A composite material fire door core panel and method of manufacturing the same

Abstract

The application discloses a composite fireproof door core plate and a manufacturing method thereof. The composite fireproof door core plate is prepared from raw materials, wherein the content of inorganic fillers is not less than 80 wt.%, and the content of plastic is 12 wt.% to 15 wt.%. In the manufacturing process, a composition including plastic and mineral powder is extruded at a temperature higher than the melting point of the plastic to form granules; and then the granules are heated to a temperature higher than the melting point of the plastic, and the granules are pressed at a pressure of 15 MPa to 18 MPa to extrude a thin-walled composite fireproof door core plate with a through-hole cavity. The composite fireproof door core plate is prepared from waste plastics, waste mineral powder and straws, and is energy-saving and environment-friendly, and is not easy to absorb water and return to moisture. The combustion performance of the core plate can meet the A1 level requirement, and the composite fireproof door core plate can be used for manufacturing heat-insulating fireproof doors (A type).

Description

TECHNICAL FIELD

[0001] The present application relates to the field of fireproof doors, in particular to a composite fireproof door core plate and a manufacturing method thereof. BACKGROUND

[0002] Fireproof door refers to a door that can meet the requirements of fire resistance stability, integrity and heat insulation for a certain period of time. It is a fire-resistant partition set between fire compartments, evacuation staircases, vertical shafts, etc., which can block the spread of fire and smoke for a certain period of time, giving a certain time to ensure personnel safety evacuation and evacuation.

[0003] Fireproof doors are mainly divided into wooden fireproof doors and steel fireproof doors, which are filled with high-temperature-resistant non-combustible fillers such as rock wool and glass wool. The national standard GB 12955-2008 "Fireproof Door" requires that the combustion performance of the internal filler meets the A1 level requirement specified in the national standard GB 8624-2006 "Combustion Performance Classification of Building Materials and Products":

[0004] Table 1

[0005]

[0006] The non-combustible filler with A1 level combustion performance requirement is made into a fireproof door core plate, which can save the support of the framework and simplify the preparation steps of the fireproof door. The existing fireproof door core plate is divided into two types: expanded perlite plate and magnesite fireproof door core plate. However, the supply of expanded perlite plate is limited, and the magnesite fireproof door core plate is prone to brine return and moisture absorption and powdering. Therefore, it is urgent to develop a new fireproof door core plate. SUMMARY

[0007] The present application provides a composite fireproof door core plate and a manufacturing method thereof to overcome the defects of existing fireproof door core plates that are prone to brine return, moisture absorption and powdering. The composite fireproof door core plate uses waste plastics, waste mineral powder and straw waste as raw materials, is energy-saving and environmentally friendly, is not prone to water absorption and moisture absorption, and has a core plate combustion performance that meets the A1 level requirement, and can be used to manufacture heat-insulating fireproof doors (A type).

[0008] The technical solution of the present application is as follows:

[0009] In a first aspect, the present application provides a method for manufacturing a composite fireproof door core plate, which comprises:

[0010] pressurizing the composition comprising the plastic and the inorganic filler at a temperature higher than the melting point of the plastic at a pressure of 15 MPa to 18 MPa to form a flat composite fireproof door core plate;

[0011] wherein the content of the inorganic filler is not less than 80 wt.%, and the content of the plastic is 12 wt.% to 15 wt.%.

[0012] In some embodiments, the plastic is a thermoplastic or a thermoset, and the inorganic filler includes at least mineral powder. Preferably, the plastic is a thermoset selected from one or more of epoxy resin, silicone resin, and polyurethane.

[0013] In a second aspect, the present application provides another method for manufacturing a composite fire door core panel, the method comprising:

[0014] extruding a composition including a plastic and an inorganic filler at a temperature higher than a melting point of the plastic to form a pellet;

[0015] heating the pellet to a temperature higher than a melting point of the plastic, pressurizing the pellet at a pressure of 15-18 MPa, and extruding a thin-walled composite fire door core panel having a plurality of through-hole cavities;

[0016] wherein the inorganic filler is present in an amount of not less than 80 wt.%, and the plastic is present in an amount of 12-15 wt.%.

[0017] In some embodiments, the thin-walled composite fire door core panel having the through-hole cavities has a wall thickness of 3±1 mm.

[0018] In some embodiments, the mineral powder and the plastic have a particle size of less than 50 mesh, and a water content of less than 5 wt.%.

[0019] In some embodiments, the pellet has a diameter of 6-8 mm.

[0020] In some embodiments, before the composition is heated to a temperature higher than the melting point of the plastic, the composition is rotated at a speed of 800-1000 rpm for 8-10 minutes to remove water from the composition.

[0021] In some embodiments, the composition includes 12-15 wt.% of the plastic, ≤2 wt.% of straw, 50-65 wt.% of the mineral powder, 15-30 wt.% of the vitrified microbead, 1-3 wt.% of the silane coupling agent, 1-3 wt.% of stearic acid, and 1-3 wt.% of the compatibilizer.

[0022] In some embodiments, the straw is one or more of wheat, corn, and rice, has a length of ≤4 mm, and a water content of ≤7 wt.%; the vitrified microbead has an expansion ratio of ≥4 times; and the silane coupling agent is one or more of vinyltrimethoxysilane, vinyltriethoxysilane, and vinyltripropoxysilane.

[0023] In a third aspect, the present application provides a composite fire door core panel manufactured by the method for manufacturing a composite fire door core panel described above. BRIEF DESCRIPTION OF DRAWINGS

[0024] Once the detailed disclosure of the present invention below is taken into consideration, the various advantages of the invention will become apparent, especially when considered in conjunction with the accompanying drawings, wherein:

[0025] Figure 1 The diagram shows the composite fireproof door core panel manufactured in Examples 9-16. This fireproof door core panel is thin-walled and hollow, and compared with existing fireproof door core panels, it has the advantages of good heat insulation and convenient installation.

[0026] Figure 2 This is a schematic diagram of a composite fire door core board with through-hole cavities perpendicular to the core board plane, manufactured for Comparative Example 2. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention are described clearly and completely below. Unless otherwise specified, all materials used in the following embodiments are commercially available.

[0028] Unless otherwise specified, the numerical values ​​of ingredients or components used herein are expressed as a weight percentage or wt.% of each ingredient in the composition. The numerical values ​​provided should be at most and include the given endpoints.

[0029] The main raw materials of the composite fireproof door core board provided by the present invention are inorganic fillers and plastics, wherein the content of inorganic fillers is not less than 80 wt.% and the content of plastics is 12 wt.% to 15 wt.%. The plastics are melted at a temperature higher than their melting point to form an inorganic filler binder.

[0030] Regarding the above-mentioned raw materials, the present invention provides a method for manufacturing composite fireproof door core panels, which is a compression molding method. The method includes: pressing a composition comprising plastic and inorganic filler at a pressure of 15MPa to 18MPa at a temperature higher than the melting point of the plastic to form a flat composite fireproof door core panel. The method is applicable to thermoplastic plastics and thermosetting plastics, especially thermosetting plastics that do not remelt after curing. The thermosetting plastic is selected from one or more of epoxy resin, silicone resin, and polyurethane.

[0031] Regarding the above-mentioned raw materials, another method for manufacturing composite fireproof door core panels provided by the present invention is extrusion. This method includes: extruding a composition comprising plastic and inorganic fillers to form granules at a temperature above the melting point of the plastic; heating the granules to a temperature above the melting point of the plastic; pressurizing the granules under a pressure of 15 MPa to 18 MPa; and extruding a thin-walled composite fireproof door core panel having multiple through-cavities (see...). Figure 1 ).

[0032] In both of the above methods, the particle size of the mineral powder and the plastic is less than 50 mesh, and the moisture content is less than 5 wt.%.

[0033] In some embodiments, the flat composite fireproof door core panel manufactured by compression molding has a plurality of through-hole cavities perpendicular to the plane of the composite fireproof door core panel.

[0034] In some embodiments, in a thin-walled composite fireproof door core board manufactured by extrusion with multiple through-cavities, the through-cavities extend along the extrusion direction of the composite fireproof door core board (see...). Figure 1 ).

[0035] In some embodiments, the wall thickness of the thin-walled composite fireproof door core panel with through-hole cavity is 3±1mm. The wall thickness refers to the thickness of the thin wall surrounding the through-hole cavity, not the overall thickness of the composite fireproof door core panel. The composite fireproof door core panel with through-hole cavity is more than 90% lighter than the solid composite fireproof door core panel with overall thickness, and its thermal insulation performance is improved by more than 50%.

[0036] In some embodiments, the diameter of the pellets is 6-8 mm.

[0037] In some embodiments, the mineral powder is one or more of fly ash, titanium dioxide slag, red mud, phosphogypsum, steel slag, and desulfurized gypsum.

[0038] In some embodiments, the mineral powder is phosphogypsum after heavy metal removal, with a particle size of less than 50 mesh and a moisture content of less than 5 wt.%.

[0039] In some embodiments, the composition is rotated at a speed of 800-1000 rpm for 8-10 minutes before being heated to a temperature above the melting point of the plastic to remove moisture from the composition.

[0040] In some embodiments, the composition comprises 12 wt.% to 15 wt.% plastic, ≤2 wt.% straw, 50 wt.% to 65 wt.% mineral powder, 15 wt.% to 30 wt.% vitrified microspheres, 1 wt.% to 3 wt.% silane coupling agent, 1 wt.% to 3 wt.% stearic acid, and 1 wt.% to 3 wt.% compatibilizer.

[0041] In some embodiments, the straw is one or more of wheat, corn, and rice, with a length ≤4mm and a moisture content ≤7wt.%; the expansion ratio of the vitrified microspheres is ≥4 times; and the silane coupling agent is one or more of vinyltrimethoxysilane, vinyltriethoxysilane, and vinyltripropoxysilane.

[0042] As a preferred embodiment of the above technical solution, in the step of extruding a composition comprising plastic and inorganic filler to form granules, the temperature is set sequentially to 120°C, 180°C, 180°C, 175°C, 170°C, 165°C, 165°C, and 165°C according to the material flow direction.

[0043] As a preferred embodiment of the above technical solution, in the step of heating the granules to a temperature higher than the melting point of plastics and pressurizing the granules under a pressure of 15MPa to 18MPa to form a composite fireproof door core board, the extruder temperature is set sequentially to 180℃, 175℃, 170℃, 165℃, and 165℃ according to the material flow direction, the die temperature is set sequentially to 150℃, 150℃, 150℃, and 150℃, and the pressure is set to 15MPa to 18MPa.

[0044] Unless otherwise stated, the plastic granules used in the following examples are all 80-mesh polyethylene granules, and the mineral powder is 80-mesh phosphogypsum. This phosphogypsum has been treated with magnetic separation to remove heavy metals before use, and its moisture content is less than 1 wt.%. The compatibilizers used in the following examples are all maleic anhydride compatibilizers; the silane coupling agent is vinyltrimethoxysilane; the stearic acid is C18 stearic acid; and the straw is wheat straw with a length of 1-2 mm and a moisture content of less than 1 wt.%. When the composite fire door core panels manufactured in the following examples and comparative examples are used to manufacture fire doors, approximately 2 mm thick steel plates need to be added to both sides of the core panel.

[0045] Examples 1-8

[0046] A composition comprising plastic and inorganic filler (as listed in Table 2) is placed in a mold (length*width*thickness = 160mm*60mm*35mm) and pressurized at 15MPa to 18MPa at a temperature of 100°C to form a flat building component.

[0047] The samples were tested according to GB 8624-2012 "Classification of Combustion Performance of Building Materials and Products" standard, and the tested items are listed in Table 2.

[0048] Table 2. Raw material composition and combustion performance of flat building components in Examples 1-8

[0049]

[0050] - indicates that it was not tested. Example 6 was not tested for combustion performance because it could not be molded.

[0051] Examples 1-8 used different amounts of plastic. The results in Table 1 show that when the plastic content is ≥16 wt.%, the flat building components cannot meet the requirements of the A1 fire performance rating. When the plastic content is 13 wt.%, adding a small amount of straw can still meet the requirements of the A1 fire performance rating. However, when the straw content is ≥4 wt.%, the flat building components also cannot meet the requirements of the A1 fire performance rating.

[0052] Examples 9-16

[0053] Using raw materials of the same type but different component contents, and manufacturing processes such as extrusion... Figure 1 The thin-walled composite fireproof door core board with multiple through cavities shown is illustrated in Table 2 below, which lists the raw material composition of Examples 9-16. The specific steps of the extrusion process used are as follows:

[0054] (1) Place the composition into a high-speed mixer, set the speed to 800-1000 rpm, start the high-speed mixer and rotate for 8-10 minutes. The composition will heat up to about 120°C. After the moisture has evaporated, release it from the high-speed mixer and let it cool for later use.

[0055] (2) Add the raw material processed in step (1) into the conical twin-screw granulator. Set the temperature of the temperature controller to 120℃, 180℃, 180℃, 175℃, 170℃, 165℃, 165℃ and 165℃ in sequence. Start the conical twin-screw granulator and plasticize the raw material through high temperature. Then cut it into granules or half-granules with a diameter of 6-8mm through the granulator head.

[0056] (3) Add the prepared granules or semi-granules to the parallel twin-screw extruder. Set the temperature of the parallel twin-screw extruder to 180℃, 175℃, 170℃, 165℃, and 165℃ in sequence. Set the die temperature to 150℃, 150℃, 150℃, and 150℃ in sequence. After starting the machine, control the current at 40A and set the pressure to 16MPa. After extrusion through the die, cut according to the length requirements of the fire door (overall length * width * thickness = 1600 * 600 * 35) to obtain the composite fire door core board with a wall thickness of 3±1mm.

[0057] The sample inspection items of the composite fireproof door core panels manufactured in Examples 9 to 16 are listed in Table 3.

[0058] Table 3. Composition of fireproof door core board materials and fire resistance and heat insulation performance in Examples 9-16

[0059]

[0060] Comparative Example 1

[0061] According to the extrusion process of Examples 9-16, composite fireproof door core panels were manufactured using the following composition, which included 11 wt.% plastic, 60 wt.% mineral powder, 24 wt.% vitrified microspheres, 1 wt.% silane coupling agent, 2 wt.% stearic acid, and 2 wt.% compatibilizer. It was found that the extruded product had poor bonding strength and was easy to fall apart when lifted, which was inferred to be due to insufficient plastic content.

[0062] Comparative Example 2

[0063] Using the compression molding process of Examples 1-8, a composite fireproof door core board with through-hole cavities perpendicular to the core board plane is manufactured using a composition with the same composition as in Example 15. This composite fireproof door core board has the same overall dimensions as that of Example 15. Figure 2 As shown.

[0064] Comparative Example 3

[0065] Solid composite fireproof door core panels were manufactured using the extrusion process of Examples 9-16 and the same composition as in Example 15. The solid composite fireproof door core panels had the same overall dimensions as in Example 7.

[0066] The weight and fire resistance and heat insulation performance of the composite fireproof door core panels of Example 15, Comparative Example 2, and Comparative Example 3 were compared, and the results are listed in Table 4.

[0067] Table 4

[0068]

[0069] The above results show that the thin-walled composite fireproof door core board with through-hole cavity manufactured by extrusion in Example 15 of the present invention is about 85% lighter than the solid composite fireproof door core board of the same size manufactured by extrusion in Comparative Example 3. Compared with the composite fireproof door core board with through-hole cavity perpendicular to the core board plane manufactured in Comparative Example 2, it is not only lighter, but also has greatly improved fire resistance and heat insulation performance.

[0070] All scopes disclosed herein include endpoints, and endpoints are independently combined with each other. The word "or" as used herein means "and / or". "Optional" or "optionally" means that the event or situation described below may or may not occur, and the description includes both the possibility of the event occurring and the possibility of its non-occurrence. As used herein, "combination" includes blends, mixtures, alloys, reaction products, etc. "Combination thereof" means "including one or more of the listed items and optionally not listed similar items". All references are incorporated herein by reference.

[0071] In the context of describing the invention (particularly in the context of the following claims), unless otherwise specified herein or the context clearly contradicts it, the use of the terms “a,” “an,” and “the,” and similar indicators, is interpreted to cover both the singular and plural. Furthermore, it should be noted that the terms “first,” “second,” etc., do not indicate any order, quantity, or importance herein, but are used to distinguish one element from another. The modifier “about,” used in conjunction with quantity, includes the indicated value and has the meaning indicated by the context (e.g., it includes the degree of error associated with the measurement of a specific quantity).

[0072] While typical embodiments have been illustrated for illustrative purposes, the foregoing description should not be considered as limiting the scope of this document. Therefore, various modifications, adjustments, and substitutions can be made by those skilled in the art without departing from the spirit and scope of this document.

Claims

1. A method for manufacturing composite fireproof door core panels, characterized in that, The method is an extrusion method, including: At a temperature above the melting point of the plastic, a composition comprising plastic and inorganic fillers is extruded to form granules; The granules are heated to a temperature higher than the melting point of plastics, and then pressurized under a pressure of 15MPa~18MPa to extrude a thin-walled composite fireproof door core board with multiple through cavities. The composition comprises 12 wt.% to 15 wt.% plastic, ≤2 wt.% straw, 50 wt.% to 65 wt.% mineral powder, 15 wt.% to 30 wt.% vitrified microspheres, 1 wt.% to 3 wt.% silane coupling agent, 1 wt.% to 3 wt.% stearic acid, and 1 wt.% to 3 wt.% compatibilizer; the thin-walled composite fireproof door core board with multiple through-hole cavities has a wall thickness of 3 ± 1 mm, and the through-hole cavities extend along the extrusion direction of the composite fireproof door core board.

2. The method for manufacturing composite fireproof door core panels according to claim 1, characterized in that: Both the mineral powder and the plastic have a particle size of less than 50 mesh and a moisture content of less than 5 wt.%.

3. The method for manufacturing composite fireproof door core panels according to claim 1, characterized in that: The diameter of the granules is 6-8 mm.

4. The method for manufacturing composite fireproof door core panels according to claim 1, characterized in that: Before heating the composition to a temperature higher than the melting point of the plastic, rotate it at a speed of 800-1000 rpm for 8-10 minutes to remove moisture from the composition.

5. The method for manufacturing composite fireproof door core panels according to claim 1, characterized in that: The straw is one or more of wheat, corn, and rice, with a length ≤4mm and a moisture content ≤7wt.%; the expansion ratio of the vitrified microspheres is ≥4 times; the silane coupling agent is one or more of vinyltrimethoxysilane, vinyltriethoxysilane, and vinyltripropoxysilane.

6. A composite material fireproof door core panel, characterized in that: It is manufactured by the method for manufacturing composite fireproof door core panels according to any one of claims 1 to 5.

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