Active-passive integrated fireproof insulation board and preparation method thereof

Abstract

The invention relates to an active and passive integrated fireproof insulation board and a preparation method thereof. The active and passive integrated fireproof insulation board comprises n passive fireproof layers and n or n + 1 active fireproof layers, the passive fireproof layer and the active fireproof layer are laminated into a whole; the passive fireproof layer comprises inorganic fiber felt and aerogel; the aerogel is obtained by curing an adhesive aerogel stock solution, and the stock solution comprises the following components in parts by mass: 1000-4000 parts of silica sol, 50-150 parts of silicate, 10-50 parts of a phosphate adhesive, 5-20 parts of quick lime, 5-50 parts of titanium dioxide, 10-50 parts of calcium stearate, 5-50 parts of a hydrophobic modifier, 5-50 parts of an acid-base regulator and 1000-4000 parts of a solvent; the active fireproof layer is at least one of inorganic fireproof plates such as a gypsum fireproof plate and the like which can actively consume energy after being heated and decomposed. The problems that an existing fireproof insulation board is high in organic matter content, poor in flame retardance and high in hygroscopicity, and the thermal insulation performance and safety are obviously reduced after the fireproof insulation board is used are solved.

Description

Technical Field

[0001] The invention relates to the technical field of building materials, and in particular to an active and passive integrated fireproof insulation board and a preparation method thereof. Background Art

[0002] Fireproof and thermal insulation integrated panels are a type of building material that combines the functions of fire prevention and thermal insulation. They are usually used on the exterior walls, interior walls, roofs and other parts of buildings. They are designed to improve the safety and energy efficiency of buildings. When a fire occurs, they can delay the spread of fire, buy time for personnel evacuation, reduce property losses, and effectively reduce heat exchange inside and outside the building, thereby reducing the energy consumption of air conditioning and heating systems, and achieving the goal of energy conservation and emission reduction. Fireproof and thermal insulation integrated panels usually include a multi-layer structure, including a fire-resistant layer made of non-combustible or flame-retardant materials, an insulation layer made of thermal insulation phase change materials, and other functional layers. Current fireproof and thermal insulation integrated panels have the following problems:

[0003] (1) Since organic adhesives are used to bond different functional layers, the fireproof performance of the fireproof and thermal insulation integrated board is difficult to reach Class A non-combustibility. In addition, the organic components in the fireproof and thermal insulation integrated board will release a large amount of toxic and harmful gases in a high temperature environment or when burned, making the fire environment worse, increasing the difficulty of personnel evacuation, and causing environmental pollution.

[0004] (2) Since organic materials such as polystyrene boards and polystyrene are used as phase change materials in the fireproof and thermal insulation integrated panels, the fireproof performance of the fireproof and thermal insulation integrated panels is insufficient, and there are huge fire safety hazards.

[0005] (3) The use of porous inorganic fiber materials such as rock wool and perlite as thermal insulation materials in the fireproof and thermal insulation integrated board results in the fireproof and thermal insulation integrated board having high water absorption and poor weather resistance. Water absorption and moisture will cause the structural safety and service life of the fireproof and thermal insulation integrated board to be seriously reduced, and it will not be able to withstand the influence of severe weather and environmental factors. Water absorption and moisture will also cause the fireproof and thermal insulation effect of the fireproof and thermal insulation integrated board to be reduced.

[0006] Chinese patent application CN115503300A discloses a composite rock wool fireproof thermal insulation decorative integrated board, including a rock wool thermal insulation layer, a surface treatment layer and a finishing layer arranged in sequence from top to bottom, the surface treatment layer is composed of a surface treatment agent, the surface treatment agent includes BC-413 pure acrylic emulsion, VAE705 emulsion and water; the rock wool thermal insulation layer is composed of rock wool felt and silica aerogel slurry; the finishing layer is composed of silicate cement, fine sand, stone powder, water reducer, sodium polynaphthalene formaldehyde sulfonate, curing agent and water. This scheme increases the bonding strength of the rock wool composite thermal insulation board through the surface treatment layer, improves the tensile properties of the rock wool thermal insulation layer and the finishing layer and the acid and alkali resistance of the board; the rock wool thermal insulation layer is obtained by compounding the rock wool felt with silica aerogel, and the thermal insulation, heat insulation and fireproof performance is improved; wherein the silica aerogel is hydrophobically treated to reduce its hygroscopicity. This solution overcomes the first two shortcomings of the fireproof and thermal insulation integrated board, but does not do any processing on the rock wool therein and still uses a lot of organic components, which greatly reduces the fireproof performance and environmental protection of the fireproof and thermal insulation board. In addition, the problems of high water absorption and poor weather resistance of rock wool have not been effectively solved, affecting the long-term use effect and safety.

[0007] Therefore, it is necessary to improve the existing technology to obtain a fireproof and heat-insulating integrated board with high fire safety performance, good heat preservation effect and low moisture absorption. Summary of the invention

[0008] 1. Technical issues to be resolved

[0009] In view of the above-mentioned shortcomings and deficiencies of the prior art, the present invention provides an active and passive integrated fireproof and thermal insulation board, which solves the problems existing in the prior art of high organic content in the fireproof and thermal insulation integrated board, insufficient fireproof performance and environmental protection of the board, high hygroscopicity, and decreased performance and safety after long-term use.

[0010] (II) Technical solution

[0011] In order to achieve the above object, the main technical solutions adopted by the present invention include:

[0012] In a first aspect, the present invention provides an active and passive integrated fireproof insulation board, comprising: n passive fireproof layers and n or n+1 active fireproof layers, wherein n is a natural number; the passive fireproof layers and the active fireproof layers are superimposed on each other as a whole;

[0013] The passive fireproof layer comprises an inorganic fiber felt as a porous skeleton material and aerogel filled in the pores of the skeleton material and coated on the outside of the skeleton material; the aerogel is obtained by curing and drying an adhesive aerogel stock solution, and the adhesive aerogel stock solution comprises, by mass, 1000-4000 parts of silica sol, 50-150 parts of soluble silicate, 10-50 parts of phosphate adhesive, 5-20 parts of quicklime, 5-50 parts of titanium dioxide, 10-50 parts of calcium stearate, 5-50 parts of hydrophobic modifier, 10-50 parts of acid-base regulator and 1000-4000 parts of solvent.

[0014] According to a preferred embodiment of the present invention, the active fireproof layer can be at least one of inorganic fireproof boards that actively consume energy when decomposed by heat, such as gypsum fireproof board, glass magnesium fireproof board, cement fiberboard and silicate fiberboard.

[0015] According to a preferred embodiment of the present invention, the inorganic fiber felt can be a fiber felt composed of one or a mixture of two or more of mullite fiber felt, aluminum silicate fiber felt, glass fiber felt, and alumina fiber felt.

[0016] According to a preferred embodiment of the present invention, in the passive fire protection layer, the mass proportion of the inorganic fiber felt is 70-95%, preferably 85-90%; the rest is aerogel.

[0017] According to a preferred embodiment of the present invention, the phosphate adhesive can be at least one of aluminum dihydrogen phosphate, magnesium phosphate and zinc phosphate. These phosphate adhesives have both adhesive and flame retardant effects. Among them, aluminum dihydrogen phosphate is preferred, which has strong high temperature resistance and flame retardancy.

[0018] According to a preferred embodiment of the present invention, the soluble silicate may be at least one of lithium silicate, sodium silicate and potassium silicate. These silicates are both pH regulators and inorganic adhesives, and can also be used as catalysts to catalyze and accelerate the polycondensation reaction of sol precursors (such as silica sol) to form a more uniform and stable sol system, thereby obtaining a better quality aerogel; they can also change the structure of the silicon-oxygen skeleton to a certain extent. They mainly enhance the network structure by introducing additional silicon-oxygen bonds, thereby improving the mechanical strength and thermal stability of the aerogel. In addition, soluble silicates can control the density and porosity of the aerogel, and by changing the ratio, aerogels with different pore size distributions and specific surface areas can be prepared.

[0019] According to a preferred embodiment of the present invention, the silica sol is a commercially available silica sol product with a solid content greater than 25%.

[0020] According to a preferred embodiment of the present invention, the hydrophobic modifier can be at least one of polydimethylsiloxane, trimethylchlorosilane, hexamethyldisilazane, hexamethyldisiloxane, methyltrimethoxysilane, methyltriethoxysilane, dimethyldimethoxysilane, and dimethyldiethoxysilane; the acid-base regulator can be at least one of acetic acid, hydrochloric acid, phosphoric acid, ammonia water, ammonium carbonate, and ammonium bicarbonate; and the solvent is water, methanol, or ethanol, preferably water.

[0021] According to a preferred embodiment of the present invention, in the adhesive aerogel stock solution, the silica sol is preferably 1000-2000 parts, 2000-3000 parts, 3000-3500 parts or 3500-4000 parts; the soluble silicate is preferably 50-70 parts, 70-90 parts, 90-110 parts, 110-130 parts or 130-150 parts; the phosphate adhesive is preferably 10-20 parts, 20-30 parts, 30-40 parts or 40-50 parts; the quicklime is preferably 5-8 parts, 8-12 parts, 1 2-15 parts, 15-17 parts or 17-20 parts; titanium dioxide is preferably 5-15 parts, 15-30 parts, 30-40 parts or 40-50 parts; calcium stearate is preferably 10-20 parts, 20-30 parts, 30-40 parts or 40-50 parts; hydrophobic modifier is preferably 5-15 parts, 15-30 parts, 30-40 parts or 40-50 parts; acid-base regulator is preferably 10-20 parts, 20-30 parts, 30-40 parts or 40-50 parts; the solvent is water, preferably 2000-4000 parts.

[0022] According to a preferred embodiment of the present invention, 10-30 parts by mass of phase change microcapsule material is further added to the adhesive aerogel stock solution, the shell layer of the phase change microcapsule material is silicon dioxide, melamine-formaldehyde resin, polyurea-polyurethane, or polyamide, and the phase change core material of the phase change microcapsule material is at least one of paraffin, alkanes, fatty acids and their esters, sodium sulfate dodecahydrate, calcium chloride hexahydrate, polyethylene glycol, and neopentyl glycol; wherein, polyurea-polyurethane or polyamide can further improve the flame retardant properties by introducing monomers or additives containing flame retardant elements such as phosphorus, halogens, and nitrogen.

[0023] Preferably, the shell layer of the phase change microcapsule material is silicon dioxide, which has good compatibility with silicon aerogel and is an inorganic material with good flame retardancy; the second choice is melamine-formaldehyde resin, which is an organic polymer but can expand when heated and form a carbon layer to provide additional protection, so it also has a certain flame retardancy. When silicon dioxide is used as the shell material of the phase change microcapsule, the phase change core material can be wrapped by the sol-gel method.

[0024] In a second aspect, the present invention further provides a method for preparing an active and passive integrated fireproof insulation board, comprising the following steps:

[0025] S1: preparing the raw materials according to the composition of the adhesive aerogel stock solution in the above scheme, dividing the solvent into two parts, adding soluble silicate, quicklime and titanium dioxide to one part of the solvent and stirring, to obtain a mixed solution 1; adding silica sol and phosphate adhesive to the other part of the solvent and stirring, to obtain a mixed solution 2;

[0026] S2: Mixing the mixed solution 1 and the mixed solution 2 and stirring them, adding an acid-base regulator to adjust the pH to 6-7 during the stirring process to obtain a mixed solution 3;

[0027] S3: adding calcium stearate and a hydrophobic modifier to the mixed solution 3 and stirring to obtain an adhesive aerogel stock solution;

[0028] S4: impregnating the inorganic fiber felt with the adhesive aerogel stock solution until it is fully impregnated to obtain an inorganic fiber felt impregnated with the aerogel stock solution;

[0029] S5: Laying the inorganic fiber felt impregnated with the aerogel stock solution on the active fireproof layer to obtain an unshaped fireproof insulation board;

[0030] S6: The unshaped fireproof and thermal insulation board is first subjected to pressurized gel shaping and curing, and then subjected to microwave drying and aging treatment to obtain an active and passive integrated fireproof and thermal insulation board.

[0031] According to a preferred embodiment of the present invention, in step S2, during the mixing and stirring of the mixed solution 1 and the mixed solution 2, an acid-base regulator is added to adjust the pH to 6. Under weakly acidic conditions, the silica sol has better stability, slower reaction rate, and better pore structure adjustability.

[0032] Preferably, the stirring speed in S1 is low-speed stirring of 100-800 rpm, preferably using about 1 / 2 of the total amount of solvent each time; the stirring speed in S2 is high-speed stirring of 1500-2000 rpm; and the stirring speed in S3 is low-speed stirring of 100-800 rpm.

[0033] According to a preferred embodiment of the present invention, in step S3, phase change microcapsule material may be added together with calcium stearate.

[0034] According to a preferred embodiment of the present invention, in step S4, before the inorganic fiber felt is impregnated, the inorganic fiber felt is dried to remove moisture from the inorganic fiber felt so that the inorganic fiber felt can fully absorb the adhesive aerogel stock solution prepared in the above step.

[0035] According to a preferred embodiment of the present invention, in step S6, the conditions for pressurized gel shaping and curing are: maintaining the pressure at 2-5MPa and the temperature at 30-50°C for curing; the conditions for microwave drying and aging treatment are: drying and aging for 1-30min in the microwave band of 1000-2500MHz frequency and 50-100°C.

[0036] (III) Beneficial effects

[0037] 1. The active and passive integrated fireproof insulation board of the present invention does not use organic adhesives between the active fireproof layer and the passive fireproof layer. Compared with the prior art, the fireproof insulation integrated board of the present invention has lower organic matter content and higher fireproof ability. The fire resistance limit time of the fireproof insulation integrated board can reach more than 1.5h, and can reach non-combustible grade above A2.

[0038] 2. Since the passive fire protection layer of the present invention adopts a composite structure of aerogel and inorganic fiber felt, and a phosphate adhesive (preferably aluminum dihydrogen phosphate) and titanium dioxide are added to the aerogel, the phosphate adhesive is an inorganic adhesive, which not only has good fire resistance but also has good adhesion. Quicklime promotes the hydrolysis of silica sol in the passive fire protection layer and enhances the strength of the aerogel, while enhancing the bonding strength between the aerogel and the fiber, and between the passive fire protection layer and the active fire protection layer.

[0039] By adding phosphate adhesive, the aerogel stock solution has good adhesion, so that the aerogel can be firmly bonded to the inorganic fiber felt to improve the strength of the insulation board. The inorganic fiber felt impregnated with the aerogel stock solution and the active fire protection layer can be well combined into an integrated structure under pressure treatment (2-5MPa), avoiding stratification and improving durability.

[0040] 3. The present invention also increases the hydrophobicity of the fireproof and heat-insulating integrated board by adding a hydrophobic modifier to the passive fireproof layer. Compared with the prior art, the 24h water absorption rate of the fireproof and heat-insulating board of the present invention is reduced from 70% to 4%. Since the hydrophobic modifier is added to the aerogel stock solution, the inorganic fiber felt is also hydrophobically modified when it is impregnated and coated. Compared with the prior art, the hygroscopicity of the inorganic fiber felt can be greatly reduced, the weather resistance of the heat-insulating board can be improved, and the heat-insulating board can be prevented from being peeled off from the building due to excessive weight after absorbing moisture, thereby improving the safety of use.

[0041] 4. The present invention significantly improves the fire resistance limit of the fireproof and heat-insulating integrated board by synergizing the active fireproofing principle that the active fireproofing layer undergoes chemical reactions under fire to absorb heat and release water vapor, and the passive fireproofing principle that the low thermal conductivity of the passive fireproofing layer isolates heat. The active and passive integrated fireproof and heat-insulating board with a sandwich structure (with an aerogel layer reinforced by inorganic fiber felt in the middle) has a fire resistance limit that is more than 30% higher than that of a single-layer active fireproof board of the same thickness. During the fire prevention period, the temperature of the platform period of the temperature rise curve on the back-fire surface is reduced by 0-30°C, and the equivalent thermal conductivity can reach below 0.09W / (mK).

[0042] 5. Since the present invention introduces a large amount of aerogel and inorganic fiber into the fireproof insulation board, while meeting the structural strength, the equivalent density of the fireproof insulation board of the present invention is significantly reduced, and it has the characteristics of light weight and high strength, and is suitable for use in steel structure buildings and prefabricated buildings. The insulation board can be treated with a decorative layer on the surface of the active fireproof layer as needed to improve the fireproof and heat-insulating performance and decorativeness.

[0043] 6. Furthermore, in some embodiments of the present invention, a small amount of phase change microcapsule material is added to the aerogel stock solution to enhance the active temperature regulation function of the insulation board, achieve heat insulation / cold insulation, reduce indoor heat / cold loss, reduce building energy loss, and achieve energy saving. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 This is the active and passive integrated fireproof insulation board of Example 1.

[0045] Figure 2 This is the active and passive integrated fireproof insulation board of Example 4.

[0046] Figure 3 It is the temperature curve of the fire-exposed surface and the temperature curve of the non-fired surface of the fireproof insulation board.

[0047] Figure 4 This is the temperature curve of the back-fire surface of the fireproof insulation board.

[0048] Figure 5 This is the state of the active and passive integrated fireproof insulation board of Example 1 in the combustion test.

[0049] Figure 6 This is the back side of the active and passive integrated fireproof insulation board of Example 1 after the combustion test is completed. DETAILED DESCRIPTION

[0050] In order to better explain the present invention and facilitate understanding, the present invention is described in detail below through specific implementation modes in conjunction with the accompanying drawings.

[0051] The present invention proposes an active and passive integrated fireproof insulation board, comprising n passive fireproof layers and n or n+1 active fireproof layers, n passive fireproof layers and n or n+1 active fireproof layers, wherein n is a natural number; the passive fireproof layers and the active fireproof layers are superimposed on each other as a whole;

[0052] The passive fireproof layer comprises an inorganic fiber felt as a porous skeleton material and aerogel filled in the pores of the skeleton material and coated on the outside of the skeleton material; the aerogel is obtained by curing and drying an adhesive aerogel stock solution, and the adhesive aerogel stock solution comprises, by mass, 1000-4000 parts of silica sol, 50-150 parts of soluble silicate, 10-50 parts of phosphate adhesive, 5-20 parts of quicklime, 5-50 parts of titanium dioxide, 10-50 parts of calcium stearate, 5-50 parts of hydrophobic modifier, 5-50 parts of acid-base regulator and 1000-4000 parts of solvent.

[0053] Among them, aerogel is a porous and efficient thermal insulation material, and its extremely high porosity leads to its low density, low thermal conductivity and high specific surface area. The adhesive aerogel stock solution prepared by the present invention can further improve the fire resistance, temperature regulation ability, corrosion resistance, hydrophobicity, bonding ability and structural strength of aerogel.

[0054] The passive fireproof layer and the active fireproof layer of the present invention are superimposed, and the fire resistance limit of the fireproof and heat-insulating integrated board is significantly improved by synergistically exerting the active fireproof effect of the active fireproof layer decomposing under fire, absorbing heat and releasing water vapor during decomposition, and the passive fireproof effect of the passive fireproof layer's low thermal conductivity and heat insulation. The three-layer composite fireproof and heat-insulating board prepared by arranging an aerogel layer reinforced by inorganic fiber felt in the middle and arranging an active fireproof layer on the top and bottom has a fireproof limit of more than 30% higher than that of an active fireproof board of the same thickness. During the fire prevention period, the temperature of the platform period of the temperature rise curve on the back-fire surface is reduced by 0-30°C.

[0055] Preferably, the active fireproof layer can be at least one of gypsum fireproof board, glass magnesium fireproof board, cement fiberboard, silicate fiberboard and inorganic composite board. A fireproof board commonly used on the market that absorbs heat and releases water vapor when decomposed can be used, and the thickness of the active fireproof layer is 10-150mm.

[0056] Preferably, the inorganic fiber felt can be one of mullite fiber felt, aluminum silicate fiber felt, glass fiber felt, and alumina fiber felt, or a fiber felt composed of a mixture of two or more thereof. Common inorganic fiber felts on the market can be used. Preferably, the thickness of the inorganic fiber felt is 5-30 mm.

[0057] Preferably, in the passive fire protection layer, the inorganic fiber felt accounts for 70-95% by mass, preferably 85-90%; the rest is aerogel; thereby, the structural strength of the passive fire protection layer can be greatly improved, making it easier to assemble it in the building wall with metal parts such as screws.

[0058] Preferably, the silica sol is a commercially available product with a solid content of more than 25%. The commercially available silica sol product is a dispersion containing nano-sized silica particles uniformly distributed in water or an organic solvent.

[0059] Preferably, the phosphate adhesive can be at least one of aluminum dihydrogen phosphate, magnesium phosphate and zinc phosphate. These phosphate adhesives have both adhesive and flame retardant effects. Among them, aluminum dihydrogen phosphate is preferred, which has strong high temperature resistance and flame retardancy, and can also be used as a catalyst to promote the hydrolysis of silica sol in the aerogel raw material and enhance the strength of the aerogel. The phosphate adhesive can promote the adhesion of the aerogel stock solution, so that the aerogel stock solution can be well adhered to the inorganic fiber felt, and can also make the inorganic fiber felt impregnated with the aerogel stock solution firmly bonded to the active fireproof layer to form an integrated insulation board.

[0060] Preferably, the soluble silicate may be at least one of lithium silicate, sodium silicate and potassium silicate. These soluble silicates can change the structure of the silicon-oxygen skeleton. They mainly enhance the network structure by introducing additional silicon-oxygen bonds, thereby improving the mechanical strength and thermal stability of the aerogel. In addition, the soluble silicate can control the density and porosity of the aerogel, and by changing the ratio, aerogels with different pore size distributions and specific surface areas can be prepared.

[0061] Preferably, metal oxides such as quicklime and titanium dioxide are added to the aerogel stock solution to form an inorganic adhesive together with aluminum dihydrogen phosphate, which can promote the hydrolysis of silica sol during the preparation of the passive fire protection layer and enhance the strength of the aerogel, improve the durability of the connection between the passive fire protection layer and the active fire protection layer, and prevent peeling at the connection between the passive fire protection layer and the active fire protection layer after long-term use.

[0062] Preferably, calcium stearate added to the aerogel stock solution can be used to modify the surface of the aerogel particles to impart hydrophobicity; help prevent the agglomeration of nano-sized particles, thereby improving the stability of the aerogel stock solution to obtain a uniform aerogel structure, to avoid the formation of larger pores or uneven density distribution, and to enhance the mechanical strength, toughness and high temperature stability of the aerogel. Calcium stearate can also be used as a lubricant to improve mixing uniformity and fluidity, making the processing process smoother.

[0063] Preferably, a hydrophobic modifier is added to the aerogel stock solution to change the water absorption of the aerogel, thereby preventing the pores in the aerogel from absorbing water, causing the weight of the insulation board to increase, thereby creating a safety hazard.

[0064] Preferably, the acid-base regulator can be at least one of acetic acid, hydrochloric acid, phosphoric acid, sulfuric acid, ammonia water, ammonium carbonate, and ammonium bicarbonate. The acid-base regulator is used to provide a weakly acidic environment to properly stabilize the aerogel stock solution and avoid problems such as low aerogel strength and uneven pore size / structure distribution caused by the formation of aerogel too fast.

[0065] Preferably, 10-30 parts by mass of phase change microcapsule material is also added to the adhesive aerogel stock solution, the shell layer of the phase change microcapsule material is silica, melamine-formaldehyde resin, polyurea-polyurethane, or polyamide, and the phase change core material of the phase change microcapsule material is at least one of paraffin, alkanes, fatty acids and their esters, sodium sulfate dodecahydrate, calcium chloride hexahydrate, polyethylene glycol, and neopentyl glycol; wherein the silica shell layer and melamine-formaldehyde resin themselves are flame retardant; and polyurea-polyurethane or polyamide can further improve the flame retardant properties by introducing monomers or additives containing flame retardant elements such as phosphorus, halogens, and nitrogen.

[0066] More preferably, the shell layer of the phase change microcapsule material is silicon dioxide, which has good compatibility with silica aerogel. When silicon dioxide is used as the shell layer material of the phase change microcapsule, the phase change core material can be wrapped by the sol-gel method, and the preparation can be carried out according to the existing technology.

[0067] The present invention also provides a method for preparing an active and passive integrated fireproof and thermal insulation board, comprising:

[0068] S1: preparing the raw materials according to the composition of the adhesive aerogel stock solution in the above scheme, dividing the solvent into two parts, adding soluble silicate, quicklime and titanium dioxide to one part of the solvent and stirring, to obtain a mixed solution 1; adding silica sol and phosphate adhesive to the other part of the solvent and stirring, to obtain a mixed solution 2;

[0069] S2: Mixing the mixed solution 1 and the mixed solution 2 and stirring them, adding an acid-base regulator to adjust the pH to 6-7 during the stirring process to obtain a mixed solution 3;

[0070] S3: adding calcium stearate and a hydrophobic modifier to the mixed solution 3 and stirring to obtain an adhesive aerogel stock solution;

[0071] S4: impregnating the inorganic fiber felt with the adhesive aerogel stock solution until it is fully impregnated to obtain an inorganic fiber felt impregnated with the aerogel stock solution;

[0072] S5: Laying the inorganic fiber felt impregnated with the aerogel stock solution on the active fireproof layer to obtain an unshaped fireproof insulation board;

[0073] S6: The unshaped fireproof and thermal insulation board is first subjected to pressurized gel shaping and curing, and then subjected to microwave drying and aging treatment to obtain an active and passive integrated fireproof and thermal insulation board.

[0074] Preferably, the stirring speed in step S1 is 100-800 r / min.

[0075] Preferably, the stirring speed in step S2 is 1500-2000 r / min.

[0076] Preferably, in step S2, an acid-base regulator is added to adjust the pH during the mixing and stirring of the mixed solution 1 and the mixed solution 2, so that the pH of the aerogel stock solution obtained after stirring is 6, and a weakly acidic environment is maintained during the stirring process. At this time, the stability of the silica sol is better, the reaction rate is slower, and the pore structure is more adjustable; but the acidic environment should not be too strong, so as to avoid causing the aerogel to form too slowly, affecting the extension of the insulation board molding cycle, and reducing the strength of the aerogel.

[0077] Preferably, in step S3, the stirring speed is 100-800 r / min. In the embodiment of adding phase change microcapsule material, the phase change microcapsule material can be added in this step and stirred evenly at a low speed to avoid shear force from high-speed stirring that damages the phase change microcapsule material.

[0078] Preferably, in step S4, before the inorganic fiber felt is impregnated, the inorganic fiber felt is dried at a temperature of 40-120° C. for 12-24 hours, and when the inorganic fiber felt is impregnated, the impregnation time is 2-30 minutes. The inorganic fiber felt has a thickness of 5-30 mm.

[0079] Preferably, in step S5, when the inorganic fiber felt impregnated with the aerogel stock solution is laminated with the active fireproof layer, an alternating lamination method or a sandwich lamination method can be adopted. When the alternating lamination is performed, a layer of inorganic fiber felt and a layer of active fireproof layer can be laminated alternately layer by layer, or two or more layers of inorganic fiber felt as a group and two / multiple layers of active fireproof layer as a group can be laminated alternately group by group.

[0080] Preferably, in step S6, a layer of plastic film (protective film) is coated on the unshaped fireproof insulation board, and then pressurized gel shaping curing is performed, and the curing is maintained at a pressure of 2-5MPa and a temperature of 30-50°C for 15min-1h; the plastic film can prevent the rapid volatilization of moisture; after the pressurized gel shaping curing, microwave drying and aging treatment is performed, and the microwave frequency is 1000-2500MHz, the temperature is 50-100°C, and the aging time is 1-30min. Microwave drying and aging can not only make the passive fireproof layer and the active fireproof layer more firmly bonded, but also further decompose or evaporate the organic materials introduced in the preparation process of the fireproof insulation board, reduce the organic content in the fireproof insulation board, and improve the flame retardancy.

[0081] In order to better understand the above technical solution, exemplary embodiments of the present invention will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present invention are shown in the accompanying drawings, it should be understood that the present invention can be implemented in various forms and should not be limited by the embodiments described herein. On the contrary, these embodiments are provided to enable a clearer and more thorough understanding of the present invention and to fully convey the scope of the present invention to those skilled in the art.

[0082] Example 1

[0083] like Figure 1 As shown, an active and passive integrated fireproof insulation board of this embodiment includes a passive fireproof layer and two layers of commercially available glass magnesium fireproof boards, and the two layers of commercially available glass magnesium fireproof boards are located on both sides of the passive fireproof layer to form a sandwich structure. Among them, the passive fireproof layer includes aerogel and aluminum silicate fiber 30-dimensional felt, and the aerogel is formed by curing the aerogel stock solution filled in the gaps of the aluminum silicate fiber felt and wrapped on the outside of the aluminum silicate fiber felt. The thickness of the aluminum silicate fiber felt is 15mm. The aerogel stock solution contains 1000 parts of silica sol, 15 parts of aluminum dihydrogen phosphate, 100 parts of lithium silicate, 10 parts of quicklime, 10 parts of titanium dioxide, 10 parts of calcium stearate, 50 parts of polydimethylsiloxane (hydrophobic modifier), 5 parts of acetic acid (pH regulator) and 3000 parts of water by mass.

[0084] The preparation method of the fireproof insulation board is as follows:

[0085] S1: Prepare the raw materials and solvent in proportion; add lithium silicate, quicklime and titanium dioxide to 1 / 2 of the water and stir at a stirring speed of 500 r / min to obtain a mixed solution 1; add silica sol and aluminum dihydrogen phosphate to the remaining 1 / 2 of the water and stir at a stirring speed of 500 r / min to obtain a mixed solution 2.

[0086] S2: Mix the mixed solution 1 and the mixed solution 2 and stir them at a stirring speed of 1500 r / min. During the stirring process, acetic acid is added to adjust the pH to 6. After the stirring is completed, a mixed solution 3 is obtained.

[0087] S3: Calcium stearate and polydimethylsiloxane were added to the mixed solution 3 and stirred at a stirring speed of 500 r / min. After low-speed stirring, an adhesive aerogel stock solution was obtained.

[0088] S4: drying the aluminum silicate fiber felt at a drying temperature of 100°C for 18 hours, and impregnating the dried aluminum silicate fiber felt into the above-mentioned adhesive aerogel stock solution for 20 minutes to obtain the aluminum silicate fiber felt impregnated with the aerogel stock solution.

[0089] S5: Lay the aluminum silicate fiber felt impregnated with aerogel stock solution on the glass magnesium fireproof board, take another glass magnesium fireproof board and lay it on the other side of the aluminum silicate fiber felt to obtain an unshaped fireproof insulation board.

[0090] S6: Wrap a layer of PVA plastic film on the unshaped fireproof insulation board, then apply 2MPa to the unshaped fireproof insulation board and cure the gel in a curing box at 45℃ for 30 minutes. After the gel is set, it is transferred to the microwave band of 1000-2500MHz frequency and aged at 60℃ for 30min. At this point, the preparation of the active and passive integrated fireproof insulation board is completed.

[0091] The active and passive integrated fireproof insulation board of this embodiment was subjected to a 1200°C combustion test (see the test conditions for details). Figure 5 ), record the fire temperature and back fire temperature of the fireproof insulation board, the temperature curve of the fire temperature 1 is as follows Figure 3 As shown, the temperature curve of backfire temperature 1 is as follows Figure 3 , Figure 4 As shown ( Figure 3 The three back-fire temperature curves basically overlap. Figure 4 ) It can be seen from the figure that when the fire temperature 1 is 1000-1300°C, the back-fire temperature 1 never exceeds 200°C within 0-90min of the combustion test, especially the back-fire temperature 1 is maintained at a low temperature of 70-90°C during the combustion test time of 0-75min. After the combustion test, the back-fire surface of the insulation of this embodiment is observed. Figure 6 As shown in the figure, the back-to-fire side still maintains the original color of the insulation board, and no black paste phenomenon occurs. The equivalent density of the main and passive integrated fireproof insulation board of this embodiment is only 0.7g / cm 3 It can be seen that the active and passive integrated fireproof and heat-insulating board of this embodiment has a very low equivalent density, light weight and excellent flame retardant and heat-insulating effect.

[0092] Example 2

[0093] This embodiment provides an active and passive integrated fireproof insulation board, which is different from the embodiment 1 in that the fireproof insulation board includes a passive fireproof layer and a gypsum fireproof board (a total of 2 layers), the passive fireproof layer includes aerogel and glass fiber felt, and the aerogel is formed by curing the aerogel stock solution filled in the gaps of the glass fiber felt and wrapped around the outside of the glass fiber felt. The aerogel stock solution contains 3000 parts of silica sol, 100 parts of lithium silicate, 15 parts of zinc phosphate, 12 parts of quicklime, 10 parts of titanium dioxide, 10 parts of calcium stearate, 45 parts of trimethylchlorosilane (hydrophobic modifier), 5 parts of hydrochloric acid (pH adjuster, adjust the pH of the aerogel stock solution to 6) and 4000 parts of water by mass.

[0094] The preparation method of the fireproof insulation board is as shown in Example 1, and the glass fiber felt is immersed in the aerogel stock solution for 30 minutes. The curing conditions are: 5MPa is applied to the unformed fireproof insulation board and the gel is cured in a curing box at 50°C for 30 minutes, and then transferred to the microwave band with a frequency of 1000-2500MHz and aged at 50°C for 20 minutes. According to the test, the active and passive integrated fireproof insulation board of this embodiment has a fire resistance limit of more than 70 minutes with a thickness of 24mm, and a volume water absorption rate of less than 5% in humid air for 24 hours.

[0095] Example 3

[0096] This embodiment provides an active and passive integrated fireproof insulation board, which is different from Example 1 in that the fireproof insulation board includes a passive fireproof layer and two layers of gypsum fireproof boards, and the passive fireproof layer is sandwiched between the two layers of gypsum fireproof boards. The passive fireproof layer includes aerogel and mullite fiber felt, and the aerogel is formed by curing the aerogel stock solution filled in the gap of the mullite fiber felt and wrapped on the outside of the mullite fiber felt. The composition of the aerogel stock solution is: 2000 parts of silica sol, 150 parts of sodium silicate, 30 parts of aluminum dihydrogen phosphate, 20 parts of quicklime, 10 parts of titanium dioxide, 10 parts of calcium stearate, 20 parts of trimethylchlorosilane (hydrophobic modifier), 30 parts of dimethyldimethoxysilane (hydrophobic modifier), 10 parts of acetic acid and 3600 parts of water. The preparation method of the fireproof insulation board is shown in Example 1.

[0097] The active and passive integrated fireproof insulation board of this embodiment was subjected to a 1200°C combustion test (see the test conditions for details). Figure 5 ), record the fire temperature 2 and the back fire temperature 2 of the fireproof insulation board, where the temperature curve of the fire temperature 2 is as follows Figure 3 As shown, the temperature curve of backfire temperature 2 is as follows Figure 3 , Figure 4As shown in the figure, when the fire temperature 2 is 1000-1300°C, the back-fire temperature 2 never exceeds 200°C within 0-90min of the combustion test, especially during the 0-75min combustion test time, the back-fire temperature 2 is maintained at a low temperature of 70-90°C. It can be seen that the active and passive integrated fireproof and heat-insulating board of this embodiment has an excellent flame retardant and heat-insulating effect.

[0098] Example 4

[0099] This embodiment provides an active and passive integrated fireproof insulation board, such as Figure 2 As shown, the difference from Example 1 is that the fireproof insulation board includes a passive fireproof layer, a gypsum fireproof board and a glass magnesium fireproof board, and the passive fireproof layer is sandwiched between a gypsum fireproof board and a glass magnesium fireproof board to form a sandwich structure. The passive fireproof layer includes aerogel and aluminum silicate fiber felt, and the aerogel is formed by solidifying the aerogel stock solution filled in the gaps of the aluminum silicate fiber felt and wrapped around the outside of the aluminum silicate fiber felt. The composition of the aerogel stock solution is that 10 parts of phase change microcapsule material are added to Example 1. The method for preparing the fireproof insulation board is shown in Example 1. The phase change microcapsule material is added to the aerogel stock solution in step S3.

[0100] The shell layer of the phase change microcapsule material is melamine-formaldehyde resin (60% by mass), and the phase change core material is sodium sulfate dodecahydrate (40% by mass). The particle size of the phase change microcapsule material is 100-300 μm. The preparation steps of the phase change microcapsule material can refer to the prior art, or to the following method: (1) dissolving sodium sulfate dodecahydrate in an appropriate amount of warm water at 50-60°C to form a uniform solution; (2) adding acetone to a container and adding 2% of a hydrophobic surfactant; (3) stirring at a stirring speed of 15-20 rpm, while stirring, slowly adding the sodium sulfate aqueous solution to the acetone to form a stable W / O emulsion. (4) mixing melamine and formaldehyde in a molar ratio of 1:3, and adjusting the pH to 8-9 with a pH regulator to promote the formation of prepolymers. (5) Stirring at a stirring speed of 15-20 rpm, gradually dropwise add the melamine-formaldehyde prepolymer solution into the aforementioned W / O emulsion while stirring; raising the temperature to 85° C. to promote the occurrence of the cross-linking reaction, reacting for 3 hours, filtering, and drying the precipitate to obtain the product.

[0101] The active and passive integrated fireproof insulation board of this embodiment was subjected to a 1200°C combustion test (see the test conditions for details). Figure 5 The temperature curve of the fire temperature is shown in Figure 1. Figure 3 As shown (simultaneous test with the insulation board of Example 1), the temperature curve 3 of the back-fire temperature is as follows Figure 3 , Figure 4As shown in the figure, when the fire temperature is 1000-1300℃, the backfire temperature 3 never exceeds 200℃ within 0-90min of the combustion test, especially during the 0-75min combustion test time, the backfire temperature 3 is maintained at a low temperature of 70-90℃. Among them, the backfire temperature 3 is always lower than the backfire temperature 1 and the backfire temperature 2 at each moment during the fire time, indicating that the active and passive integrated fireproof insulation board of this embodiment has better thermal insulation capacity.

[0102] Example 5

[0103] This embodiment provides an active and passive integrated fireproof insulation board, which is different from Embodiment 1 in that the fireproof insulation board includes two layers of passive fireproof layers and three layers of cement fiber boards. It can be seen from the temperature curve of the fireproof temperature and the temperature curve of the backfire temperature of the fireproof insulation board that the fireproof insulation board of this embodiment can withstand a backfire temperature of 1200°C for more than 110 minutes, and the ability to isolate heat further increases with the increase in the number of layers, which can ensure the stability of the backfire surface temperature for a long time, and has excellent and stable fire resistance.

[0104] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An active and passive integrated fireproof insulation board, characterized in that: include: n passive fire protection layers and n or n+1 active fire protection layers, where n is a natural number; The passive fire protection layer and the active fire protection layer are superimposed on each other as a whole; The passive fireproof layer comprises an inorganic fiber felt as a porous skeleton material and aerogel filled in the pores of the skeleton material and coated on the outside of the skeleton material; the aerogel is obtained by curing and drying an adhesive aerogel stock solution, and the adhesive aerogel stock solution comprises, by mass, 1000-4000 parts of silica sol, 50-150 parts of soluble silicate, 10-50 parts of phosphate adhesive, 5-20 parts of quicklime, 5-50 parts of titanium dioxide, 10-50 parts of calcium stearate, 5-50 parts of hydrophobic modifier, 5-50 parts of acid-base regulator and 1000-4000 parts of solvent.

2. The active and passive integrated fireproof insulation board according to claim 1, characterized in that: The active fireproof layer can be at least one of inorganic fireproof boards such as gypsum fireproof board, glass magnesium fireproof board, cement fiberboard and silicate fiberboard that actively consume energy when decomposed by heat.

3. The active and passive integrated fireproof and thermal insulation board according to claim 1, characterized in that: The inorganic fiber felt can be one of mullite fiber felt, aluminum silicate fiber felt, glass fiber felt, and alumina fiber felt, or a fiber felt composed of a mixture of two or more thereof.

4. The active and passive integrated fireproof and heat-insulating board according to claim 1, characterized in that: In the passive fire protection layer, the inorganic fiber felt accounts for 70-95% by mass, and the rest is aerogel.

5. The active and passive integrated fireproof and heat-insulating board according to claim 1, characterized in that: The phosphate adhesive may be at least one of aluminum dihydrogen phosphate, magnesium phosphate and zinc phosphate; the soluble silicate may be at least one of lithium silicate, sodium silicate and potassium silicate.

6. The active and passive integrated fireproof and heat-insulating board according to claim 1, characterized in that: The adhesive aerogel stock solution is further added with 10-30 parts by mass of a phase change microcapsule material, wherein the shell layer of the phase change microcapsule material is silicon dioxide, melamine-formaldehyde resin, polyurea-polyurethane, or polyamide, and the phase change core material of the phase change microcapsule material is at least one of paraffin, alkanes, fatty acids and their esters, sodium sulfate dodecahydrate, calcium chloride hexahydrate, polyethylene glycol, and neopentyl glycol.

7. A method for preparing an active and passive integrated fireproof and thermal insulation board, characterized in that: include: S1: Prepare the raw materials of the adhesive aerogel stock solution according to any one of claims 1 to 6, divide the solvent into two parts, add soluble silicate, quicklime and titanium dioxide to one part of the solvent and stir to obtain a mixed solution 1; add silica sol and phosphate adhesive to the other part of the solvent and stir to obtain a mixed solution 2; S2: Mixing the mixed solution 1 and the mixed solution 2 and stirring them, adding an acid-base regulator to adjust the pH to 6-7 during the stirring process to obtain a mixed solution 3; S3: adding calcium stearate and a hydrophobic modifier to the mixed solution 3 and stirring to obtain an adhesive aerogel stock solution; S4: impregnating the inorganic fiber felt with the adhesive aerogel stock solution until it is fully impregnated to obtain an inorganic fiber felt impregnated with the aerogel stock solution; S5: Laying the inorganic fiber felt impregnated with the aerogel stock solution on the active fireproof layer to obtain an unshaped fireproof insulation board; S6: The unshaped fireproof and thermal insulation board is first subjected to pressurized gel shaping and curing, and then subjected to microwave drying and aging treatment to obtain an active and passive integrated fireproof and thermal insulation board.

8. The method for preparing the fireproof and heat-insulating board according to claim 7, characterized in that: During the mixing and stirring of the mixed solution 1 and the mixed solution 2, an acid-base regulator is added to adjust the pH to 6.

9. The method for preparing the fireproof and heat-insulating board according to claim 7, characterized in that: In step S4, before the inorganic fiber felt is impregnated, the inorganic fiber felt is dried to remove moisture from the inorganic fiber felt so that the inorganic fiber felt can fully absorb the adhesive aerogel stock solution prepared in the above step.

10. The method for preparing the fireproof and heat-insulating board according to claim 7, characterized in that: In step S6, the conditions for pressurized gel shaping and curing are: maintaining a pressure of 2-5MPa and a temperature of 30-50°C for 15min-1h; the conditions for microwave drying and aging treatment are: drying and aging for 1-30min in a microwave band of 1000-2500MHz frequency and 50-100°C.

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