Production method of a high-strength polystyrene foamed thermal insulation board

Abstract

The present invention belongs to the technical field of foamed thermal insulation boards, and relates to a production method of high-strength polystyrene foamed thermal insulation boards. In the present invention, linear phenolic resin in the phenolic urethane resin foaming adhesive reacts with polyisocyanate. The two double bonds R—N=C=O of the isocyanate group in the polyisocyanate molecule have extremely active chemical properties and are easily attacked by the hydroxyl groups on the phenolic resin molecule, causing the hydrogen atom to transfer to the nitrogen atom, and then connecting and hardening. The foaming adhesive containing phenolic urethane resin has low water absorption, moisture-proof and waterproof properties. The phenolic urethane self-hardening resin includes phenolic resin and polyisocyanate, has a fast and uniform curing speed, higher bonding strength and high-temperature strength, forms a network structure on the surface of the powder, and the thermal insulation board has high tensile and compressive strengths. Divinylbenzene forms a cross-linked support connection structure inside under the action of a cross-linking agent, thereby increasing the tensile and compressive strengths of the thermal insulation board.

Description

Technical Field

[0001] The present invention belongs to the technical field of foamed thermal insulation boards, and in particular to a production method of high-strength polystyrene foamed thermal insulation boards. Background Art

[0002] Modified polystyrene boards are a large category, including the so-called homogeneous boards, silica boards, real gold boards, etc. They all share the same essence. Using a non-combustible material in a compartmentalized manner to wrap the EPS particles, the thermosetting composite polystyrene foam thermal insulation board uses polystyrene foam particles or boards as the thermal insulation matrix and is made into a plate-shaped product by compounding with a treatment agent. Its compounding processes mainly include particle coating, mixed molding, or substrate penetration, etc. It has the characteristics of maintaining a certain shape under fire conditions and not producing molten dripping substances. On December 15, 2020, CN201910516132.2, a production process of a foamed thermal insulation board, disclosed that a raw material composition including 50-80 parts of silica, 13-19 parts of binder, 5-8 parts of polystyrene particles, and 20-40 parts of water was mixed evenly. Using polystyrene particles or boards as the thermal insulation matrix and made into a plate-shaped product by compounding with a treatment agent, its compounding processes mainly include particle coating, mixed molding, or substrate penetration, etc. It has the characteristics of maintaining a certain shape under fire conditions and not producing molten dripping substances. Polystyrene boards or polystyrene particles are only one of its raw materials, and other materials are also needed. A board with a certain fire resistance ability made through a specific production process is called a thermosetting composite polystyrene board. As is well known, there is a big contradiction in this type of thermal insulation material in the current market: when the thermal insulation performance of the board is improved, the bulk density will decrease, but the combustion performance of the board has to be sacrificed; when the combustion performance grade of the board is improved, the bulk density of the board increases accordingly, and the thermal insulation performance decreases. At the same time, if B-class materials are used for external wall insulation in public construction projects and high-rise civil construction projects, there will be very big potential safety hazards. Therefore, those skilled in the art are eager to develop a production method of high-strength polystyrene foamed thermal insulation boards. Summary of the Invention

[0003] In view of the above problems, the present invention aims to provide a production method of high-strength polystyrene foamed thermal insulation boards.

[0004] The present invention is achieved through the following technical solutions:

[0005] A production method of a high-strength polystyrene foam insulation board, in addition to the step of conventionally pre-foaming EPS particles with steam and then ripening for 6 to 8 hours, is characterized by further comprising the following steps: First step, prepare a uniform foaming adhesive solution by mixing phenolic urethane resin, foaming agent, and divinylbenzene in a mass ratio of 9 to 10:2 to 3:1 for standby; Second step, spray the prepared foaming adhesive solution and heat-insulating powder on the surface of the heat-insulating powder in a volume ratio of 1:4 to 5 to obtain foamed heat-insulating powder; Third step, stir and mold: convey the ripened EPS particles to a mixer, and at the same time, based on the weight of the EPS particles as 100% benchmark, meter and add 43 to 47% of the foamed heat-insulating powder and 0.4 to 0.8% of the cross-linking agent, stir and mix the ingredients, then convey them into a plate molding machine, and then stand for 2 to 3 minutes under a pressure of 0.05 to 0.1 MPa and then coagulate and mold in the mold, the mold cavity temperature is 120 to 125 °C, and the molding time is 3 to 4 minutes; Fourth step, cure and mold: After demolding from the mold, the curing time is 6 to 8 hours, the curing conditions are a temperature of 33 to 35 °C and a relative humidity of 40 to 45%, or heat through an oven at 60 °C for 2 to 6 hours; Fifth step, cut and polish: Send the molded plate to the cutting and polishing workshop, cut with an electric heating wire and then polish to obtain.

[0006] Further, the cross-linking agent is a mixture of N-methylimidazole and dicumyl peroxide in a mass ratio of 1:2 to 3.

[0007] Further, the heat-insulating powder in the second step is one of perlite powder, shale ceramsite sand powder, and pumice powder.

[0008] Pumice powder has been used as an abrasive for grinding and cleaning denture bases and alloys. Shale ceramsite sand is a heat-insulating and lightweight porous basic material prepared by using shale or slate with self-expansion performance as the sole raw material.

[0009] Further, the foaming agent is one of sodium bicarbonate and azodicarbonamide.

[0010] Further, the phenolic urethane resin is a two-component phenolic urethane resin for casting composed of linear phenolic resin and polyisocyanate.

[0011] The beneficial effects of the present invention:

[0012] In the present invention, a reaction between linear phenolic resin and polyisocyanate in a phenolic urethane resin foaming adhesive solution is adopted. The two double bonds of the isocyanate group in the polyisocyanate molecule, R—N=C=O, have extremely active chemical properties and are easily attacked by the hydroxyl groups on the phenolic resin molecules, causing hydrogen atoms to transfer to nitrogen atoms and then connecting to harden. This cross-linking reaction does not produce small-molecule by-products, is clean and environmentally friendly, and adds divinylbenzene and a foaming agent. Using EPS particles as raw materials, uniformly mixing foaming heat-insulating powder, a non-combustible thermal insulation board is made, thereby realizing a high-quality thermal insulation material with advantages such as A2-level fire protection, strong bonding force, safety and reliability, convenient construction, high cost performance, and great market potential.

[0013] Compared with the prior art, the present invention has the following advantages:

[0014] The foaming adhesive solution containing phenolic urethane resin has low water absorption, moisture-proof and waterproof properties. It has strong bonding performance. The phenolic urethane self-hardening resin includes phenolic resin and polyisocyanate, with a fast and uniform curing speed, higher bonding strength and high-temperature strength. It forms a network structure on the surface of the inorganic powder. The thermal insulation board has high tensile and compressive strengths. Divinylbenzene forms a cross-linked support connection structure inside under the action of the cross-linking agent, thereby increasing the tensile and compressive strengths of the thermal insulation board. During the construction process, the material will not deform due to external forces, resulting in bending, warping and other phenomena, ensuring the flatness, cleanliness and stability of the wall surface after construction. The production operation is simple and the loss is low. Specific embodiments

[0015] The following specific examples are used to illustrate the present invention, but they do not limit the present invention.

[0016] Example 1

[0017] Step 1, Foaming: Turn on the SPJ120 pre-foaming machine and the screw feeder respectively. The motor must run smoothly without any strange noise. After power-on, run it without load for 30 minutes and then supply compressed air. The screw feeder feeds Xingda XB301 EPS particles into the foaming machine. The EPS particles are heated by steam. According to the previous conditions, the steam source pressure is 0.7 MPa, the air pressure is 0.6 MPa, the voltage is 380 V, the frequency is 50 Hz, the steam is saturated steam, and the cyclopentane foaming agent accounts for 78% of the EPS mass ratio; Step 2, Aging bin sinking: Place the particles just out of the pre-foaming machine in the aging bin for 8 hours; Step 3, Phenolic urethane resin: Shengquan PEPSET phenolic urethane resin, specifically a two-component phenolic urethane resin for casting composed of linear phenolic resin and polyisocyanate. Specifically, 8.2 parts of linear phenolic resin NP-101HB and NP-102HB are mixed with 6.8 parts of polyisocyanate, and then 2% of the catalyst NP-103 based on the mass of the linear phenolic resin is added. The phenolic urethane resin, foaming agent, and divinylbenzene are prepared into a uniform foaming adhesive solution in a mass ratio of 9:2:1 for standby. The foaming agent is sodium bicarbonate; Step 4, Spray the prepared foaming adhesive solution and the thermal insulation powder on the surface of the thermal insulation powder in a volume ratio of 1:4. The thermal insulation powder is Chengsong perlite powder, with a bulk density of 50 kg / m 3 , moisture content of 0.5%, and the sieve residue on a 4.75 mm sieve hole sieve is ≤2% to obtain foamed thermal insulation perlite powder; Step 5, Stirring and molding: Transport the aged EPS particles to the mixer. At the same time, based on the weight of the EPS particles as 100% reference, measure and add 45% of the foamed thermal insulation perlite powder and 0.46% of the cross-linking agent, and then stir and mix the ingredients and transport them into the board molding machine. The cross-linking agent is a mixture of N-methylimidazole and dicumyl peroxide with a mass ratio of 1:2.5. Then, let it stand for 2 minutes under a pressure of 0.05 MPa and then condense and form in the mold. The mold cavity temperature is 120 °C, and the molding time is 3 minutes; Step 6, Curing and molding: After demolding from the mold, the curing time is 8 hours. The curing conditions are: temperature 33 °C, relative humidity 45%; Step 7, Cutting and grinding: Send the formed board to the cutting and grinding workshop, cut it with an electric heating wire and then grind it to obtain a G-type polystyrene insulation board with dimensions of 1200 mm × 600 mm × 100 mm.

[0018] Product: The board surface is smooth, free of oil stains, deformation, the cut is straight, the cut surface is flat, and there are no burrs.

[0019] Example 2

[0020] Step 1, Foaming: Turn on the SPJ120 pre-foaming machine and the screw feeder separately. The motor must run smoothly without any abnormal noise. After power-on, run it without load for 30 minutes and then supply compressed air. The screw feeder feeds Xingda XB301 EPS particles into the foaming machine. Rely on steam to heat the EPS particles. According to the previous steam gas source pressure of 0.7 MPa, air pressure of 0.6 MPa, voltage of 380 V, frequency of 50 Hz, the steam is saturated steam, and the cyclopentane foaming agent accounts for 78% of the EPS mass ratio for foaming; Step 2, Aging bin sinking: Place the particles just out of the pre-foaming machine in the aging bin for 6 hours;

[0021] A production method of a high-strength polystyrene foamed insulation board, including the step of conventional steam pre-foaming EPS particles and then aging for 6 hours. Its characteristics are that it also includes the following steps: Step 1, Phenolic urethane resin, specifically a two-component phenolic urethane resin for casting composed of linear phenolic resin and polyisocyanate. Specifically, 8.2 mL of linear phenolic resin NF-301 and 6.8 mL of NF-302 polyisocyanate are mixed to obtain it. Prepare a uniform foaming adhesive solution by mixing phenolic urethane resin, foaming agent, and divinylbenzene according to a mass ratio of 9:3:1. The foaming agent is azodicarbonamide; Step 2, Spray the prepared foaming adhesive solution and heat-insulating powder on the surface of the heat-insulating powder evenly according to a volume ratio of 1:5. The heat-insulating powder is Chaosu Jiayang CS-HSH-58U-01 pumice powder, with an average particle size of 58 microns and a moisture content of 0.5%, to obtain foamed heat-insulating pumice powder; Step 3, Stirring and molding: Transport the aged EPS particles to a mixer. At the same time, based on the weight of the EPS particles as 100% reference, measure and add 47% of the foamed heat-insulating pumice powder and 0.8% of the cross-linking agent for stirring and batching, and then transport them into the SPB200LFT board molding machine. The cross-linking agent is a mixture of N-methylimidazole and dicumyl peroxide with a mass ratio of 1:3. Then, let it stand for 2.5 minutes under a pressure of 0.08 MPa and then condense and form in the mold. The mold cavity temperature is 125 °C and the molding time is 3 minutes; Step 4, Curing and molding: After demolding from the mold, the curing time is 6 hours, and the curing conditions are heating in an oven at 60 °C for 6 hours; Step 5, Cutting and grinding: Send the molded board to the cutting and grinding workshop, cut it with an electric wire and then grind it to obtain a G-type polystyrene insulation board with dimensions of 1200 mm × 600 mm × 100 mm.

[0022] Product: The surface of the board is smooth, free of oil stains, deformation, the cut is straight, the cut surface is flat, and there is no burr.

[0023] Example 3

[0024] Step 1, Foaming: Turn on the SPJ120 pre-foaming machine and the screw feeder respectively. The motor must run smoothly without any abnormal noise. After power-on, run it without load for 30 minutes and then supply compressed air. The screw feeder feeds Xingda XB301 EPS particles into the foaming machine. The EPS particles are heated by steam. According to the process with a previous steam source pressure of 0.7 MPa, air pressure of 0.6 MPa, voltage of 380 V, frequency of 50 Hz, the steam is saturated steam, and the cyclopentane foaming agent accounts for 78% of the EPS mass ratio. The foaming density is 36.0 kg / cm 3 is carried out. The particles are in a softened state. During the heating process, the foaming agent cyclopentane in the free space of the homogeneous polystyrene particle molecular structure evaporates into gas, thus forming countless bubble nuclei in the beads. As the gas volume increases and expands, the bubble volume in the beads increases and the bead density decreases; Step 2, Depositing in the curing bin: Place the particles just out of the pre-foaming machine in the curing bin for 10 h; Step 3, Phenolic urethane resin, specifically the two-component phenolic urethane resin for casting composed of linear phenolic resin and polyisocyanate. Specifically, it is 8.2 parts of linear phenolic resin NF-301 8.2 parts of L, and NF-302 polyisocyanate is mixed with the cross-linking agent in the following Step 5 and then added together. Prepare a uniform foaming adhesive solution by mixing phenolic urethane resin, foaming agent, and divinylbenzene according to a mass ratio of 9:2:1. The foaming agent is sodium bicarbonate; Step 4, Spray the prepared foaming adhesive solution and the thermal insulation powder on the surface of the thermal insulation powder evenly according to a volume ratio of 1:4. The thermal insulation powder is shale ceramsite powder with a fineness modulus of 1.85, and its particle size distribution is shown in Table 1, obtaining the foamed thermal insulation shale ceramsite powder; Step 5, Stirring and molding: Transport the cured EPS particles to the mixer. At the same time, based on the weight of the EPS particles as 100% reference, measure and add 43% of the foamed thermal insulation shale ceramsite powder and 0.4% of the cross-linking agent, stir and mix the ingredients, and then transport them into the SPB200LFT board molding machine. The cross-linking agent is a mixture of N-methylimidazole and diisopropylbenzene peroxide with a mass ratio of 1:2. Then, let it stand for 2.5 minutes under a pressure of 0.05 MPa and then solidify and form in the mold. The mold cavity temperature is 120 °C and the molding time is 3 minutes; Step 6, Curing and molding: After demolding from the mold, the curing time is 8 h, and the curing conditions are a temperature of 35 °C and a relative humidity of 45%; Step 7, Cutting and grinding: Send the formed board to the cutting and grinding workshop, cut it with an electric heating wire and then grind it to obtain a G-type polystyrene insulation board with dimensions of 1200 mm × 600 mm × 100 mm.

[0025] Product: The board surface is smooth, free of oil stains, deformation, the cut is straight, the cut surface is flat, and there are no burrs.

[0026] Table 1 Particle size distribution of shale ceramsite powder

[0027]

[0028] The polystyrene foam insulation boards of Examples 1 to 3 were subjected to performance tests, and the test results are shown in Table 1

[0029] Table 1 Performance test results of the polystyrene foam insulation boards of Examples 1 to 3

[0030] Note: The dimension measurement was carried out in accordance with the provisions of GB / T 6342-1996; the appearance was carried out in accordance with the provisions of GB / T 10801.1-2002; the determination of apparent density was carried out in accordance with the provisions of GB / T 6343-2009; the determination of compressive strength was carried out in accordance with the provisions of GB / T 8813-2008; the tensile strength perpendicular to the surface direction was carried out in accordance with the provisions of Appendix D of JG 149-2003 "External Thermal Insulation Systems for Exterior Walls with Thin Plaster on Expanded Polystyrene Boards"; the determination of thermal conductivity was carried out in accordance with the provisions of GB / T 10295; the determination of water absorption rate was carried out in accordance with the provisions of GB / T 8810-2005; the determination of dimensional stability was carried out in accordance with the provisions of GB / T 10801.1-2002; the determination of fracture bending load was carried out in accordance with the provisions of GB / T 10801.1-2002

Claims

1. A production method of a high-strength polystyrene foam insulation board, including the step of post-curing EPS particles pre-expanded by conventional steam for 6 - 8 h, characterized in that, it further includes the following steps: The first step: Prepare a uniform foaming adhesive liquid by mixing phenol urethane resin, foaming agent, and divinylbenzene in a mass ratio of 9 - 10∶2 - 3∶1; the phenol urethane resin is a two-component phenol urethane resin composed of linear phenolic resin and polyisocyanate; The second step: Spray the prepared foaming adhesive liquid and heat insulation powder evenly on the surface of the heat insulation powder according to a volume ratio of 1∶4 - 5 to obtain foamed heat insulation powder. The heat insulation powder is one of shale ceramsite powder and pumice powder, and the foaming agent is one of sodium bicarbonate and azodicarbonamide; The third step: Stir and mold: Transport the cured EPS particles to a mixer, and at the same time, based on the weight of the EPS particles as 100% benchmark, measure and add 43 - 47% of the foamed heat insulation powder and 0.4 - 0.8% of the cross-linking agent for stirring and batching. The cross-linking agent is a mixture of N-methylimidazole and dicumyl peroxide with a mass ratio of 1∶2 - 3, transport it into a board molding machine, then stand still for 2 min - 3 min under a pressure of 0.05 - 0.1 MPa and then condense and mold in the mold. The mold cavity temperature is 120 - 125℃, and the molding time is 3 - 4 min; The fourth step: Cure and mold: After demolding from the mold, cure at a temperature of 33 - 35℃ and a relative humidity of 40 - 45% for 6 - 8 h or heat in an oven at 60℃ for 2 - 6 h; The fifth step: Cut and polish: Send the molded board to a cutting and polishing workshop, cut with an electric heating wire and then polish to obtain.

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