A three-dimensional fabric-reinforced flame-retardant foaming material and its preparation method

Abstract

The present invention discloses a three-dimensional fabric reinforced flame-retardant foaming material and a preparation method thereof. The foaming material comprises the following components in parts by mass: 63 parts - 77 parts of unsaturated resin; 27 parts - 33 parts of unsaturated monomer; 10 parts - 50 parts of hollow microsphere foaming agent; 1 part - 4 parts of curing agent; 0.1 part - 3 parts of accelerator; 1 part - 10 parts of flame retardant; 0.1 part - 2 parts of auxiliary agent; and a three-dimensional fiber fabric accounting for 20% - 50% of the total mass of the components. A lightweight and high-strength flame-retardant foaming material is obtained through a heat self-expansion molding process (HEM), effectively reducing the preparation cost on the basis of ensuring controllable density of the foaming material and having properties such as lightweight, high strength and flame retardancy.

Description

Technical Field

[0001] The present invention relates to the technical field of foaming materials, and particularly relates to a three-dimensional fabric reinforced flame-retardant foaming material and a preparation method thereof. Background Art

[0002] Structural foaming materials are foaming materials based on plastics (such as PVC, PET, etc.) and modified through a continuous polymerization network. At present, structural foaming materials are usually of a hollow structure (similar to the structure of hollow bricks), which are prone to water absorption and water ingress problems. Moreover, the foam mechanical strength of existing plastic-based foaming materials is insufficient, while high-strength foaming resin materials such as polymethacrylimide are expensive and not conducive to popularization and application. Summary of the Invention

[0003] The present invention provides a three-dimensional fabric reinforced flame-retardant foaming material and a preparation method thereof. A lightweight, high-strength and flame-retardant foaming material is obtained through a heat self-expansion molding process (HEM, Heat Expansion Molding), effectively reducing the preparation cost on the basis of ensuring controllable density of the foaming material and having properties such as lightweight, high strength and flame retardancy.

[0004] A three-dimensional fabric reinforced flame-retardant foaming material provided by the present invention comprises the following components in parts by mass:

[0005] 63 parts - 77 parts of unsaturated polyester resin;

[0006] 27 parts - 33 parts of unsaturated monomer;

[0007] 10 parts - 50 parts of hollow microsphere foaming agent;

[0008] 1 part - 4 parts of curing agent;

[0009] 0.1 part - 3 parts of accelerator;

[0010] 1 part - 10 parts of flame retardant;

[0011] 0.1 part - 2 parts of auxiliary agent;

[0012] And a three-dimensional fiber fabric accounting for 20% - 50% of the total mass of the components.

[0013] In some embodiments, the weight average molecular weight of the unsaturated polyester resin is 500 - 10000, and the molar content of phthalic anhydride in the preparation raw materials accounts for 0 - 70% of the total molar of dibasic acids, and the molar content of maleic anhydride accounts for 30% - 100% of the total molar of dibasic acids.

[0014] In some embodiments, the unsaturated monomer is one or more of styrene, methyl methacrylate, methyl acrylate and butyl methacrylate.

[0015] In some of these embodiments, the hollow microsphere foaming agent is one of FN-100SS, F-105, FN-105, F-170, FN-180SS, FN-180S, FN-180, FN-190SSD, F-230D, F-260D, F-2800D, F-2830D, F-2860D, F-30, F-36, F36LV, F-48, F-50, F-65 and FN-80GS of Matsumoto Yushi Yakuhin K.K. of Japan;

[0016] or, one of 031DU40, 051DU40, 093DU20, 461DU20, 551DU40, 909DU80, 920DU120, 920DU80, 930DU120, 950DU80, 951DU120, 980DU100 and 980DU120 of NOURYOU.

[0017] In some of these embodiments, the three-dimensional fiber fabric is one or more of glass fiber, carbon fiber, polypropylene fiber and polyethylene terephthalate fiber.

[0018] In some of these embodiments, the overall shape of the three-dimensional fiber fabric is fishbone-shaped or planar mesh-shaped, and the mesh arrangement shape of the three-dimensional fiber fabric is one or more of 1-shaped, V-shaped, X-shaped, N-shaped and 1X1-shaped. Among them, the fishbone shape means that the overall shape of a three-dimensional fiber fabric is arranged in a fishbone shape, and the interval between fishbones is adjusted according to the proportion of the three-dimensional fiber fabric in the total mass; the planar mesh shape means that the overall shape of a three-dimensional fiber fabric is a plane, and there are meshes on the plane, and the size of the meshes is adjusted according to the proportion of the three-dimensional fiber fabric in the total mass; the mesh arrangement shape is the shape of the side meshes of the three-dimensional fiber fabric.

[0019] In some of these embodiments, the curing agent is methyl ethyl ketone peroxide, CAS: 1338-23-4; the accelerator is cobalt isooctanoate, CAS: 136-52-7.

[0020] In some of these embodiments, the flame retardant is one or more of halogen-based flame retardants, phosphorus-based flame retardants, antimony-based flame retardants, aluminum hydroxide flame retardants, magnesium hydroxide flame retardants, organosilicon-based flame retardants and graphene

[0021] In some of these embodiments, the additives include one or more of defoamers, anti-settling agents and high-temperature wetting agents.

[0022] In some of these embodiments, the defoamer is one of BYK-067A, BYK-070 and BYK-141 of BYK Chemie GmbH of Germany;

[0023] The anti-settling agent is BYK-P105 or BYK-W066 of BYK Chemie GmbH;

[0024] The high-temperature resistant wetting agent is one of DISPERBYK-103, DISPERBYK-106, DISPERBYK-107, DISPERBYK-108 and DISPERBYK-2205 of BYK Chemie GmbH.

[0025] The present invention also provides a preparation method of a three-dimensional fabric reinforced flame-retardant foaming material. A lightweight and high-strength flame-retardant foaming material is obtained through a heat self-expansion molding process (HEM, Heat Expansion Molding), including:

[0026] S1, uniformly stirring and mixing unsaturated polyester resin, unsaturated monomer, hollow microsphere foaming agent, curing agent, accelerator and auxiliary agent under the action of a blender to obtain a foaming body;

[0027] S2, uniformly applying a mold release agent to the mold, preheating the mold, then placing the three-dimensional fiber fabric into the mold, and pouring the foaming body obtained in step S1 into the mold;

[0028] S3, after locking the mold, performing hot pressing by a hot press;

[0029] S4, after the mold is cooled, demolding the foaming material in the mold to obtain a three-dimensional fabric reinforced flame-retardant foaming material.

[0030] In some embodiments, the stirring speed of the blender is 100 r / min - 900 r / min, and the stirring time is 5 min - 10 min; the preheating temperature of the mold is 50°C - 150°C; the hot pressing temperature of the hot press is 100°C - 150°C, and the hot pressing time is 5 min - 60 min; the mold cooling temperature is less than 50°C.

[0031] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0032] 1. Compared with expensive PMI, an economical unsaturated polyester resin is used as the foaming base resin, greatly reducing the raw material cost. At the same time, the reactivity of the unsaturated resin endows the foaming material with high production efficiency, has good comprehensive material strength, and meets the high-strength performance characteristics of the foaming material;

[0033] 2. By using a hollow microsphere foaming agent, the unsaturated resin can generate foam, improving the foaming effect. And the foaming material has uniform cell structure, closed cells, low density and controllable density. The lower limit of the foaming density can reach 0.05 g / cm 3 , realizing the performance characteristics of lightweight and high-strength of the foaming material and waterproof performance;

[0034] 3. The three-dimensional fiber fabric is used to fill the foaming material, so as to utilize the three-dimensional network structure to endow the foaming material with strong and tough performance characteristics and the designability of the product structure.

[0035] 4. Auxiliaries such as defoaming agents, anti-settling agents, high-temperature resistant wetting agents, and flame retardants are used to improve the uniformity, high-temperature resistance, and flame retardant properties of the foaming material, and the application effect of self-extinguishing when removed from the fire can be achieved. Detailed implementation manners

[0036] To make the above objects, features, and advantages of the present invention more obvious and understandable, the following provides a detailed description of the specific implementation manners of the present invention. Many specific details are set forth in the following description in order to fully understand the present invention. However, the present invention can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without departing from the connotation of the present invention. Therefore, the present invention is not limited by the specific embodiments disclosed below.

[0037] As used herein, the term "prepared from" is synonymous with "comprising". The terms "comprising", "including", "having", "containing", or any other variation thereof used herein are intended to cover non-exclusive inclusion. For example, a composition, step, method, article, or device containing the listed elements is not necessarily limited to those elements, but may include other elements not expressly listed or elements inherent to such composition, step, method, article, or device.

[0038] When an equivalent, concentration, or other value or parameter is expressed as a range, a preferred range, or a range defined by a series of upper preferred values and lower preferred values, it should be understood that all ranges formed by any pairing of any range upper limit or preferred value with any range lower limit or preferred value are specifically disclosed, regardless of whether the ranges are separately disclosed. For example, when the range "1 to 5" is disclosed, the described range should be interpreted as including the ranges "1 to 4", "1 to 3", "1 to 2", "1 to 2 and 4 to 5", "1 to 3 and 5", etc. When a numerical range is described herein, unless otherwise stated, the range is intended to include its end values and all integers and fractions within the range.

[0039] In addition, the indefinite articles "a" and "an" before the elements or components of the present invention do not limit the quantity requirements (i.e., the number of occurrences) of the elements or components. Therefore, "a" or "an" should be interpreted as including one or at least one, and the singular form of the element or component also includes the plural form, unless the quantity clearly refers to the singular form.

[0040] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the technical field to which this invention belongs. The terms used in the description of the present invention herein are for the purpose of describing specific embodiments only and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more of the related listed items.

[0041] Example 1

[0042] A method for preparing a three-dimensional fabric reinforced flame-retardant foaming material, comprising the following steps:

[0043] S1, all raw materials except the three-dimensional fiber fabric are stirred and mixed evenly under the action of a stirrer with a stirring speed of 100 r / min and a stirring time of 10 min to obtain a foaming body, wherein 63 parts of unsaturated polyester resin, 27 parts of styrene, 12 parts of F-105, 1 part of methyl ethyl ketone peroxide, 0.2 part of cobalt isooctanoate, 0.1 part of BYK-067A, 0.1 part of BYK-P105, 0.1 part of DISPERBYK-103, and 1.1 parts of graphene; the weight-average molecular weight of the unsaturated polyester resin is 550, and the molar content of phthalic anhydride in the preparation raw materials accounts for 1% of the total molar of dibasic acids, and the molar content of maleic anhydride accounts for 99% of the total molar of dibasic acids;

[0044] S2, the mold is evenly coated with a mold release agent, and the mold is preheated to 50 °C, then the glass fiber fabric is placed into the mold, and the foaming body of step S1 is poured into the mold, wherein the glass fiber fabric accounts for 50% of the total mass of the above raw materials, the fabric plane shape is a plane mesh shape, and the fabric side mesh shape is a V shape;

[0045] S3, after the mold is locked, hot pressing is carried out by a hot press, the hot pressing temperature is 100 °C, and the hot pressing time is 60 min;

[0046] S4, after the mold is cooled to a temperature less than 50 °C, the foaming material in the mold is demolded to obtain a three-dimensional fabric reinforced flame-retardant foaming material.

[0047] Example 2

[0048] S1. Mix all the raw materials except the three-dimensional fiber fabric evenly under the action of a blender with a stirring speed of 500 r / min and a stirring time of 8 min to obtain a foam. Among them, there are 70 parts of unsaturated polyester, 30 parts of methyl methacrylate; 30 parts of 031DU40, 2.5 parts of methyl ethyl ketone peroxide, 1.5 parts of cobalt isooctanoate, 0.2 parts of BYK-070, 0.2 parts of BYK-W066, 0.5 parts of DISPERBYK-106, and 5 parts of decabromodiphenylethane; the weight-average molecular weight of the unsaturated polyester resin is 5000, and the molar content of phthalic anhydride in the preparation raw materials accounts for 40% of the total molar amount of dibasic acids, and the molar content of maleic anhydride accounts for 60% of the total molar amount of dibasic acids;

[0049] S2. Uniformly apply a mold release agent to the mold, preheat the mold to 150 °C, then place the carbon fiber fabric into the mold, and pour the foam obtained in step S1 into the mold. Among them, the carbon fiber fabric accounts for 35% of the total mass of the above raw materials, the fabric plane shape is fishbone-shaped, and the side mesh shape is X-shaped;

[0050] S3. After locking the mold, perform hot pressing with a hot press. The hot pressing temperature is 150 °C and the hot pressing time is 30 min;

[0051] S4. After the mold is cooled to a temperature less than 50 °C, demold the foam material in the mold to obtain a three-dimensional fabric-reinforced flame-retardant foam material.

[0052] Example 3

[0053] S1. Mix all the raw materials except the three-dimensional fiber fabric evenly under the action of a blender with a stirring speed of 900 r / min and a stirring time of 5 min to obtain a foam. Among them, there are 77 parts of unsaturated polyester, 33 parts of acrylate, and 49 parts of 951DU120; 3.8 parts of methyl ethyl ketone peroxide, 2.5 parts of cobalt isooctanoate, 0.3 parts of BYK-141, 0.3 parts of BYK-W066, 1.2 parts of DISPERBYK-108, and 9.9 parts of silicone resin; the weight-average molecular weight of the unsaturated polyester resin is 9500, and the molar content of phthalic anhydride in the preparation raw materials accounts for 70% of the total molar amount of dibasic acids, and the molar content of maleic anhydride accounts for 30% of the total molar amount of dibasic acids;

[0054] S2. Uniformly apply a mold release agent to the mold, preheat the mold to 100 °C, then place the polypropylene fiber fabric into the mold, and pour the foam obtained in step S1 into the mold. Among them, the polypropylene fiber fabric accounts for 20% of the total mass of the above raw materials, the fabric plane shape is fishbone-shaped, and the side mesh shape is 1X1-shaped;

[0055] S3. After locking the mold, hot pressing is carried out using a hot press, with a hot pressing temperature of 135 °C and a hot pressing time of 30 min;

[0056] S4. After the mold is cooled to a temperature less than 50 °C, the foaming material in the mold is demolded to obtain a three-dimensional fabric reinforced flame-retardant foaming material.

[0057] Example 4

[0058] S1. All raw materials except the three-dimensional fiber fabric are stirred and mixed evenly under the action of a stirrer with a stirring speed of 100 r / min and a stirring time of 10 min to obtain a foaming body. Among them, there are 63 parts of unsaturated polyester resin, 27 parts of styrene, 30 parts of FN-180, 1 part of methyl ethyl ketone peroxide, 0.2 part of cobalt octoate, 0.1 part of BYK-067A, 0.1 part of BYK-P105, 0.1 part of DISPERBYK-103, and 1.1 parts of ammonium polyphosphate; the weight-average molecular weight of the unsaturated polyester resin is 550, and the molar content of phthalic anhydride in the preparation raw materials accounts for 1% of the total molar amount of dibasic acids, and the molar content of maleic anhydride accounts for 99% of the total molar amount of dibasic acids;

[0059] S2. The mold is evenly coated with a mold release agent, and the mold is preheated to 50 °C. Then, the polypropylene fiber fabric is placed into the mold, and the foaming body from step S1 is poured into the mold. Among them, the polypropylene fiber fabric accounts for 50% of the total mass of the above raw materials, the plane shape of the fabric is a plane mesh shape, and the side mesh shape is a V shape;

[0060] S3. After locking the mold, hot pressing is carried out using a hot press, with a hot pressing temperature of 100 °C and a hot pressing time of 60 min;

[0061] S4. After the mold is cooled to a temperature less than 50 °C, the foaming material in the mold is demolded to obtain a three-dimensional fabric reinforced flame-retardant foaming material.

[0062] Example 5

[0063] S1. All raw materials except the three-dimensional fiber fabric are stirred and mixed evenly under the action of a stirrer with a stirring speed of 500 r / min and a stirring time of 8 min to obtain a foaming body. Among them, there are 70 parts of unsaturated polyester, 30 parts of methyl methacrylate; 30 parts of 909DU80, 3.8 parts of methyl ethyl ketone peroxide, 1.5 parts of cobalt octoate, 0.2 part of BYK-070, 0.2 part of BYK-W066, 0.5 part of DISPERBYK-106, and 9.9 parts of decabromodiphenylethane; the weight-average molecular weight of the unsaturated polyester resin is 5000, and the molar content of phthalic anhydride in the preparation raw materials accounts for 40% of the total molar amount of dibasic acids, and the molar content of maleic anhydride accounts for 60% of the total molar amount of dibasic acids;

[0064] S2. Apply a release agent evenly on the mold, preheat the mold to 100 °C, then place the carbon fiber fabric into the mold, and pour the foam obtained in step S1 into the mold. The carbon fiber fabric accounts for 35% of the total mass of the above raw materials. The planar shape of the fabric is fishbone-shaped, and the side mesh shape is 1X1-shaped;

[0065] S3. After locking the mold, perform hot pressing using a hot press. The hot pressing temperature is 150 °C, and the hot pressing time is 5 min;

[0066] S4. After the mold cools to a temperature below 50 °C, demold the foam material in the mold to obtain a three-dimensional fabric-reinforced flame-retardant foam material.

[0067] Example 6

[0068] A preparation method of a three-dimensional fabric-reinforced flame-retardant foam material includes the following steps:

[0069] S1. Stir and mix all raw materials except the three-dimensional fiber fabric evenly at a stirring speed of 100 r / min and a stirring time of 10 min in a blender to obtain a foam. Among them, there are 77 parts of unsaturated polyester, 33 parts of methyl acrylate, 49 parts of F-2860D; 3.8 parts of methyl ethyl ketone peroxide, 1.5 parts of cobalt isooctanoate, 0.3 part of BYK-141, 0.3 part of BYK-W066, 1.2 parts of DISPERBYK-108, and 9.9 parts of antimony trioxide; the weight-average molecular weight of the unsaturated polyester resin is 9500, and the molar content of phthalic anhydride in the preparation raw materials accounts for 70% of the total molar of dibasic acids, and the molar content of maleic anhydride accounts for 30% of the total molar of dibasic acids;

[0070] S2. Apply a release agent evenly on the mold, preheat the mold to 100 °C, then place the fishbone-shaped glass fiber fabric into the mold, and pour the foam obtained in step S1 into the mold. The glass fiber fabric accounts for 20% of the total mass of the above raw materials. The planar shape of the fabric is fishbone-shaped, and the side mesh shape is N-shaped;

[0071] S3. After locking the mold, perform hot pressing using a hot press. The hot pressing temperature is 100 °C, and the hot pressing time is 60 min;

[0072] S4. After the mold cools to a temperature below 50 °C, demold the foam material in the mold to obtain a three-dimensional fabric-reinforced flame-retardant foam material.

[0073] Example 7

[0074] A preparation method of a three-dimensional fabric-reinforced flame-retardant foam material includes the following steps:

[0075] S1. Mix all the raw materials except the three-dimensional fiber fabric evenly under the action of a mixer with a stirring speed of 100 r / min and a stirring time of 10 min to obtain a foam. Among them, there are 63 parts of unsaturated polyester resin, 27 parts of styrene, 12 parts of F-36; 1 part of methyl ethyl ketone peroxide, 0.2 part of cobalt isooctanoate, 0.1 part of BYK-067A, 0.1 part of BYK-P105, 0.1 part of DISPERBYK-108, and 5 parts of magnesium hydroxide; the weight-average molecular weight of the unsaturated polyester resin is 550, and the molar content of phthalic anhydride in the preparation raw materials accounts for 1% of the total molar amount of dibasic acids, and the molar content of maleic anhydride accounts for 99% of the total molar amount of dibasic acids;

[0076] S2. Apply a release agent evenly to the mold, preheat the mold to 50 °C, then place the fishbone-shaped glass fiber fabric into the mold, and pour the foam obtained in step S1 into the mold. Among them, the glass fiber fabric accounts for 50% of the total mass of the above raw materials, the plane shape of the fabric is a plane mesh shape, and the side mesh shape is a V shape;

[0077] S3. After locking the mold, perform hot pressing using a hot press. The hot pressing temperature is 100 °C and the hot pressing time is 60 min;

[0078] S4. After the mold is cooled to a temperature less than 50 °C, demold the foam material in the mold to obtain a three-dimensional fabric-reinforced flame-retardant foam material.

[0079] Example 8

[0080] S1. Mix all the raw materials except the three-dimensional fiber fabric evenly under the action of a mixer with a stirring speed of 900 r / min and a stirring time of 5 min to obtain a foam. Among them, there are 70 parts of unsaturated polyester, 30 parts of methyl methacrylate; 30 parts of 951DU120, 2.5 parts of methyl ethyl ketone peroxide, 1.5 parts of cobalt isooctanoate, 0.2 part of BYK-070, 0.2 part of BYK-W066, 0.5 part of DISPERBYK-106, and 5 parts of graphene; the weight-average molecular weight of the unsaturated polyester resin is 5000, and the molar content of phthalic anhydride in the preparation raw materials accounts for 40% of the total molar amount of dibasic acids, and the molar content of maleic anhydride accounts for 60% of the total molar amount of dibasic acids;

[0081] S2. Apply a release agent evenly to the mold, preheat the mold to 150 °C, then place the fishbone-shaped polypropylene fiber fabric into the mold, and pour the foam obtained in step S1 into the mold. Among them, the polypropylene fiber fabric accounts for 50% of the total mass of the above raw materials;

[0082] S3. After locking the mold, perform hot pressing using a hot press. The hot pressing temperature is 150 °C and the hot pressing time is 5 min;

[0083] S4. After the mold is cooled to a temperature below 50°C, the foamed material in the mold is demolded to obtain a three-dimensional fabric-reinforced flame-retardant foamed material.

[0084] Example 9

[0085] S1. All raw materials except the three-dimensional fiber fabric are stirred and mixed evenly at a stirring speed of 500 r / min and a stirring time of 8 min in a blender to obtain a foamed body. Among them, there are 77 parts of unsaturated polyester, 33 parts of butyl methacrylate, 49 parts of 980DU120, 3.8 parts of methyl ethyl ketone peroxide, 2.5 parts of cobalt isooctanoate, 0.3 part of BYK-141, 0.3 part of BYK-W066, 1.2 parts of DISPERBYK-103, and 9.9 parts of aluminum hydroxide; the weight-average molecular weight of the unsaturated polyester resin is 9500, and the molar content of phthalic anhydride in the preparation raw materials accounts for 70% of the total molar amount of dibasic acids, and the molar content of maleic anhydride accounts for 30% of the total molar amount of dibasic acids.

[0086] S2. The mold is evenly coated with a mold release agent and preheated to 150°C. Then, the fishbone-shaped carbon fiber fabric is placed into the mold, and the foamed body from step S1 is poured into the mold. Among them, the carbon fiber fabric accounts for 20% of the total mass of the above raw materials, the plane shape of the fabric is a plane mesh shape, and the side mesh shape is an N shape.

[0087] S3. After the mold is locked, hot pressing is carried out using a hot press. The hot pressing temperature is 135°C, and the hot pressing time is 30 min.

[0088] S4. After the mold is cooled to a temperature below 50°C, the foamed material in the mold is demolded to obtain a three-dimensional fabric-reinforced flame-retardant foamed material.

[0089] Comparative Example 1

[0090] The weight-average molecular weight of the unsaturated polyester resin in Comparative Example 1 is 15000, and other components, dosages, and preparation processes are the same as those in Example 2.

[0091] Comparative Example 2

[0092] In Comparative Example 2, the blowing agent is replaced with sodium bicarbonate, and other components, dosages, and preparation processes are the same as those in Example 2.

[0093] Comparative Example 3

[0094] In Comparative Example 3, the accelerator is replaced with dimethyl-p-toluidine, and other components, dosages, and preparation processes are the same as those in Example 2.

[0095] Comparative Example 4

[0096] Comparative Example 4 does not contain a flame retardant, and the other components, dosages, and preparation processes are the same as those in Example 2.

[0097] The three-dimensional fabric-reinforced flame-retardant foamed materials obtained from the above examples and comparative examples were tested. The formulation dosages and material property results of the above examples are shown in Table 1 below, and the material property results of the above comparative examples are shown in Table 2 below. The flame retardant grade is the flame retardant grade based on the UL94 standard.

[0098] Table 1 Formulation Dosages and Material Property Results of Examples

[0099]

[0100]

[0101] As can be seen from Table 1 above, the density of the three-dimensional fabric-reinforced flame-retardant foamed material of the present invention is between 0.05 g / cm 3 -0.3 g / cm 3 , the flexural strength is between 4 / Mpa - 10 / Mpa, the compressive strength is between 5.5 / Mpa - 11 / Mpa, featuring the characteristics of being lightweight and high-strength. The flame retardant grade is between V2 - V0, having high-temperature resistance and flame retardant properties, and being able to achieve the application effect of self-extinguishing when removed from the fire.

[0102] Table 2 Material Property Results Table of Comparative Examples

[0103] Comparative Example 1 2 3 4 Material density <![CDATA[0.355g / cm 3 > <![CDATA[1.86g / cm 3 > <![CDATA[1.45g / cm 3 > <![CDATA[0.077g / cm 3 > Flexural strength of the material 9.7 Mpa 45.5 / Mpa 38.9 / Mpa 5.4 / Mpa Compressive strength of the material 10.7 / Mpa 35.6 / Mpa 22.5 / Mpa 7.3 / Mpa Flame retardant grade of the material V1 V1 V1 Non-flammable

[0104] Combining Table 1 and Table 2, it can be seen that by using an unsaturated polyester resin with a weight average molecular weight of 500 - 10,000, a hollow microsphere foaming agent, a cobalt isooctanoate accelerator, and adding a flame retardant, the present invention can obtain a lightweight and high-strength flame-retardant foamed material.

[0105] The technical features of the above-described embodiments can be combined arbitrarily. For the sake of brevity of description, not all possible combinations of the technical features in the above embodiments are described. However, as long as these combinations of technical features do not conflict, they should all be considered as falling within the scope described in this specification.

[0106] The above-described specific embodiments further elaborate on the purpose, technical solutions, and beneficial effects of the present invention. It should be understood that the above are only specific embodiments of the present invention and are not used to limit the protection scope of the present invention. In particular, it is pointed out that for those skilled in the art, any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention should all be included within the protection scope of the present invention.

Claims

1. A three-dimensional fabric reinforced flame retardant foam material, characterized in that: The three-dimensional fabric reinforced flame-retardant foam material is prepared based on a thermal self-expansion molding process, and the three-dimensional fabric reinforced flame-retardant foam material includes the following components in parts by mass: Unsaturated polyester resin 63-77 parts; Unsaturated monomer 27-33 parts; 10-50 parts of hollow microsphere foaming agent; 1-4 parts of curing agent; Accelerator 0.1-3 parts; 1-10 parts of flame retardant; Additives 0.1-2 parts; and a three-dimensional fiber fabric comprising 20% ​​to 50% of the total mass ratio of the components; The weight average molecular weight of the unsaturated polyester resin is 500 to 10,000; the accelerator is cobalt isooctanoate, CAS: 136-52-7; and the auxiliary agent includes one or more of a defoaming agent, an anti-settling agent and a high temperature resistant wetting agent.

2. The three-dimensional fabric reinforced flame retardant foam material according to claim 1, characterized in that: The molar content of phthalic anhydride in the preparation raw materials accounts for 0-70% of the total molar content of the dibasic acid, and the molar content of maleic anhydride accounts for 30%-100% of the total molar content of the dibasic acid.

3. The three-dimensional fabric reinforced flame retardant foam material according to claim 1, characterized in that: The unsaturated monomer is one or more of styrene, methyl methacrylate, methyl acrylate and butyl methacrylate.

4. The three-dimensional fabric reinforced flame retardant foam material according to claim 1, characterized in that: The hollow microsphere foaming agent is one of MSH-890, FN-100SS, F-105, FN-105, F-170, FN-180SS, FN-180S, FN-180, FN-190SSD, F-230D, F-260D, F-2860D, F-30, F-36, F36LV, F-48, F-50, F-65 and FN-80GS of Matsumoto Oil Pharmaceutical Co., Ltd. of Japan; Or, one of NOURYOU's 031DU40, 051DU40, 093DU20, 461DU20, 551DU40, 909DU80, 920DU120, 920DU80, 930DU120, 950DU80, 951DU120, 980DU100 and 980DU120.

5. The three-dimensional fabric reinforced flame retardant foam material according to claim 1, characterized in that: The three-dimensional fiber fabric is one or more of glass fiber, carbon fiber, polypropylene fiber and polyethylene terephthalate fiber.

6. The three-dimensional fabric reinforced flame retardant foam material according to claim 1, characterized in that: The plane shape of the three-dimensional fiber fabric is a fishbone shape or a plane mesh shape, and the side mesh shape of the three-dimensional fiber fabric is one or more of a 1-shape, a V-shape, an X-shape, an N-shape and a 1X1-shape.

7. The three-dimensional fabric reinforced flame retardant foam material according to claim 1, characterized in that: The curing agent is methyl ethyl ketone peroxide, CAS: 1338-23-4.

8. The three-dimensional fabric reinforced flame retardant foam material according to claim 1, characterized in that: The flame retardant is one or more of a halogen flame retardant, a phosphorus flame retardant, an antimony flame retardant, an aluminum hydroxide flame retardant, a magnesium hydroxide flame retardant, an organosilicon flame retardant and graphene.

9. The three-dimensional fabric reinforced flame retardant foam material according to claim 1, characterized in that: The defoamer is one of BYK-067A, BYK-070 and BYK-141 produced by German BYK Chemicals; The anti-settling agent is BYK-P105 or BYK-W066 from German BYK Chemicals; The high temperature resistant wetting agent is one of DISPERBYK-103, DISPERBYK-106, DISPERBYK-107, DISPERBYK-108 and DISPERBYK-2205 produced by German BYK Chemical.

10. A method for preparing the three-dimensional fabric reinforced flame retardant foam material according to any one of claims 1 to 9, characterized in that: include: S1, stirring and mixing all the raw materials except the three-dimensional fiber fabric in a stirrer to obtain a foam; the stirring speed of the stirrer is 100r / min-900r / min, and the stirring time is 5min-10min; S2, evenly applying a release agent on the mold, preheating the mold, placing the three-dimensional fiber fabric in the mold, and pouring the foamed body of step S1 into the mold; the preheating temperature is 50°C-150°C; S3, after the mold is locked, hot pressing is performed using a hot press; the hot pressing temperature is 100°C-150°C, and the hot pressing time is 5min-60min; S4, after the mold is cooled to a temperature less than 50° C., the foaming material in the mold is demolded to obtain a three-dimensional fabric reinforced flame-retardant foaming material.

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