepared by a Bayer process, and the D50 particle size is 200 mu m; the fine-particle aluminum hydroxide powder is prepared by a sintering process, the D50 particle size of the fine-particle aluminum hydroxide powder is 15 mu m, the fine-particle magnesium hydroxide powder is prepared by an ore method, and the D50 particle size of the fine-particle magnesium hydroxide powder is 20 mu m;
secondly, putting the slurry obtained in the first step into extrusion molding equipment with an extrusion roller thickness gap set to be 3.5mm to prepare a sheet;
thirdly, the sheet obtained in the second step is placed on a transmission mesh belt with the linear speed of 2 m/min, the sheet is sequentially heated and baked by 9 ovens with the following temperatures under the transmission of the transmission mesh belt, the moisture in the aqueous emulsion in the sheet is evaporated, the sheet is pressed for the first time by a first rolling mill with the gap between an upper roller and a lower roller being set to be 3.1mm between No. 4 and No. 5 ovens, the sheet is pressed by a second rolling mill with the gap between the upper roller and the lower roller being set to be 3.0mm between No. 8 and No. 9 ovens, and the sheet is rolled into a finished fireproof core material with the thickness of 3.0mm and the width of 1530 mm:
the oven set temperature of No. 1 was 198 deg.c,
the oven set temperature of 2 nd oven was 200 c,
the oven set temperature of No. 3 was 172 c,
the oven set temperature of 4 th oven was 146 c,
the oven set temperature of 5 th oven was 145 c,
the oven set point temperature of 6 th oven was 142 c,
the oven set point temperature of 7 th was 156 c,
the oven setting temperature of 8 th oven was 160 c,
oven 9 set temperature 160 ℃.
The fireproof core material obtained by the method is placed in a furnace to be tested for the combustion performance of the building material according to GB/T14402 and GB/T20284 test methods, and the following performances can be achieved by the test results:
the performance data measured by the above experiment meet the judgment condition of A2-grade fire-retardant rating specified by GB 8624-2012 standard: the total heat value of the product is less than or equal to 3.0MJ/kg, the burning growth rate index is less than or equal to 120W/S, the heat release amount in 600S is less than or equal to 7.5MJ, and the transverse flame spread length is less than the edge of the sample. The peel strength reaches the industrial standard, and the processing fluidity meets the requirements of a continuous production process.
Example 7
Taking 40 parts of VAE emulsion and 200 parts of inorganic flame-retardant powder consisting of 150 parts of aluminum hydroxide powder and magnesium hydroxide powder with the D50 particle size range of 1-200 mu m and 50 parts of mixed powder of coarse-grain heavy calcium carbonate and quartz sand with the D50 particle size range of 100-400 mu m in total, mixing and stirring the mixture under vacuum condition to prepare slurry, wherein the powder particles of the aluminum hydroxide and the magnesium hydroxide used in the slurry comprise the following components in parts by weight: the coarse aluminum hydroxide powder is prepared by a sintering process, and the D50 particle size D50 is 100 mu m; the fine-particle aluminum hydroxide powder is prepared by a Bayer process, the D50 particle size D50 is 10 mu m, the fine-particle magnesium hydroxide powder is prepared by a chemical method, and the D50 particle size D50 is 20 mu m;
secondly, putting the slurry obtained in the first step into extrusion molding equipment with an extrusion roller thickness gap set to be 3.6mm to prepare a sheet;
thirdly, placing the sheet obtained in the second step on a transmission mesh belt with the linear speed of 2.5 m/min, sequentially passing through 9 ovens with the following temperatures by the transmission of the transmission mesh belt, respectively heating and baking the sheet by the 9 ovens, evaporating the water in the water emulsion in the sheet, firstly pressing the sheet by a first rolling mill with the gap between an upper roller and a lower roller being set to be 3.2mm between No. 4 and No. 5 ovens, pressing the sheet by a second rolling mill with the gap between the upper roller and the lower roller being set to be 3.0mm between No. 8 and No. 9 ovens, and rolling the sheet into a finished fireproof core material with the thickness of 3.0mm and the width of 1270 mm:
the oven set temperature of 1 st oven was 338 c,
the 2 nd oven was set to a temperature of 268 c,
the oven setting temperature of No. 3 was 196 c,
the oven set temperature of No. 4 was 196 c,
the oven set temperature of 5 th oven was 139 c,
the oven setting temperature of No. 6 was 196 c,
the oven set temperature of 7 th oven was 197 c,
the oven set point temperature of 8 th oven was 214 c,
oven set point temperature of 225 ℃ for oven 9.
The fireproof core material obtained by the method is placed in a furnace to be tested for the combustion performance of the building material according to GB/T14402 and GB/T20284 test methods, and the following performances can be achieved by the test results:
the performance data measured by the above experiment meet the judgment condition of A2-grade fire-retardant rating specified by GB 8624-2012 standard: the total heat value of the product is less than or equal to 3.0MJ/kg, the burning growth rate index is less than or equal to 120W/S, the heat release amount in 600S is less than or equal to 7.5MJ, and the transverse flame spread length is less than the edge of the sample. The peel strength reaches the industrial standard, and the processing fluidity meets the requirements of a continuous production process.
Example 8
Taking 40 parts of VAE emulsion and 200 parts of inorganic flame-retardant powder consisting of 160 parts of coarse-particle aluminum hydroxide powder, 20 parts of fine-particle aluminum hydroxide powder and 20 parts of coarse-particle heavy calcium carbonate powder with the D50 particle size range of between 100 and 400 mu m, mixing and stirring under vacuum condition to prepare slurry, wherein in the powder particles of the aluminum hydroxide used in the slurry: the coarse aluminum hydroxide powder is prepared by a sintering process, and the D50 particle size is 100 mu m; the fine aluminum hydroxide powder is prepared by a Bayer process, and the D50 particle size is 15 mu m; the coarse magnesium hydroxide powder is prepared by chemical method or ore method, and has D50 particle size of 100 μm
Secondly, putting the slurry obtained in the first step into extrusion molding equipment with an extrusion roller thickness gap set to be 5.5mm to prepare a sheet;
thirdly, the sheet obtained in the second step is placed on a transmission mesh belt with the linear speed of 1.5 m/min, the sheet passes through 9 ovens with the following temperatures in sequence by the transmission of the transmission mesh belt, the sheet is heated and baked by the 9 ovens respectively, the moisture in the water emulsion in the sheet is evaporated, the sheet is pressed for the first time by a first rolling mill with the gap between an upper roller and a lower roller being set to be 5.1mm between No. 4 and No. 5 ovens, the sheet is pressed by a second rolling mill with the gap between the upper roller and the lower roller being set to be 5.0mm between No. 8 and No. 9 ovens, and the sheet is rolled into a finished fireproof core material with the thickness of 5.0mm and the width of 1800 mm:
the oven set point temperature of 1 st oven was 222 c,
the oven set temperature of 2 nd oven was 211 c,
the oven set temperature of 3 rd was 163 c,
the oven set temperature of item 4 was 142 c,
the oven set temperature of 5 th oven was 143 c,
the oven set point temperature of 6 th oven was 142 c,
the oven set temperature of 7 th was 150 c,
the oven setting temperature of 8 th oven was 156 c,
oven 9 set temperature was 165 ℃.
The fireproof core material obtained by the method is placed in a furnace to be tested for the combustion performance of the building material according to GB/T14402 and GB/T20284 test methods, and the following performances can be achieved by the test results:
the performance data measured by the above experiment meet the judgment condition of A2-grade fire-retardant rating specified by GB 8624-2012 standard: the total heat value of the product is less than or equal to 3.0MJ/kg, the burning growth rate index is less than or equal to 120W/S, the heat release amount in 600S is less than or equal to 7.5MJ, and the transverse flame spread length is less than the edge of the sample. The peel strength reaches the industrial standard, and the processing fluidity meets the requirements of a continuous production process.
Example 9
Taking 40 parts of VAE emulsion and 200 parts of inorganic flame-retardant powder consisting of 160 parts of coarse magnesium hydroxide powder, 20 parts of fine magnesium hydroxide powder and 20 parts of coarse heavy calcium carbonate powder with the D50 particle size range of 100-: the fine magnesium hydroxide powder is prepared by a chemical method, and the D50 particle size is 20 mu m; the coarse magnesium hydroxide powder is prepared by an ore method, and the D50 particle size is 200 mu m;
secondly, putting the slurry obtained in the first step into extrusion molding equipment with an extrusion roller thickness gap set to be 5.5mm to prepare a sheet;
thirdly, the sheet obtained in the second step is placed on a transmission mesh belt with the linear speed of 1.5 m/min, the sheet passes through 9 ovens with the following temperatures in sequence by the transmission of the transmission mesh belt, the sheet is heated and baked by the 9 ovens respectively, the moisture in the water emulsion in the sheet is evaporated, the sheet is pressed for the first time by a first rolling mill with the gap between an upper roller and a lower roller being set to be 5.1mm between No. 4 and No. 5 ovens, the sheet is pressed by a second rolling mill with the gap between the upper roller and the lower roller being set to be 5.0mm between No. 8 and No. 9 ovens, and the sheet is rolled into a finished fireproof core material with the thickness of 5.0mm and the width of 1800 mm:
the oven set point temperature of 1 st oven was 222 c,
the oven set temperature of 2 nd oven was 211 c,
the oven set temperature of 3 rd was 163 c,
the oven set temperature of item 4 was 142 c,
the oven set temperature of 5 th oven was 143 c,
the oven set point temperature of 6 th oven was 142 c,
the oven set temperature of 7 th was 150 c,
the oven setting temperature of 8 th oven was 156 c,
oven 9 set temperature was 165 ℃.
The fireproof core material obtained by the method is placed in a furnace to carry out a building material combustion performance test and a monomer combustion test according to GB/T14402 and GB/T20284 test methods, and the following performances can be achieved through the test:
the performance data measured by the above experiment meet the judgment condition of A2-grade fire-retardant rating specified by GB 8624-2012 standard: the total heat value of the product is less than or equal to 3.0MJ/kg, the burning growth rate index is less than or equal to 120W/S, the heat release amount in 600S is less than or equal to 7.5MJ, and the transverse flame spread length is less than the edge of the sample. The peel strength reaches the industrial standard, and the processing fluidity meets the requirements of a continuous production process.
In the above embodiments, the small-particle-size inorganic filler and the large-particle-size inorganic filler are used in combination, and only calcium carbonate (coarse whiting powder) is used without adding magnesium hydroxide and aluminum hydroxide, so that the calorific value can be less than 3.0MJ/kg at a lower cost, and the A2-grade standard can also be achieved. In the above embodiments, aluminum hydroxide and magnesium hydroxide can be further compounded to achieve a better synergistic flame retardant effect, so as to inhibit flame generation. The principle is as follows: the aluminum hydroxide is heated and decomposed at the temperature of 200-400 ℃ to release crystal water, the magnesium hydroxide is heated and decomposed at the temperature of 300-500 ℃ to release crystal water, and the two inorganic flame retardants mutually provide complementary action in different temperature ranges, so that the effective flame retardance and smoke suppression can be realized in all the test temperature ranges by combining the two.
The solids content of the aqueous emulsions of the various embodiments described above can generally be selected to be 50%.
The method ensures that the average D50 particle size of inorganic flame retardant powder particles is not less than 10 mu m by utilizing the combination of different thicknesses and sizes of two inorganic flame retardants and matching small particle sizes and large particle sizes so as to avoid influencing the processing flowability and save the manufacturing cost; meanwhile, the maximum particle size of most inorganic flame-retardant powder particles is not more than 1000 microns through matching of different D50 particle sizes, so that better flame-retardant effect is provided through full decomposition of fine powder.
The fire-proof standard of A2 grade is realized by reasonably matching fine particles and coarse particles, the dosage of the emulsion is reduced, and the manufacturing cost is saved. The common D50 particle size of the coarse particles is not less than 200 mu m, the processing fluidity of the slurry is improved, the heat value of the unit weight of the core material is reduced, and the glue consumption of the unit volume is reduced. The D50 particle size range of the fine particles is kept between 1 and 200 mu m, so that the good filling and flame-retardant effects are exerted, and the compactness and strength of the core material are improved.
Based on the principle, the inorganic filler flame retardant with different D50 particle size ranges in the above embodiments can be exchanged in types, and the combination and collocation of the fine aluminum hydroxide powder, the fine magnesium hydroxide powder and the coarse magnesium hydroxide powder can realize the same A2 grade flame retardant effect as the above embodiments.
Wherein, taking the total weight of the inorganic flame-retardant powder material of 200 parts as an example:
the component proportion of the fine powder with the D50 particle size range of between 5 and 50 mu m is between 40 and 180 parts
The component proportion of coarse powder with the D50 particle size range of 200-400 mu m is between 20-160 parts
D50 the component proportion of the fine magnesium hydroxide powder particles with the particle size range of 5-50 μm is 0-180 parts;
the component proportion of the aluminum hydroxide powder particles with the D50 particle size range of between 5 and 50 mu m is between 0 and 180 parts.
The inorganic flame retardant powder can be replaced by other powder fillers such as titanium dioxide, quartz sand, talcum powder and silicon dioxide according to the requirement in the mixing and pulping process, and the adding amount of the powder filler is generally not more than half of the total amount of the inorganic flame retardant powder. The powder replacement materials can provide a good effect of reducing the heat value of the material per unit weight, and the inorganic flame-retardant powder material can absorb the environmental heat value through the pyrolysis and oxidation of the inorganic flame-retardant powder material and still ensure that the whole fireproof core material reaches the A2-grade fireproof requirement.
The material proportion of the A2-grade fireproof core material provided by the above embodiments can be completely manufactured by matching with a flow line production process. Putting glue and powder which are weighed quantitatively into a stirrer, uniformly stirring the glue and the powder in a vacuum environment of the stirrer, conveying the glue and the powder to an extrusion roller for shaping and extruding, and controlling the width and the thickness of an extruded sheet respectively through the distance between baffle plates of the extrusion roller and the gap between the rollers. And (4) supporting and shaping the slurry by using non-woven fabrics up and down while the slurry enters the extrusion roller.
After the sheet is extruded, the core plate sequentially enters an oven to be baked under the transmission of a transmission mesh belt, and the water of the water-based emulsion is removed to gradually solidify to provide adhesive strength for the inorganic flame retardant powder particles.
And then, the fireproof core material finished product is shaped through two rolling mills and 9 ovens. The 1 st rolling mill is arranged between the No. 4 and No. 5 ovens, is a single-group rolling mill and mainly has the effect of leveling the surface of a core material; the 2 nd rolling mill is arranged between the 8 th oven and the 9 th oven and is a double-group roller rolling mill which compacts the core material through double-group continuous rolling, thereby playing the roles of increasing the compactness of the core material and improving the strength of the core material. Other implementations may be possible with the number of ovens actually used. When the number of the ovens is reduced, the linear speed of the transmission mesh belt is required to be correspondingly reduced so as to ensure that the sheet can be completely dried; when the number of ovens is increased, the line speed is generally increased correspondingly to achieve the same drying and setting effect. The rolling mill between the ovens can ensure the core material to be pressed by controlling the clearance between the upper roller and the lower roller, and plays the roles of leveling and compacting.
If the thickness of the finished core material is 3mm, the thickness gap of the extrusion roller can be generally set between 3.5mm and 3.6mm, certain shrinkage can occur in the actual baking process, the gap between the upper roller and the lower roller of the first rolling mill is set to be 3.1mm to 3.2mm, and the gap between the second rolling mill is set to be 3.0 mm.
After the core plate is discharged from the last oven, the surface temperature of the core plate is controlled to be 120-plus-130 ℃, then the surface film pasting can be further carried out through a film pasting machine according to the customer requirements, then the two sides of the fireproof core material are trimmed, and then the fireproof core material is wound through a constant-tension winding machine. The rolling requires the core material to keep a certain temperature, at least more than 50 ℃, so the cooling is not needed in the actual production.
The length of the 9-component oven can be selected to be 6 meters, and the actual baking time of the sheet in the oven can be changed according to the line speed. The specific linear speed can be set according to the temperature range of the oven, and the temperature of the corresponding oven and the time for getting in and out of the oven are correspondingly adjusted due to different thicknesses and widths of the sheets. Generally, when the thickness of the sheet is relatively small (for example, the thickness of the finished fireproof core material needs to be controlled within 3.0 mm), and the width is relatively narrow (for example, the width of the finished fireproof core material needs to be less than 1300mm), the linear speed of the transmission mesh belt can be correspondingly set to be increased to more than 2.5 m/min, and the temperature of each partitioned oven is relatively kept below 200 ℃. When the thickness of the finished fireproof core plate is more than or equal to 3.0mm and the width is more than 1300mm, the linear speed of the transmission mesh belt is generally set to be less than or equal to 2.5 m/min, and the temperature of most ovens in the subarea ovens needs to be set to be more than 200 ℃.
The temperature of each oven required by the fireproof core materials with different dimensions can be specifically shown in the temperature setting parameters in the following table.
| Core material specification | Baking oven | 1# | 2# | 3# | 4# | 5# | 6# | 7# | 8# | 9# | Line speed |
| 2.0*1280 | Set temperature | 175 | 177 | 164 | 135 | 145 | 142 | 155 | 160 | 154 | 2.5 m/min |
| 2.4*1140 | Set temperature | 185 | 185 | 170 | 142 | 145 | 143 | 158 | 162 | 160 | 2.7 m/min |
| 3.0*660 | Set temperature | 275 | 265 | 203 | 204 | 145 | 191 | 198 | 213 | 160 | 2.8 m/min |
| 3.0*1020 | Set temperature | 225 | 215 | 176 | 146 | 145 | 142 | 158 | 163 | 160 | 2.7 m/min |
| 3.0*1270 | Set temperature | 338 | 268 | 196 | 196 | 139 | 196 | 197 | 214 | 225 | 2.5 m/min |
| 3.0*1460 | Set temperature | 325 | 293 | 214 | 214 | 146 | 191 | 198 | 213 | 260 | 2.5 m/min |
| 3.0*1530 | Set temperature | 198 | 200 | 172 | 146 | 145 | 142 | 156 | 160 | 160 | 2 m/min |
| 3.1*1240 | Set temperature | 215 | 205 | 175 | 140 | 145 | 142 | 158 | 162 | 164 | 2.5 m/min |
| 3.3*1250 | Set temperature | 223 | 227 | 184 | 153 | 147 | 146 | 160 | 168 | 175 | 2.5 m/min |
| 3.4*1280 | Set temperature | 326 | 282 | 206 | 205 | 146 | 146 | 191 | 198 | 213 | 2 m/min |
| 3.5*1220 | Set temperature | 223 | 245 | 189 | 158 | 149 | 146 | 159 | 167 | 173 | 2.5 m/min |
| 3.8*1250 | Set temperature | 213 | 218 | 188 | 155 | 148 | 145 | 161 | 164 | 176 | 2 m/min |
| 5.0*1790 | Set temperature | 245 | 215 | 172 | 144 | 145 | 142 | 158 | 163 | 165 | 1.5 m/min |
| 5.0*1800 | Set temperature | 222 | 211 | 163 | 142 | 143 | 142 | 150 | 156 | 165 | 1.5 m/min |
Comparative example a
The inorganic flame-retardant powder material in the above example 4 is adjusted to the following components in parts by weight:
200 parts of an inorganic flame retardant consisting of 10 parts of fine particle size calcium carbonate powder, 10 parts of fine particle size aluminum hydroxide powder, 10 parts of fine particle size magnesium hydroxide powder and 170 parts of coarse particle size calcium carbonate powder;
then putting the slurry prepared from the inorganic flame retardant powder particles into extrusion molding equipment to prepare a sheet;
and then, the obtained sheet is heated and baked by 9 ovens successively according to the same temperature setting as that of the embodiment 4, the water content in the aqueous emulsion in the sheet is evaporated, and the sheet is rolled to obtain the finished fireproof core material.
The fireproof core material obtained by the method is placed in a furnace to be tested for the combustion performance of the building material according to GB/T14402 and GB/T20284 test methods, and the following performances can be achieved by the test results:
the performance data measured by the experiment obviously shows that in the comparative example, the proportion of the fine particle flame-retardant powder is too small, the proportion of the coarse particle powder is too high, and the organic matter content of the emulsion in unit weight of the core material is increased, so that the heat value exceeds the standard value and cannot reach the A2-grade fireproof index specified in GB 8624-2012. Meanwhile, the addition of a large amount of coarse particles influences the processing fluidity and the flatness of the core material of the slurry, and the slurry is not easy to process and form.
Comparative example b
The component proportion of the inorganic flame retardant in the above example 5 in parts by weight is adjusted as follows:
200 parts of inorganic flame-retardant powder consisting of 130 parts of fine-particle-size calcium carbonate powder, 30 parts of fine-particle aluminum hydroxide powder, 30 parts of fine-particle magnesium hydroxide powder and 10 parts of coarse-particle-size calcium carbonate powder;
then putting the slurry prepared from the inorganic flame retardant powder particles into extrusion molding equipment to prepare a sheet;
and then, the obtained sheet is heated and baked by 9 ovens successively according to the same temperature setting as that of the example 5, the water content in the aqueous emulsion in the sheet is evaporated, and the sheet is rolled to obtain the finished fireproof core material.
The fireproof core material obtained by the method is placed in a furnace to be tested for the combustion performance of the building material according to GB/T14402 and GB/T20284 test methods, and the following performances can be achieved by the test results:
the performance data measured by the experiment obviously shows that in the comparative example, the volume of the powder of the unit weight of the core material is increased due to the fact that the proportion of the coarse particle size powder is too small, the heat value test exceeds the standard value, and the A2-grade fireproof index specified in GB 8624-2012 cannot be reached. Meanwhile, the addition of a large amount of fine powder makes the slurry become very viscous, which is not beneficial to extrusion processing and influences continuous production.
Comparative example c
The component proportions of the inorganic flame retardant in the above example 6 in parts by weight were adjusted to:
200 parts of inorganic flame-retardant powder consisting of 50 parts of fine-particle aluminum hydroxide powder, 50 parts of fine-particle magnesium hydroxide powder, 90 parts of fine-particle calcium carbonate powder and 10 parts of coarse-particle calcium carbonate powder;
then putting the inorganic flame retardant powder particles and slurry prepared from 40 parts of VAE emulsion into extrusion molding equipment to prepare a sheet;
and then, the obtained sheet is heated and baked by 9 ovens successively according to the same temperature setting as that of the example 6, the water content in the aqueous emulsion in the sheet is evaporated, and the sheet is rolled to obtain the finished fireproof core material.
The fireproof core material obtained by the method is placed in a furnace to be tested for the combustion performance of the building material according to GB/T14402 and GB/T20284 test methods, and the following performances can be achieved by the test results:
the performance data measured by the above experiments obviously shows that in the comparative example, because the coarse-particle flame-retardant powder material matched in the water-soluble emulsion is too little to meet the index requirement of the processability, the combustion heat value of the water-soluble emulsion cannot meet the index of A2-grade fire-proof grade specified by GB 8624-2012 standard, and the water-soluble emulsion cannot be used for producing and manufacturing the fire-proof plate.
Comparative example d
The component proportions of the inorganic flame retardant in the above example 7 in parts by weight were adjusted to:
200 parts of inorganic flame-retardant powder consisting of 10 parts of fine-particle aluminum hydroxide powder, 10 parts of fine-particle magnesium hydroxide powder, 10 parts of fine-particle calcium carbonate powder and 170 parts of coarse-particle calcium carbonate powder;
then putting the inorganic flame retardant powder particles and slurry prepared from 40 parts of VAE emulsion into extrusion molding equipment to prepare a sheet;
the obtained sheet was subjected to heat baking in 9 ovens successively at the same temperature setting as in example 7 to evaporate water contained in the aqueous emulsion in the sheet, and the sheet was rolled to obtain a fireproof core material.
The fireproof core material obtained by the method is placed in a furnace to be tested for the combustion performance of the building material according to GB/T14402 and GB/T20284 test methods, and the following performances can be achieved by the test results:
the performance data measured by the above experiments clearly show that, in the comparative example, because the water-soluble emulsion is excessively mixed with coarse-particle flame-retardant powder, the water-soluble emulsion cannot meet the index requirement of the processing performance, and the combustion heat value of the water-soluble emulsion cannot meet the index of the A2-grade fire-proof grade specified by the GB 8624 and 2012 standards, and the water-soluble emulsion cannot be used for producing and manufacturing the fire-proof plate.
The above are merely embodiments of the present application, and the description is specific and detailed, but not construed as limiting the scope of the present application. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the concept of the present application, which falls within the protection scope of the present application.
Claims (13)
1. A fireproof core material is characterized by comprising 17.5-22.5 parts of aqueous emulsion cured substance and 200 parts of powder material in parts by weight;
wherein the powder material comprises calcium carbonate powder particles.
2. The fire retardant core material of claim 1 wherein the aqueous emulsion cure is any one or a combination of styrene-acrylic, vinyl acetate-ethylene copolymer, acrylic acid, vinyl acetate-acrylic;
the calcium carbonate powder particles are heavy calcium carbonate powder or calcite mineral powder.
3. A fire retardant core material as claimed in claim 2, characterised in that the powder further comprises: any one or more powder particles of aluminum hydroxide, magnesium hydroxide, titanium dioxide, quartz sand and silicon dioxide.
4. A fire-resistant core material according to claim 3, characterised in that the aluminium hydroxide, magnesium hydroxide in the powder has a D50 particle size in the range 5-50 μm, the weight of which is 0-90% of the total mass of the powder;
the maximum range of the rest of the powder particles is not more than 1000 μm;
and the powder particles with the D50 particle size range of 5-50 mu m account for 20-90% of the total mass of the powder.
5. A fire retardant core material according to claim 4 wherein the calcium carbonate powder particles comprise coarse particle size calcium carbonate powder and fine particle size calcium carbonate powder;
wherein the D50 particle size range of the fine particle size calcium carbonate powder is between 5 and 50 mu m, and the weight of the fine particle size calcium carbonate powder accounts for 20 to 90 percent of the total weight of the powder;
the D50 particle size range of the coarse particle size calcium carbonate powder is between 100 and 400 mu m, and the weight of the coarse particle size calcium carbonate powder accounts for 10 to 80 percent of the total weight of the powder.
6. A fire retardant core material as claimed in claim 3, characterised in that said fluff comprises coarse and fine particle fluff;
the fine particle powder is any one or a plurality of powder particles of aluminum hydroxide, magnesium hydroxide, quartz sand, silicon dioxide and calcium carbonate, the D50 particle size range is between 5 and 50 mu m, and the weight of the D50 particle accounts for 20 to 90 percent of the total weight of the powder;
the coarse powder is any one or more powder particles of calcium carbonate, aluminum hydroxide, magnesium hydroxide, quartz sand and silicon dioxide, the D50 particle size range is between 100 and 400 mu m, and the weight of the D50 particle size range accounts for 10 to 80 percent of the total weight of the powder.
7. A fire-resistant core material as claimed in claim 4, comprising, in parts by weight, 17.5-22.5 parts of aqueous emulsion condensate, 60 parts of aluminium hydroxide powder particles, 40 parts of magnesium hydroxide powder particles and 100 parts of calcium carbonate powder particles, wherein 40 parts of calcium carbonate powder particles have a D50 particle size in the range 5-50 μm.
8. A fire-resistant core material as claimed in claim 7, characterised in that the aluminium hydroxide powder particles have a D50 particle size of 10-15 μm; the D50 particle size of the magnesium hydroxide powder particles is 10-20 μm; the maximum particle size of the calcium carbonate powder particles does not exceed 1000 μm.
9. A method for manufacturing a fireproof core material is characterized by comprising the following steps:
mixing 35-45 parts of aqueous emulsion and 200 parts of powder in parts by weight under a vacuum condition, and stirring to prepare slurry;
putting the slurry into extrusion molding equipment to prepare a sheet;
heating and baking the sheet material, applying pressure, and evaporating water contained in the sheet material to obtain the fireproof core material;
wherein the powder material comprises heavy calcium carbonate powder.
10. A method of manufacturing a fire retardant core material as claimed in claim 9 wherein the aqueous emulsion is any one of or a mixture of a styrene acrylic emulsion, a VAE emulsion, an acrylic emulsion or an acrylic emulsion.
11. A method of manufacturing a fire retardant core material as claimed in claim 10 wherein no more than 100 parts of any one or a combination of the following powder particles are added during the mixing and stirring under vacuum to form a slurry: aluminum hydroxide, magnesium hydroxide, titanium dioxide, quartz sand, silicon dioxide and quartz sand.
12. The method of manufacturing a flameproof core material according to claim 11, wherein the aluminum hydroxide powder particles have a D50 particle size of 14 μm; the D50 particle size of the magnesium hydroxide powder particles is 15 μm; the maximum particle size of the calcium carbonate powder particles does not exceed 1000 μm.
13. A method of manufacturing a fire retardant core according to claims 9 to 12 wherein the step of applying heat and pressure to the sheet material comprises:
the sheets are sequentially fed into a plurality of ovens set at a temperature between 120 ℃ and 330 ℃, and between the ovens, the sheets are flattened and compacted to the required size of the fireproof core material by using at least 2 rolling mills.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115838257A (en) * | 2022-12-12 | 2023-03-24 | 大连亚泰科技新材料股份有限公司 | A2-grade fireproof material prepared from brucite tailings and preparation method thereof |
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| JP2000153570A (en) * | 1998-11-19 | 2000-06-06 | Yamamoto Yogyo Kako Kk | Decorative sheet for surface finish of building |
| CN103562281A (en) * | 2011-05-31 | 2014-02-05 | 株式会社Ｔｂｍ | Method for producing inorganic substance powder highly-oriented thin film sheet |
| CN103953169A (en) * | 2014-03-18 | 2014-07-30 | 江苏协诚科技发展有限公司 | A2 level fireproof core board and manufacturing method thereof |
| CN106715082A (en) * | 2014-09-29 | 2017-05-24 | 株式会社Ｔｂｍ | Precursor of sheet for vacuum molding use, sheet for vacuum molding use, method for producing the sheet, and method for producing molded article |
| CN106795052A (en) * | 2016-09-05 | 2017-05-31 | 江苏阿路美格新材料股份有限公司 | Fire prevention core volume and its manufacture method |
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| JP2000153570A (en) * | 1998-11-19 | 2000-06-06 | Yamamoto Yogyo Kako Kk | Decorative sheet for surface finish of building |
| CN103562281A (en) * | 2011-05-31 | 2014-02-05 | 株式会社Ｔｂｍ | Method for producing inorganic substance powder highly-oriented thin film sheet |
| CN103953169A (en) * | 2014-03-18 | 2014-07-30 | 江苏协诚科技发展有限公司 | A2 level fireproof core board and manufacturing method thereof |
| CN106715082A (en) * | 2014-09-29 | 2017-05-24 | 株式会社Ｔｂｍ | Precursor of sheet for vacuum molding use, sheet for vacuum molding use, method for producing the sheet, and method for producing molded article |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115838257A (en) * | 2022-12-12 | 2023-03-24 | 大连亚泰科技新材料股份有限公司 | A2-grade fireproof material prepared from brucite tailings and preparation method thereof |
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