A lightweight melamine insulation board and its preparation method

Abstract

The present invention discloses a lightweight melamine insulation board and a preparation method thereof. The lightweight melamine insulation board is characterized by being formed by hot-pressing multiple layers of overlapping modified melamine insulation resin fiber fabric prepregs; the modified melamine insulation resin fiber fabric prepregs are obtained by coating a modified melamine insulation resin adhesive on a basalt fiber fabric and then baking it; and the modified melamine insulation resin adhesive is composed of a mixture of melamine resin, silicone resin, polyether-modified epoxy resin, melamine salt, nano-modifier, modifying agent, curing agent, accelerator, and solvent. The lightweight melamine insulation board of the present invention has the characteristics of light weight, low thermal conductivity, high mechanical strength, high mechanical toughness, and high flame retardancy, and is suitable for use in transportation, building insulation, energy industry, and other fields.

Description

Technical Field

[0001] This invention relates to laminated panels and their preparation, specifically to a lightweight melamine insulation board and its preparation method. The lightweight melamine insulation board is suitable for use in transportation, building insulation, the energy industry, and other fields, and is particularly suitable as a lightweight insulation material for new energy vehicles, lithium battery packs, and submarine pipeline transportation. Background Art

[0002] With the technological development in fields such as 5G, big data, artificial intelligence, and the Internet of Things, the power density of electronic devices continues to rise, and efficient thermal management materials and solutions are urgently needed to ensure the efficiency, reliability, safety, durability, and continuous stability of products.

[0003] Thermal insulation materials are materials or composites that have insulating properties and act as a shield against heat flow. They are typically lightweight, loose, porous, and have low thermal conductivity. They are widely used in industry to prevent heat loss from thermal equipment and pipelines, or in freezing and low-temperature conditions, hence the name "heat or cold insulation." Their porous or fibrous structure provides excellent sound absorption, making them widely used in the construction industry. Lightweight thermal insulation materials are a new type of material that is lightweight, efficient, energy-efficient, and environmentally friendly. Their widespread application will help reduce energy consumption, minimize environmental pollution, and improve economic and social benefits. They are widely used in transportation, building insulation, the energy industry, and other fields.

[0004] Thermal runaway is the primary cause of safety incidents in power battery packs. At high energy densities, battery fire or explosion can occur due to factors such as battery batch consistency, the thermal stability of the materials themselves, the compatibility between battery components, and the highly flammable nature of the electrolyte. Following thermal runaway in a battery cell, the battery system must remain free of fire and explosion for five minutes. Achieving a "five-minute safe escape time" requires corresponding technical requirements for the battery pack's insulation materials to delay the explosion of faulty battery packs. With the continued rapid growth of China's new energy vehicle and lithium battery energy storage markets, the market demand for thermal management, flame-retardant, and insulation materials for lithium batteries is poised to surge.

[0005] In pursuit of volumetric energy density, lithium battery manufacturers are increasingly designing battery packs with a compact size and weight. This has led to revolutionary requirements for the battery pack outer packaging separators they use. These separators must not only ensure the overall battery pack is lightweight (low density), has high energy utilization (low thermal conductivity), and is highly safe (flame retardant), but must also possess excellent support strength, deformation resistance (mechanical strength), insulation performance (electrical strength), and thinner sheet thickness (which can be greater than or equal to 0.5mm). These requirements cannot be achieved with existing foam materials with low mechanical strength and large thickness. Existing technologies are unable to meet the demand for sandwich insulation materials in modern transportation, building insulation, energy industry, and other fields that require higher dimensional accuracy, mechanical and electrical strength, flame retardancy, and environmental protection. Summary of the Invention

[0006] The purpose of the present invention is to overcome the above-mentioned deficiencies in the prior art and provide a lightweight melamine insulation board and a preparation method thereof. 3 ~1.75g / cm 3 ), high thermal insulation (thermal conductivity (25°C) less than 0.2w / m·k), high strength (flexural strength of 350MPa~420MPa, tensile strength of 336MPa~372MPa), high heat resistance (flexural strength at 150°C 207MPa~266MPa), high toughness (notched impact strength of 65KJ / m 2 ~75KJ / m 2 ), excellent insulation (insulation resistance greater than or equal to 10 8 The invention relates to a lightweight melamine thermal insulation board with high thermal conductivity (MΩ), flame retardancy (reaching UL94 V-0 level) and thin board thickness (which can be greater than or equal to 0.5 mm) and a preparation method thereof.

[0007] The present invention provides a lightweight melamine insulation board, characterized in that the lightweight melamine insulation board is formed by hot pressing multiple layers of overlapping modified melamine insulation resin fiber fabric prepreg (the number of layers of the modified melamine insulation resin fiber fabric prepreg is not limited and can be 1 to 500 layers as required);

[0008] The modified melamine thermal insulation resin fiber fabric prepreg is obtained by coating a modified melamine thermal insulation resin adhesive on a basalt fiber fabric and then baking it;

[0009] The modified melamine thermal insulation resin adhesive is composed of 100 parts by weight of melamine resin, 15-35 parts by weight of silicone resin, 5-35 parts by weight of polyether modified epoxy resin, 5-25 parts by weight of melamine salt, 10-40 parts by weight of nano-modifier, 0.01-0.06 parts by weight of modification treatment agent, 0.2-13 parts by weight of curing agent, 0.005-0.1 parts by weight of accelerator and 60-400 parts by weight of solvent;

[0010] The basalt fiber fabric is at least one of basalt fiber plain fabric, basalt fiber twill fabric, basalt fiber gingham fabric, basalt fiber multi-axial fabric, and basalt fiber composite fabric (the production and supply companies and product models (brands) of the basalt fiber fabric include: Ningbo Fangtai Fiberglass Products Co., Ltd., Jiangsu Kangdafu New Materials Technology Co., Ltd., Tongxiang Lanshi Composite Materials Co., Ltd., etc.).

[0011] In the modified melamine thermal insulation resin adhesive of the present invention:

[0012] The melamine resin is a highly etherified melamine formaldehyde resin [the production and supply companies and product models (brands) of the highly etherified melamine formaldehyde resin include: JY-303 of Jining Juyue New Materials Co., Ltd., CYMEL303LF of Allnex, etc.];

[0013] The polyether-modified epoxy resin is produced by: Japanese ADEKA's EP-1307, EP-4000, etc.

[0014] The organic silicone resin, the production and supply enterprises and product models (brands) of the organic silicone resin are: SI-101 of Laiyang Shengbang Organic Silicone Technology Co., Ltd., KR-271 of Shin-Etsu Chemical Co., Ltd. of Japan, SM1153D of Sanmu Group, etc.

[0015] The melamine salt is phosphate [the production and supply enterprises and product models (brands) of the phosphate are: Jinan Taizhong Kexing New Material Technology Co., Ltd., Guangzhou Shanghe Chemical Technology Co., Ltd. X2023, etc.], polyphosphate [the production and supply enterprises and product models (brands) of the polyphosphate are: Hubei Longxin Chemical Industry Co., Ltd. LX9685, Zhongshan Dixin Chemical Co., Ltd. DBFPE, etc.], ammonium polyphosphate [the production and supply enterprises and product models (brands) of the ammonium polyphosphate are: Guangzhou Yinyuan New Materials Co., Ltd. FR-AP1001 of Jinan Xinnuo Chemical Co., Ltd., APP of Jinan Haobang Chemical Co., Ltd., etc.], dimelamine pyrophosphate [the production and product models (trademarks) of the dimelamine pyrophosphate include: Senfida Chemical, Wuhan Huaxiang Kejie Biotechnology Co., Ltd., etc.], melamine cyanurate [the production and product models (trademarks) of the melamine cyanurate include: Guangzhou Yinyuan New Materials Co., Ltd., Shandong Qizhuo New Materials Technology Co., Ltd., etc.] any one or a mixture of two or more thereof;

[0016] The curing agent is a mixture of any two or more of diaminodiphenyl sulfone [the production and product models (trademarks) of the diaminodiphenyl sulfone include: DDS of Jingmen Dongxin Biotechnology Co., Ltd., PA04296 of Guangdong Wengjiang Biotechnology Co., Ltd., etc.], dicyandiamide [the production and product models (trademarks) of the dicyandiamide include: Jinan Kaichuang Chemical Co., Ltd., Guangzhou Xinxi Metallurgical Chemical Co., Ltd., etc.], and diaminodiphenylmethane [the production and product models (trademarks) of the diaminodiphenylmethane include: Wuhan Zhisheng Technology Co., Ltd., Zhangjiagang Yarui Chemical Co., Ltd., Guangzhou Yangming Chemical Technology Co., Ltd., etc.];

[0017] The nano-modifier is one or a mixture of two of fumed silica [the production and supply companies and product models (brands) of the fumed silica include: TT 1000 granulate of Suzhou Unico Insulation Technology Co., Ltd.] and hollow glass microspheres [the production and supply companies and product models (brands) of the hollow glass microspheres include: C-40 of Zhongke Huaxing New Materials Co., Ltd., S4630 of 3M Company, etc.];

[0018] The modifying agent is any one of 3-aminopropyltriethoxysilane [the production and product models (trademarks) of the 3-aminopropyltriethoxysilane include: Shandong Tianming Biotechnology Development Co., Ltd., Shandong Xiya Chemical Co., Ltd., Linyi Azeroth Biotechnology Co., Ltd., etc.], 3-glycidyloxypropyltrimethoxysilane [the production and product models (trademarks) of the 3-glycidyloxypropyltrimethoxysilane include: Hubei Yongkuo Technology Co., Ltd., Nantong Runfeng Petrochemical Co., Ltd., Guangdong Wengjiang Chemical Reagent Co., Ltd., etc.], γ-aminopropyltriethoxysilane [the production and product models (trademarks) of the γ-aminopropyltriethoxysilane include: Hangzhou Jessica Chemical Co., Ltd., Henan Wanshan New Materials Technology Co., Ltd., etc.], and γ-glycidyloxypropyltrimethoxysilane [the production and product models (trademarks) of the γ-glycidyloxypropyltrimethoxysilane include: Henan Xinpeng Chemical Products Co., Ltd., Henan Xiye Chemical Co., Ltd., etc.] or a mixture of two or more thereof;

[0019] The accelerator is any one of imidazole [the production and provision of the imidazole include: 2-methylimidazole of Linyi Mingpin Chemical Co., Ltd., N,N'-carbonyldiimidazole of Shanghai Nuotai Chemical Co., Ltd., etc.], acetyl metal complex [the production and provision of the acetyl metal complex include: No. 3 curing agent of Hubei Hongfuda Biotechnology Co., Ltd., etc.], boron trifluoride ethylamine [the production and provision of the boron trifluoride ethylamine include: Beijing Xinao Xunchi Chemical Co., Ltd., Nanjing Chemical Reagent Co., Ltd., etc.], p-toluenesulfonic acid [the production and provision of the p-toluenesulfonic acid include: Datang Chemical Co., Ltd., Ji Chuang Chemical Co., Ltd., Shandong Dongyue New Materials Technology Co., Ltd., etc.], methanesulfonic acid [the production and provision of the methanesulfonic acid include: Langyu Chemical, Jinan Ronghui Chemical, etc.] or a mixture of two or more thereof;

[0020] The solvent is toluene [the production and supply enterprises and product models (brands) of the toluene include: Langfang Jinhai Chemical Co., Ltd., Shandong Qixing Chemical Co., Ltd., etc.], xylene [the production and supply enterprises and product models (brands) of the xylene include: Shandong Ruigang Chemical Co., Ltd., Shandong Guanyi Chemical Co., Ltd., etc.], acetone [the production and supply enterprises and product models (brands) of the acetone include: Jinan Daliang Chemical Co., Ltd., Kunshan Minglong Chemical Co., Ltd.], butanone [the production and supply enterprises and product models (brands) of the butanone include: Langfang Jinhai Chemical Co., Ltd., Shandong Qixing Chemical Co., Ltd. etc.], ethanol [the production and provision of ethanol and the product models (trademarks) include: Foshan Changxing New Materials Co., Ltd., Shandong Xinhongfeng New Materials Technology Co., Ltd., etc.], ethylene glycol methyl ether [the production and provision of ethylene glycol methyl ether and the product models (trademarks) include: Shandong Jinyueyuan New Materials Co., Ltd., Shandong Jinyueyuan New Materials Co., Ltd., etc.], N,N-dimethylformamide [the production and provision of N,N-dimethylformamide and the product models (trademarks) include: Dongguan Nanjian Fine Chemical Co., Ltd., Guangzhou Futuo Trading Co., Ltd., etc.] any one or a mixture of two or more thereof.

[0021] In the content of the present invention: the hot pressing molding is preferably: after preheating the template at 105°C to 155°C, the modified melamine thermal insulation resin fiber fabric prepreg is overlapped (including matching and laminating) and placed in the template, and after closing the mold, it is hot pressed under the conditions of temperature 130°C to 175°C and pressure 1MPa to 25MPa, and the hot pressing time is 0.5h to 50h (h means hours, the same below).

[0022] In the content of the present invention: the baking is preferably: placing the basalt fiber fabric coated with a modified melamine thermal insulation resin adhesive (by a gluing machine) into a drying tunnel, the drying tunnel is 50m long and divided into 4 sections, each 12.5m, and the baking temperature range is 75°C to 175°C, wherein: the first section is 75°C to 95°C, the second section is 105°C to 135°C, the third section is 135°C to 175°C, and the fourth section is 85°C to 110°C, and the speed of the gluing machine is 5m / min to 25m / min.

[0023] In the content of the present invention: The preparation method of the modified melamine thermal insulation resin adhesive is preferably: at a temperature of 50°C to 85°C, the nano modifier, the modification treatment agent, the polyether modified epoxy resin and the silicone resin are stirred and mixed at a speed of 800r / min to 1500r / min, and stirred for 1h to 3h (to prepare the modified resin for standby use), and then a curing agent is added and mixed at room temperature. After stirring for 0.5h to 2.5h, melamine resin and melamine salt are added, mixed and stirred at room temperature, stirred for 0.75h to 1.5h, and then a solvent and a accelerator are added. After stirring and mixing at room temperature, the resin molding time is tested to be 320s to 450s at 160°C to obtain the modified melamine thermal insulation resin adhesive.

[0024] In the present invention, in the modified melamine thermal insulation resin fiber fabric prepreg, the weight percentage of the (semi-cured) modified melamine thermal insulation resin adhesive is preferably 25% to 50%, and the weight percentage of the basalt fiber fabric is preferably 50% to 75%.

[0025] In the context of the present invention: the lightweight melamine insulation board has a light weight (density of 1.52g / cm 3 ~1.75g / cm 3 ), high thermal insulation (thermal conductivity (25°C) less than 0.2w / m·k), high strength (flexural strength of 350MPa~420MPa, tensile strength of 336MPa~372MPa), high heat resistance (flexural strength at 150°C 207MPa~266MPa), high toughness (notched impact strength of 65KJ / m 2 ~75KJ / m 2 ), excellent insulation (insulation resistance greater than or equal to 10 8 The invention discloses a lightweight melamine insulation board having the characteristics of high thermal conductivity (MΩ), flame retardancy (reaching UL94 V-0 grade) and thin board thickness (can be greater than or equal to 0.5 mm) and a preparation method thereof.

[0026] Another aspect of the present invention is: a method for preparing a lightweight melamine insulation board, which is characterized by comprising the following steps:

[0027] a. Ingredients: Prepare the raw materials of each component according to the ratio of 100 parts by weight of melamine resin, 15-35 parts by weight of silicone resin, 5-35 parts by weight of polyether modified epoxy resin, 5-25 parts by weight of melamine salt, 10-40 parts by weight of nano-modifier, 0.01-0.06 parts by weight of modification treatment agent, 0.2-13 parts by weight of curing agent, 0.005-0.1 parts by weight of accelerator and 60-400 parts by weight of solvent;

[0028] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 50° C. to 85° C., the nano-modifier, the modifying agent, the polyether-modified epoxy resin and the silicone resin are stirred and mixed at a speed of 800 r / min to 1500 r / min, stirred for 1 h to 3 h (to prepare a modified resin for standby use), and then a curing agent is added and mixed at room temperature. After stirring for 0.5 h to 2.5 h, melamine resin and melamine salt are added, mixed and stirred at room temperature, stirred for 0.75 h to 1.5 h, and then a solvent and an accelerator are added. After stirring and mixing at room temperature, the resin molding time is tested to be 320 s to 450 s at 160° C. to prepare a modified melamine thermal insulation resin adhesive;

[0029] c. Preparing a modified melamine thermal insulation resin fiber fabric prepreg: coating the modified melamine thermal insulation resin adhesive prepared in step b on a basalt fiber fabric, and then baking to obtain a modified melamine thermal insulation resin fiber fabric prepreg;

[0030] The basalt fiber fabric is at least one of basalt fiber plain cloth, basalt fiber twill cloth, basalt fiber woven cloth, basalt fiber multi-axial cloth, and basalt fiber composite cloth;

[0031] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold and hot pressing it at a temperature of 130°C to 175°C and a pressure of 1MPa to 25MPa for 0.5h to 50h to obtain a lightweight melamine insulation board.

[0032] In another aspect of the present invention: the baking is preferably performed by placing the basalt fiber fabric coated with a modified melamine thermal insulation resin adhesive (by a gluing machine) into a drying tunnel, the drying tunnel is 50 m long and divided into 4 sections, each 12.5 m, and the baking temperature range is 75 ° C to 175 ° C, wherein: the first section is 75 ° C to 95 ° C, the second section is 105 ° C to 135 ° C, the third section is 135 ° C to 175 ° C, and the fourth section is 85 ° C to 110 ° C, and the speed of the gluing machine is 5 m / min to 25 m / min.

[0033] Another aspect of the present invention relates to a method for preparing a lightweight melamine insulation board, wherein the ingredients in step a are:

[0034] The melamine resin is a highly etherified melamine formaldehyde resin [the production and supply companies and product models (brands) of the highly etherified melamine formaldehyde resin include: JY-303 of Jining Juyue New Materials Co., Ltd., CYMEL303LF of Allnex, etc.;

[0035] The polyether-modified epoxy resin is produced by: Japanese ADEKA's EP-1307, EP-4000, etc.

[0036] The organic silicone resin, the production and supply enterprises and product models (brands) of the organic silicone resin are: SI-101 of Laiyang Shengbang Organic Silicone Technology Co., Ltd., KR-271 of Shin-Etsu Chemical Co., Ltd. of Japan, SM1153D of Sanmu Group, etc.

[0037] The melamine salt is phosphate [the production and supply enterprises and product models (brands) of the phosphate are: Jinan Taizhong Kexing New Material Technology Co., Ltd., Guangzhou Shanghe Chemical Technology Co., Ltd. X2023, etc.], polyphosphate [the production and supply enterprises and product models (brands) of the polyphosphate are: Hubei Longxin Chemical Industry Co., Ltd. LX9685, Zhongshan Dixin Chemical Co., Ltd. DBFPE, etc.], ammonium polyphosphate [the production and supply enterprises and product models (brands) of the ammonium polyphosphate are: Guangzhou Yinyuan New Materials Co., Ltd. FR-AP1001 of Jinan Xinnuo Chemical Co., Ltd., APP of Jinan Haobang Chemical Co., Ltd., etc.], dimelamine pyrophosphate [the production and product models (trademarks) of the dimelamine pyrophosphate include: Senfida Chemical, Wuhan Huaxiang Kejie Biotechnology Co., Ltd., etc.], melamine cyanurate [the production and product models (trademarks) of the melamine cyanurate include: Guangzhou Yinyuan New Materials Co., Ltd., Shandong Qizhuo New Materials Technology Co., Ltd., etc.] any one or a mixture of two or more thereof;

[0038] The curing agent is a mixture of any two or more of diaminodiphenyl sulfone [the production and product models (trademarks) of the diaminodiphenyl sulfone include: DDS of Jingmen Dongxin Biotechnology Co., Ltd., PA04296 of Guangdong Wengjiang Biotechnology Co., Ltd., etc.], dicyandiamide [the production and product models (trademarks) of the dicyandiamide include: Jinan Kaichuang Chemical Co., Ltd., Guangzhou Xinxi Metallurgical Chemical Co., Ltd., etc.], and diaminodiphenylmethane [the production and product models (trademarks) of the diaminodiphenylmethane include: Wuhan Zhisheng Technology Co., Ltd., Zhangjiagang Yarui Chemical Co., Ltd., Guangzhou Yangming Chemical Technology Co., Ltd., etc.];

[0039] The nano-modifier is one or a mixture of two of fumed silica [the production and supply companies and product models (brands) of the fumed silica include: TT 1000 granulate of Suzhou Unico Insulation Technology Co., Ltd.] and hollow glass microspheres [the production and supply companies and product models (brands) of the hollow glass microspheres include: C-40 of Zhongke Huaxing New Materials Co., Ltd., S4630 of 3M Company, etc.];

[0040] The modifying agent is any one of 3-aminopropyltriethoxysilane [the production and product models (trademarks) of the 3-aminopropyltriethoxysilane include: Shandong Tianming Biotechnology Development Co., Ltd., Shandong Xiya Chemical Co., Ltd., Linyi Azeroth Biotechnology Co., Ltd., etc.], 3-glycidyloxypropyltrimethoxysilane [the production and product models (trademarks) of the 3-glycidyloxypropyltrimethoxysilane include: Hubei Yongkuo Technology Co., Ltd., Nantong Runfeng Petrochemical Co., Ltd., Guangdong Wengjiang Chemical Reagent Co., Ltd., etc.], γ-aminopropyltriethoxysilane [the production and product models (trademarks) of the γ-aminopropyltriethoxysilane include: Hangzhou Jessica Chemical Co., Ltd., Henan Wanshan New Materials Technology Co., Ltd., etc.], and γ-glycidyloxypropyltrimethoxysilane [the production and product models (trademarks) of the γ-glycidyloxypropyltrimethoxysilane include: Henan Xinpeng Chemical Products Co., Ltd., Henan Xiye Chemical Co., Ltd., etc.] or a mixture of two or more thereof;

[0041] The accelerator is any one of imidazole [the production and provision of the imidazole include: 2-methylimidazole of Linyi Mingpin Chemical Co., Ltd., N,N'-carbonyldiimidazole of Shanghai Nuotai Chemical Co., Ltd., etc.], acetyl metal complex [the production and provision of the acetyl metal complex include: No. 3 curing agent of Hubei Hongfuda Biotechnology Co., Ltd., etc.], boron trifluoride ethylamine [the production and provision of the boron trifluoride ethylamine include: Beijing Xinao Xunchi Chemical Co., Ltd., Nanjing Chemical Reagent Co., Ltd., etc.], p-toluenesulfonic acid [the production and provision of the p-toluenesulfonic acid include: Datang Chemical Co., Ltd., Ji Chuang Chemical Co., Ltd., Shandong Dongyue New Materials Technology Co., Ltd., etc.], methanesulfonic acid [the production and provision of the methanesulfonic acid include: Langyu Chemical, Jinan Ronghui Chemical, etc.] or a mixture of two or more thereof;

[0042] The solvent is toluene [the production and supply enterprises and product models (brands) of the toluene include: Langfang Jinhai Chemical Co., Ltd., Shandong Qixing Chemical Co., Ltd., etc.], xylene [the production and supply enterprises and product models (brands) of the xylene include: Shandong Ruigang Chemical Co., Ltd., Shandong Guanyi Chemical Co., Ltd., etc.], acetone [the production and supply enterprises and product models (brands) of the acetone include: Jinan Daliang Chemical Co., Ltd., Kunshan Minglong Chemical Co., Ltd.], butanone [the production and supply enterprises and product models (brands) of the butanone include: Langfang Jinhai Chemical Co., Ltd., Shandong Qixing Chemical Co., Ltd. etc.], ethanol [the production and provision of ethanol and the product models (trademarks) include: Foshan Changxing New Materials Co., Ltd., Shandong Xinhongfeng New Materials Technology Co., Ltd., etc.], ethylene glycol methyl ether [the production and provision of ethylene glycol methyl ether and the product models (trademarks) include: Shandong Jinyueyuan New Materials Co., Ltd., Shandong Jinyueyuan New Materials Co., Ltd., etc.], N,N-dimethylformamide [the production and provision of N,N-dimethylformamide and the product models (trademarks) include: Dongguan Nanjian Fine Chemical Co., Ltd., Guangzhou Futuo Trading Co., Ltd., etc.] any one or a mixture of two or more thereof.

[0043] In another aspect of the present invention, the performance parameters of the lightweight melamine insulation board are as follows: flexural strength at room temperature is 350MPa-420MPa, flexural strength at 150°C is 207MPa-266MPa, tensile strength is 336MPa-372MPa, notched impact strength is 65KJ / m 2 ~75KJ / m 2 , insulation resistance is greater than or equal to 10 8 MΩ, flame retardancy reaches UL94 V-0 level, thermal conductivity (25℃) is less than 0.2w / m·k, density is 1.52g / cm 3 ~1.75g / cm 3 The thickness of the plate is thin (may be greater than or equal to 0.5 mm).

[0044] In another aspect of the present invention: in the modified melamine thermal insulation resin fiber fabric prepreg described in step c: the weight percentage of the modified melamine thermal insulation resin adhesive is 25% to 50%, and the weight percentage of the basalt fiber fabric is 50% to 75%.

[0045] Compared with the prior art, the present invention has the following characteristics and beneficial effects:

[0046] (1) The lightweight melamine insulation board of the present invention is based on highly etherified melamine formaldehyde resin, silicone resin, and polyether modified epoxy resin, supplemented by modified resin and nano-modifier to improve the overall microscopic topological structure of the system, combined with a high-performance curing agent, and supplemented with high-performance basalt fiber fabric on the basis of simple medium and low temperature modification and grafting, so as to achieve the laminated board with excellent halogen-free flame retardancy and insulation, especially high temperature resistance, low thermal conductivity and excellent impact toughness, thereby obtaining a lightweight insulation board with excellent comprehensive performance;

[0047] (2) The present invention uses a mixed resin (such as melamine formaldehyde resin, silicone resin, polyether modified epoxy resin) as the matrix and is modified with ultrafine nano inorganic materials, replacing the usual organic foaming agent foaming to improve thermal insulation, thereby achieving better thermal insulation performance (thermal conductivity at 25°C reaches 0.131w / m·k0.141w / m·k) than common hard insulation boards (usually, the thermal conductivity at 25°C is greater than or equal to 0.45w / m·k). At the same time, it also effectively solves the problem of the thick thickness of existing common organic or inorganic foamed boards (usually greater than or equal to 8mm), and achieves a thickness range of greater than or equal to 0.5mm for thermal insulation boards, making them more widely applicable to electronic appliances and industries with high requirements for product intensiveness;

[0048] (3) The present invention makes full use of the combined effect of the dilution effect of the self-released gas and the heat covering effect of the material when it is heated and burned, and achieves a highly efficient flame retardant effect (reaching UL94V-0) without adding any flame retardant additives. It breaks through the problem that the existing common foaming materials are easy to burn and have thick smoke when burning, and meets the urgent requirements of my country for the "green" development of modern industry. At the same time, the present invention also solves the industry consensus that the addition of flame retardant additives significantly reduces the mechanical strength of the material, especially its temperature resistance, and produces a new type of thermal insulation material with excellent comprehensive performance (excellent mechanical strength, which can refer to the bending strength at 23℃±2℃ reaching 350MPa420MPa, the bending strength at 150℃±2℃ reaching 207MPa266MPa, that is: the bending strength retention rate at 150℃±2℃ is greater than or equal to 57%, and the thermal conductivity at 25℃ reaches 0.131w / m·k0.141w / m·k);

[0049] (4) The present invention uses basalt fiber fabric instead of common glass fiber, which ensures that the board has low thermal conductivity while achieving excellent mechanical strength, especially impact toughness (which can be: impact strength, notched specimen, up to 65KJ / m 2 75KJ / m 2); solves the problem that adding rubber elastomer additives often reduces the overall mechanical strength and heat resistance of the material (for example, as described in "The Effect of Toughening Agents on the Properties of Epoxy Resins" by Ma Tianxin and Jiang Bo);

[0050] (5) In the preparation process of the modified melamine thermal insulation resin adhesive of the lightweight melamine thermal insulation board of the present invention, the raw materials are gradually added by a medium-low temperature synthesis reaction method, and stirred and mixed at medium-low temperature to obtain a uniform modified melamine thermal insulation resin adhesive that meets the prepreg preparation process, and the preparation process is simple;

[0051] (6) The present invention mainly adopts melamine resin, which is modified and then impregnated with basalt fiber fabric to obtain a new type of thermal insulation material with excellent thermal insulation properties, good mechanical strength, insulation and flame retardancy, especially better bending strength, tensile strength and impact toughness. At the same time, it also solves the problem that the thermal insulation material obtained by the existing foaming process is thick and has poor mechanical strength. The lightweight melamine insulation board of the present invention has light weight (density of 1.52g / cm 3 ~1.75g / cm 3 ), high thermal insulation (thermal conductivity (25°C) less than 0.2w / m·k), high strength (flexural strength of 350MPa~420MPa, tensile strength of 336MPa~372MPa), high heat resistance (flexural strength at 150°C 207MPa~266MPa), high toughness (notched impact strength of 65KJ / m 2 ~75KJ / m 2 ), excellent insulation (insulation resistance greater than or equal to 10 8 MΩ), flame retardancy (reaching UL94 V-0 level) and thin sheet thickness (can be greater than or equal to 0.5mm);

[0052] (7) The preparation process of the product of the present invention is simple, and the requirements for production equipment and operators are low. It can better meet my country's requirements for "green, environmentally friendly, and efficient" production of enterprises, and greatly reduce production costs and simplify the process. The product quality and performance are excellent, and the actual use value and application prospects are good. The prepared lightweight melamine insulation board is particularly suitable for use as a lightweight insulation material in the fields of new energy vehicles, lithium battery packs, submarine pipeline transportation, etc., and has strong practicality. DETAILED DESCRIPTION

[0053] The following embodiments are intended to further illustrate the present invention, but should not be construed as limiting the scope of protection of the present invention. Non-essential improvements and adjustments made to the present invention by those skilled in the art based on the above-mentioned contents of the present invention still fall within the scope of protection of the present invention.

[0054] In the following Examples 1-19, the unit of “parts by weight” is “gram”.

[0055] Example 1:

[0056] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0057] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 16 parts by weight of silicone resin, 5 parts by weight of polyether-modified epoxy resin, 7 parts by weight of melamine salt (polyphosphate), 13 parts by weight of nano-modifier (fumed silica), 0.017 parts by weight of modifying agent (γ-aminopropyltriethoxysilane), 1.5 parts by weight of curing agent (diaminodiphenyl sulfone), 0.012 parts by weight of accelerator (imidazole), and 82 parts by weight of solvent (methyl ethyl ketone);

[0058] b. Preparation of modified melamine thermal insulation resin adhesive: At a temperature of 60° C., a nano-modifier, a modifying agent, a polyether-modified epoxy resin and a silicone resin were stirred at a speed of 850 r / min, stirred for 1.25 h, and then a curing agent was added and mixed at room temperature. After stirring for 0.65 h, melamine resin and melamine salt were added and mixed at room temperature. After stirring for 1 h, a solvent and an accelerator were added and mixed at room temperature. The resin molding time was tested at 160° C. for 366 s to obtain a modified melamine thermal insulation resin adhesive;

[0059] c. Preparing a modified melamine thermal insulation resin fiber fabric prepreg: coating the modified melamine thermal insulation resin adhesive prepared in step b on a basalt fiber fabric through a gluing machine, and then placing the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive into a drying tunnel, wherein the drying tunnel is 50 m long and divided into 4 sections, each 12.5 m long, and the baking temperature range is 75° C. to 175° C., wherein: the first section is 75° C. to 95° C., the second section is 105° C. to 135° C., the third section is 135° C. to 175° C., and the fourth section is 85° C. to 110° C. The speed of the gluing machine is 5 m / min to 25 m / min, to obtain a modified melamine thermal insulation resin fiber fabric prepreg; pre-baking the drying tunnel before baking; the fiber fabric prepreg has a soluble resin content greater than or equal to 95%, and a volatile matter content less than or equal to 2%; specific process parameters are shown in Table 1;

[0060] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0061] Example 2:

[0062] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0063] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 19 parts by weight of silicone resin, 8 parts by weight of polyether-modified epoxy resin, 5 parts by weight of melamine salt (melamine cyanurate), 15 parts by weight of nano-modifier (hollow glass microspheres), 0.013 parts by weight of modification agent (3-glycidyloxypropyltrimethoxysilane), 0.2 parts by weight of curing agent (dicyandiamide), 0.032 parts by weight of accelerator (acetyl metal complex) and 91 parts by weight of solvent (N,N-dimethylformamide);

[0064] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 55° C., the nano-modifier, the modifying agent, the polyether-modified epoxy resin and the silicone resin were stirred at a speed of 800 r / min, stirred for 1.75 h, and then a curing agent was added and mixed at room temperature. After stirring for 0.5 h, melamine resin and melamine salt were added and mixed at room temperature. After stirring for 1.15 h, a solvent and an accelerator were added and mixed at room temperature. The resin molding time was tested at 160° C. for 347 s to obtain a modified melamine thermal insulation resin adhesive;

[0065] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0066] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0067] Example 3:

[0068] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0069] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 15 parts by weight of silicone resin, 11 parts by weight of polyether-modified epoxy resin, 13 parts by weight of melamine salt (phosphate), 11 parts by weight of nano-modifier (hollow glass microspheres), 0.01 parts by weight of modifying agent (γ-aminopropyltriethoxysilane), 0.4 parts by weight of curing agent (diaminodiphenylmethane), 0.005 parts by weight of accelerator (boron trifluoride ethylamine) and 60 parts by weight of solvent (toluene);

[0070] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 50° C., the nano-modifier, the modifying agent, the polyether-modified epoxy resin and the silicone resin were stirred at a speed of 900 r / min, stirred for 2.5 h, and then a curing agent was added and mixed at room temperature. After stirring for 0.75 h, melamine resin and melamine salt were added and mixed at room temperature. After stirring for 0.75 h, a solvent and an accelerator were added and mixed at room temperature. The resin molding time was tested at 160° C. for 372 s to obtain a modified melamine thermal insulation resin adhesive;

[0071] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0072] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0073] Example 4:

[0074] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0075] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 21 parts by weight of silicone resin, 9 parts by weight of polyether-modified epoxy resin, 11 parts by weight of melamine salt (ammonium polyphosphate), 10 parts by weight of nano-modifier (fumed silica), 0.023 parts by weight of modifying agent (3-aminopropyltriethoxysilane), 0.9 parts by weight of curing agent (diaminodiphenyl sulfone), 0.021 parts by weight of accelerator (p-toluenesulfonic acid), and 125 parts by weight of solvent (ethanol);

[0076] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 65° C., the nano-modifier, modifying agent, polyether-modified epoxy resin and silicone resin were stirred at a speed of 1200 r / min, stirred for 1 hour (to prepare modified resin for standby use), and then a curing agent was added and mixed at room temperature. After stirring for 0.75 hour, melamine resin and melamine salt were added and mixed at room temperature. After stirring for 1 hour, a solvent and an accelerator were added and mixed at room temperature. The resin molding time was tested at 160° C. for 320 seconds to prepare a modified melamine thermal insulation resin adhesive.

[0077] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0078] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0079] Example 5:

[0080] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0081] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 18 parts by weight of silicone resin, 15 parts by weight of polyether-modified epoxy resin, 9 parts by weight of melamine salt (dimelamine pyrophosphate), 19 parts by weight of nano-modifier (fumed silica), 0.026 parts by weight of modifying agent (3-aminopropyltriethoxysilane), 1.3 parts by weight of curing agent (diaminodiphenyl sulfone), 0.041 parts by weight of accelerator (methanesulfonic acid), and 103 parts by weight of solvent (xylene);

[0082] b. Preparation of modified melamine thermal insulation resin adhesive: At a temperature of 55° C., a nano-modifier, a modifying agent, a polyether-modified epoxy resin and a silicone resin were stirred at a speed of 1100 r / min, stirred for 2 hours, and then a curing agent was added and mixed at room temperature. After stirring for 0.5 hours, melamine resin and melamine salt were added and mixed at room temperature. After stirring for 0.75 hours, a solvent and an accelerator were added and mixed at room temperature. The resin molding time was tested at 160° C. for 338 seconds to obtain a modified melamine thermal insulation resin adhesive;

[0083] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0084] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0085] Example 6:

[0086] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0087] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 17 parts by weight of silicone resin, 18 parts by weight of polyether-modified epoxy resin, melamine salt (5 parts by weight of polyphosphate and 5 parts by weight of dimelamine pyrophosphate), 21 parts by weight of nano-modifier (hollow glass microspheres), 0.019 parts by weight of modification agent (3-glycidyloxypropyltrimethoxysilane), 2.1 parts by weight of curing agent (dicyandiamide), 0.011 parts by weight of imidazole and 0.025 parts by weight of ethylamine trifluoride, and 116 parts by weight of solvent (ethylene glycol methyl ether);

[0088] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 70° C., the nano-modifier, the modifying agent, the polyether-modified epoxy resin and the silicone resin were stirred and mixed at a speed of 1150 r / min, and stirred for 2.5 hours to prepare a modified resin for standby use, and then a curing agent was added and mixed at room temperature. After stirring for 1 hour, melamine resin and melamine salt were added, and mixed and stirred at room temperature. After stirring for 1 hour, a solvent and an accelerator were added, and mixed and stirred at room temperature. The resin molding time was tested at 160° C. for 351 seconds to prepare a modified melamine thermal insulation resin adhesive;

[0089] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0090] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0091] Example 7:

[0092] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0093] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 20 parts by weight of silicone resin, 13 parts by weight of polyether-modified epoxy resin, melamine salt (2 parts by weight of melamine cyanurate and 6 parts by weight of ammonium polyphosphate), 26 parts by weight of nano-modifier (fumed silica), 0.015 parts by weight of modifying agent (γ-aminopropyltriethoxysilane), 3.6 parts by weight of curing agent (diaminodiphenylmethane), 0.021 parts by weight of accelerator (imidazole and 0.031 parts by weight of acetyl metal complex), and 177 parts by weight of solvent (acetone);

[0094] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 65° C., the nano-modifier, modifying agent, polyether-modified epoxy resin and silicone resin were stirred and mixed at a speed of 1350 r / min, stirred for 2.25 h to prepare a modified resin for standby use, and then a curing agent was added and mixed at room temperature. After stirring for 1.25 h, melamine resin and melamine salt were added, mixed and stirred at room temperature, stirred for 1.2 h, and then a solvent and accelerator were added, mixed and stirred at room temperature. The resin molding time was tested at 160° C. for 382 s to obtain a modified melamine thermal insulation resin adhesive;

[0095] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0096] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0097] Example 8:

[0098] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0099] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 28 parts by weight of silicone resin, 20 parts by weight of polyether-modified epoxy resin, melamine salt (5 parts by weight of melamine cyanurate and 1 part by weight of polyphosphate), 23 parts by weight of nano-modifier (fumed silica), 0.021 parts by weight of modification agent (γ-glycidyloxypropyltrimethoxysilane), curing agent (4.9 parts by weight of diaminodiphenylmethane and 5 parts by weight of dicyandiamide), accelerator (0.007 parts by weight of toluenesulfonic acid and 0.04 parts by weight of imidazole) and solvent (73 parts by weight of acetone and 73 parts by weight of xylene);

[0100] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 75° C., the nano-modifier, the modifying agent, the polyether-modified epoxy resin and the silicone resin were stirred and mixed at a speed of 1400 r / min, and stirred for 1.5 hours to prepare a modified resin for standby use, and then a curing agent was added and mixed at room temperature. After stirring for 1.5 hours, melamine resin and melamine salt were added, and mixed and stirred at room temperature. After stirring for 1 hour, a solvent and an accelerator were added, and mixed and stirred at room temperature. The resin molding time was tested at 160° C. for 401 seconds to prepare a modified melamine thermal insulation resin adhesive;

[0101] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0102] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0103] Example 9:

[0104] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0105] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 22 parts by weight of silicone resin, 17 parts by weight of polyether-modified epoxy resin, melamine salt (12 parts by weight of polyphosphate and 7 parts by weight of phosphate), 25 parts by weight of nano-modifier (hollow glass microspheres), 0.029 parts by weight of modification agent (γ-aminopropyltriethoxysilane), curing agent (2 parts by weight of diaminodiphenyl sulfone and 1.1 parts by weight of diaminodiphenylmethane), accelerator (0.047 parts by weight of imidazole and 0.053 parts by weight of methanesulfonic acid) and solvent (173 parts by weight of toluene and 19 parts by weight of ethanol);

[0106] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 70° C., the nano-modifier, the modifying agent, the polyether-modified epoxy resin and the silicone resin were stirred and mixed at a speed of 1250 r / min, and stirred for 1.45 h to prepare a modified resin for standby use, and then a curing agent was added and mixed at room temperature. After stirring for 1 h, melamine resin and melamine salt were added, and mixed and stirred at room temperature. After stirring for 1.05 h, a solvent and an accelerator were added, and mixed and stirred at room temperature. The resin molding time was tested at 160° C. for 394 s to obtain a modified melamine thermal insulation resin adhesive;

[0107] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0108] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0109] Example 10:

[0110] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0111] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 25 parts by weight of silicone resin, 21 parts by weight of polyether-modified epoxy resin, melamine salt (7 parts by weight of phosphate, 14 parts by weight of ammonium polyphosphate), 28 parts by weight of nano-modifier (fumed silica), modifying agent (0.013 parts by weight of 3-glycidoxypropyltrimethoxysilane and 0.02 parts by weight of 3-aminopropyltriethoxysilane), curing agent (4 parts by weight of diaminodiphenyl sulfone and 0.4 parts by weight of dicyandiamide), accelerator (0.038 parts by weight of acetyl metal complex and 0.025 parts by weight of boron trifluoride ethylamine) and solvent (166 parts by weight of toluene and 42 parts by weight of N,N-dimethylformamide);

[0112] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 60° C., the nano-modifier, the modifying agent, the polyether-modified epoxy resin and the silicone resin were stirred and mixed at a speed of 950 r / min, and stirred for 2.5 hours to prepare a modified resin for standby use, and then a curing agent was added and mixed at room temperature. After stirring for 1.65 hours, melamine resin and melamine salt were added, and mixed and stirred at room temperature. After stirring for 1.25 hours, a solvent and an accelerator were added, and mixed and stirred at room temperature. The resin molding time was tested at 160° C. for 414 seconds to prepare a modified melamine thermal insulation resin adhesive;

[0113] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0114] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0115] Example 11:

[0116] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0117] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 23 parts by weight of silicone resin, 25 parts by weight of polyether-modified epoxy resin, melamine salt (6 parts by weight of melamine cyanurate and 10 parts by weight of phosphate), nano-modifier (11 parts by weight of hollow glass microspheres and 20 parts by weight of fumed silica), modifying agent (0.022 parts by weight of γ-glycidyloxypropyltrimethoxysilane and 0.015 parts by weight of 3-aminopropyltriethoxysilane), curing agent (1.9 parts by weight of dicyandiamide and 3 parts by weight of diaminodiphenyl sulfone), accelerator (0.048 parts by weight of acetyl metal complex, 0.021 parts by weight of p-toluenesulfonic acid) and solvent (91 parts by weight of acetone, 90 parts by weight of ethanol and 90 parts by weight of ethylene glycol methyl ether);

[0118] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 75° C., the nano-modifier, the modifying agent, the polyether-modified epoxy resin and the silicone resin were stirred and mixed at a speed of 1350 r / min, and stirred for 2.75 h to prepare a modified resin for standby use, and then a curing agent was added and mixed at room temperature. After stirring for 2 h, melamine resin and melamine salt were added, and mixed and stirred at room temperature. After stirring for 1 h, a solvent and an accelerator were added, and mixed and stirred at room temperature. The resin molding time was tested at 160° C. for 406 s to prepare a modified melamine thermal insulation resin adhesive;

[0119] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0120] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0121] Example 12:

[0122] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0123] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 26 parts by weight of silicone resin, 22 parts by weight of polyether-modified epoxy resin, melamine salt (11 parts by weight of melamine cyanurate and 7 parts by weight of dimelamine pyrophosphate), nano-modifier (5 parts by weight of hollow glass microspheres and 30 parts by weight of fumed silica), modifying agent (0.03 parts by weight of 3-glycidyloxypropyltrimethoxysilane and 0.013 parts by weight of γ-glycidyloxypropyltrimethoxysilane), curing agent (2.8 parts by weight of diaminodiphenyl sulfone and 2.8 parts by weight of diaminodiphenylmethane), accelerator (0.037 parts by weight of methanesulfonic acid and 0.034 parts by weight of acetyl metal complex), and solvent (98 parts by weight of acetone, 62 parts by weight of xylene, and 87 parts by weight of N,N-dimethylformamide);

[0124] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 80° C., the nano-modifier, modifying agent, polyether-modified epoxy resin and silicone resin were stirred and mixed at a speed of 1500 r / min, and stirred for 2.75 h to prepare a modified resin for standby use, and then a curing agent was added and mixed at room temperature. After stirring for 1.75 h, melamine resin and melamine salt were added, and mixed and stirred at room temperature. After stirring for 1.45 h, a solvent and an accelerator were added, and mixed and stirred at room temperature. The resin molding time was tested at 160° C. for 421 s to obtain a modified melamine thermal insulation resin adhesive;

[0125] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0126] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0127] Example 13:

[0128] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0129] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 30 parts by weight of silicone resin, 28 parts by weight of polyether-modified epoxy resin, melamine salt (5 parts by weight of ammonium polyphosphate and 12 parts by weight of dimelamine pyrophosphate), nano-modifier (12 parts by weight of fumed silica and 20 parts by weight of hollow glass microspheres), modifying agent (0.041 parts by weight of 3-glycidoxypropyltrimethoxysilane and 0.01 parts by weight of γ-aminopropyltriethoxysilane), curing agent (5.2 parts by weight of diaminodiphenyl sulfone and 2.2 parts by weight of dicyandiamide), accelerator (0.057 parts by weight of p-toluenesulfonic acid and 0.021 parts by weight of boron trifluoride ethylamine) and solvent (71 parts by weight of toluene, 88 parts by weight of butanone, and 132 parts by weight of acetone);

[0130] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 65° C., the nano-modifier, the modifying agent, the polyether-modified epoxy resin and the silicone resin were stirred and mixed at a speed of 1000 r / min, and stirred for 1.25 h to prepare a modified resin for standby use, and then a curing agent was added and mixed at room temperature. After stirring for 2.15 h, melamine resin and melamine salt were added, and mixed and stirred at room temperature. After stirring for 1.05 h, a solvent and an accelerator were added, and mixed and stirred at room temperature. The resin molding time was tested at 160° C. for 411 s to obtain a modified melamine thermal insulation resin adhesive;

[0131] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0132] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0133] Example 14:

[0134] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0135] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 24 parts by weight of silicone resin, 24 parts by weight of polyether-modified epoxy resin, melamine salt (11 parts by weight of melamine cyanurate and 13 parts by weight of ammonium polyphosphate), nano-modifier (22 parts by weight of hollow glass microspheres and 15 parts by weight of fumed silica), modifying agent (0.026 parts by weight of γ-aminopropyltriethoxysilane and 0.022 parts by weight of γ-glycidoxypropyltrimethoxysilane), curing agent (0.6 parts by weight of diaminodiphenylmethane and 6 parts by weight of dicyandiamide), accelerator (0.028 parts by weight of methanesulfonic acid and 0.064 parts by weight of boron trifluoride ethylamine) and solvent (41 parts by weight of xylene, 127 parts by weight of acetone, 66 parts by weight of ethanol and 72 parts by weight of N,N-dimethylformamide);

[0136] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 60° C., the nano-modifier, modifying agent, polyether-modified epoxy resin and silicone resin were stirred and mixed at a speed of 1100 r / min, and stirred for 2.45 h to prepare a modified resin for standby use, and then a curing agent was added and mixed at room temperature. After stirring for 1.45 h, melamine resin and melamine salt were added, and mixed and stirred at room temperature. After stirring for 1 h, a solvent and an accelerator were added, and mixed and stirred at room temperature. The resin molding time was tested at 160° C. for 450 s to prepare a modified melamine thermal insulation resin adhesive;

[0137] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0138] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0139] Example 15:

[0140] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0141] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 27 parts by weight of silicone resin, 26 parts by weight of polyether modified epoxy resin, melamine salt (4.5 parts by weight of melamine cyanurate and 10.5 parts by weight of phosphate), nano-modifier (27 parts by weight of fumed silica and 12 parts by weight of hollow glass microspheres), modification agent (0.01 parts by weight of 3-aminopropyltriethoxysilane, 3 -glycidyloxypropyltrimethoxysilane 0.027 parts by weight and γ-glycidyloxypropyltrimethoxysilane 0.015 parts by weight), a curing agent (diaminodiphenyl sulfone 8.2 parts by weight and dicyandiamide 0.9 parts by weight), an accelerator (methanesulfonic acid 0.05 parts by weight, p-toluenesulfonic acid 0.05 parts by weight) and a solvent (ethylene glycol methyl ether 23 parts by weight, ethanol 115 parts by weight, butanone 80 parts by weight and acetone 109 parts by weight);

[0142] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 85° C., the nano-modifier, the modifying agent, the polyether-modified epoxy resin and the silicone resin were stirred and mixed at a speed of 1300 r / min, and stirred for 3 hours to prepare a modified resin for standby use, and then a curing agent was added and mixed at room temperature. After stirring for 2 hours, melamine resin and melamine salt were added, and mixed and stirred at room temperature. After stirring for 1.25 hours, a solvent and an accelerator were added, and mixed and stirred at room temperature. The resin molding time was tested at 160° C. for 389 seconds to prepare a modified melamine thermal insulation resin adhesive;

[0143] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0144] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0145] Example 16:

[0146] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0147] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 34 parts by weight of silicone resin, 28 parts by weight of polyether-modified epoxy resin, melamine salt (9 parts by weight of polyphosphate, 3 parts by weight of ammonium polyphosphate and 8 parts by weight of dimelamine pyrophosphate), nano-modifier (26 parts by weight of fumed silica and 7 parts by weight of hollow glass microspheres), modification agent (0.02 parts by weight of 3-glycidyloxypropyltrimethoxysilane, 0.01 parts by weight of γ-glycidyloxypropyltrimethoxysilane, 0.02 parts by weight of methyl methacrylate), 1.5 parts by weight of methyl methacrylate, ... The present invention comprises the following components: 1) a methyl methacrylate cross-linked polymer (0.02 parts by weight of hydroglyceryl ether oxide propyl trimethoxysilane and 0.02 parts by weight of γ-aminopropyl triethoxysilane), a curing agent (3.6 parts by weight of dicyandiamide and 5.3 parts by weight of diaminodiphenylmethane), an accelerator (0.033 parts by weight of acetyl metal complex, 0.035 parts by weight of imidazole and 0.026 parts by weight of ethylamine trifluoride), and a solvent (97 parts by weight of toluene, 91 parts by weight of butanone, 44 parts by weight of ethanol, 65 parts by weight of acetone and 65 parts by weight of xylene);

[0148] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 75° C., the nano-modifier, the modifying agent, the polyether-modified epoxy resin and the silicone resin were stirred and mixed at a speed of 1400 r / min, and stirred for 2 hours to prepare a modified resin for standby use, and then a curing agent was added and mixed at room temperature. After stirring for 2.5 hours, melamine resin and melamine salt were added, mixed and stirred at room temperature, and stirred for 1.15 hours. Then, a solvent and an accelerator were added, and mixed and stirred at room temperature. The resin molding time was tested at 160° C. for 396 seconds to prepare a modified melamine thermal insulation resin adhesive;

[0149] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0150] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0151] Example 17:

[0152] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0153] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 29 parts by weight of silicone resin, 35 parts by weight of polyether-modified epoxy resin, melamine salt (5 parts by weight of ammonium polyphosphate, 11 parts by weight of dimelamine pyrophosphate and 9 parts by weight of melamine cyanurate), nano-modifier (20 parts by weight of hollow glass microspheres and 20 parts by weight of fumed silica), modification agent (0.005 parts by weight of 3-aminopropyltriethoxysilane, 0.01 parts by weight of 3-glycidoxypropyltrimethoxysilane) and 0.02 parts by weight of methyl parathionate. 0.017 parts by weight, γ-aminopropyltriethoxysilane 0.034 parts by weight), a curing agent (4.4 parts by weight of diaminodiphenyl sulfone, 3.5 parts by weight of diaminodiphenylmethane and 4.1 parts by weight of dicyandiamide), an accelerator (0.022 parts by weight of an acetyl metal complex, 0.051 parts by weight of ethylamine boron trifluoride and 0.016 parts by weight of p-toluenesulfonic acid) and a solvent (57 parts by weight of toluene, 36 parts by weight of butanone, 72 parts by weight of ethylene glycol methyl ether, 117 parts by weight of acetone and 67 parts by weight of N,N-dimethylformamide);

[0154] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 80° C., the nano-modifier, modifying agent, polyether-modified epoxy resin and silicone resin were stirred and mixed at a speed of 1200 r / min, and stirred for 1.25 h to prepare a modified resin for standby use, and then a curing agent was added and mixed at room temperature. After stirring for 2.25 h, melamine resin and melamine salt were added, and mixed and stirred at room temperature. After stirring for 1.25 h, a solvent and an accelerator were added, and mixed and stirred at room temperature. The resin molding time was tested at 160° C. for 417 s to obtain a modified melamine thermal insulation resin adhesive;

[0155] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0156] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0157] Example 18:

[0158] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0159] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 35 parts by weight of silicone resin, 29 parts by weight of polyether modified epoxy resin, melamine salt (4 parts by weight of polyphosphate, 7 parts by weight of melamine cyanurate, 4 parts by weight of phosphate and 8 parts by weight of ammonium polyphosphate), nano-modifier (32 parts by weight of fumed silica and 4 parts by weight of hollow glass microspheres), modification treatment agent (0.016 parts by weight of 3-glycidoxypropyltrimethoxysilane, 0.016 parts by weight of γ-aminopropyltrimethoxysilane, 0.016 parts by weight of methyl parathionyl ... The invention discloses a composition comprising the following components: ethoxysilane (0.014 parts by weight) and gamma-glycidoxypropyltrimethoxysilane (0.024 parts by weight), a curing agent (diaminodiphenyl sulfone (7 parts by weight), diaminodiphenylmethane (3 parts by weight) and dicyandiamide (3 parts by weight), an accelerator (ethylamine boron trifluoride (0.05 parts by weight), p-toluenesulfonic acid (0.025 parts by weight) and methanesulfonic acid (0.008 parts by weight), and a solvent (xylene (81 parts by weight), butanone (75 parts by weight), ethanol (78 parts by weight), acetone (81 parts by weight) and N,N-dimethylformamide (85 parts by weight);

[0160] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 70° C., the nano-modifier, modifying agent, polyether-modified epoxy resin and silicone resin were stirred and mixed at a speed of 1150 r / min, and stirred for 1.75 h to prepare a modified resin for standby use, and then a curing agent was added and mixed at room temperature. After stirring for 2 h, melamine resin and melamine salt were added, and mixed and stirred at room temperature. After stirring for 1.5 h, a solvent and an accelerator were added, and mixed and stirred at room temperature. The resin molding time was tested at 160° C. for 436 s to obtain a modified melamine thermal insulation resin adhesive;

[0161] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0162] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0163] Example 19:

[0164] A method for preparing a lightweight melamine insulation board comprises the following steps:

[0165] a. Ingredients: prepare 100 parts by weight of melamine resin (highly etherified melamine formaldehyde resin), 33 parts by weight of silicone resin, 32 parts by weight of polyether modified epoxy resin, melamine salt (3 parts by weight of polyphosphate, 5 parts by weight of melamine cyanurate, 6 parts by weight of phosphate, 4 parts by weight of ammonium polyphosphate and 3 parts by weight of dimelamine pyrophosphate), nano-modifier (4 parts by weight of fumed silica and 34 parts by weight of hollow glass microspheres), modifying agent (0.014 parts by weight of γ-aminopropyltriethoxysilane, 0.016 parts by weight of 3-glycidoxypropyltrimethoxysilane, 0.01 5 parts by weight and γ-glycidyloxypropyltrimethoxysilane 0.015 parts by weight), a curing agent (5 parts by weight of diaminodiphenyl sulfone, 2.5 parts by weight of diaminodiphenylmethane, 4.2 parts by weight of dicyandiamide), an accelerator (0.02 parts by weight of imidazole, 0.021 parts by weight of acetyl metal complex, 0.018 parts by weight of ethylamine boron trifluoride, 0.019 parts by weight of p-toluenesulfonic acid and 0.018 parts by weight of methanesulfonic acid) and a solvent (42 parts by weight of toluene, 34 parts by weight of xylene, 61 parts by weight of butanone, 54 parts by weight of ethanol, 83 parts by weight of acetone, 43 parts by weight of N,N-dimethylformamide and 69 parts by weight of ethylene glycol methyl ether);

[0166] b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 75° C., the nano-modifier, the modifying agent, the polyether-modified epoxy resin and the silicone resin were stirred and mixed at a speed of 1250 r / min, and stirred for 2.5 h to prepare a modified resin for standby use, and then a curing agent was added and mixed at room temperature. After stirring for 2.45 h, melamine resin and melamine salt were added, mixed and stirred at room temperature, and stirred for 1.25 h. Then, a solvent and an accelerator were added, and mixed and stirred at room temperature. The resin molding time was tested at 160° C. for 334 s to obtain a modified melamine thermal insulation resin adhesive;

[0167] c. Preparation of modified melamine thermal insulation resin fiber fabric prepreg: The modified melamine thermal insulation resin adhesive prepared in step b is coated on the basalt fiber fabric through a gluing machine, and then the basalt fiber fabric coated with the modified melamine thermal insulation resin adhesive is placed in a drying tunnel. The drying tunnel is 50m long and divided into 4 sections, each 12.5m long. The baking temperature range is 75℃~175℃, wherein: the first section is 75℃~95℃, the second section is 105℃~135℃, the third section is 135℃~175℃, and the fourth section is 85℃~110℃. The speed of the gluing machine is 5m / min~25m / min to obtain the modified melamine thermal insulation resin fiber fabric prepreg. The drying tunnel is pre-baked before baking. The soluble resin content of the fiber fabric prepreg is greater than or equal to 95%, and the volatile matter is less than or equal to 2%. Specific process parameters are shown in Table 1.

[0168] d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold, and hot pressing the template at a temperature of 130°C to 175°C and a pressure of 1 MPa to 25 MPa for 0.5 h to 50 h. Specific process parameters are shown in Table 2, thereby producing a lightweight melamine insulation board.

[0169] The specific process parameters of Examples 1 to 19 and the technical performance test results of the lightweight melamine insulation board are shown in Tables 1, 2, and 3 below respectively:

[0170] Table 1: Preparation process parameters and central control technical indicators of modified melamine thermal insulation resin fiber fabric prepreg in Example

[0171]

[0172]

[0173] Table 2: Lightweight melamine insulation board pressing process parameters

[0174]

[0175] Table 3: Technical performance test data of lightweight melamine insulation boards prepared in Examples 1-19

[0176]

[0177] As shown in Table 1 and Table 2, the lightweight melamine insulation board of the present invention has a bending strength of 350MPa to 420MPa at room temperature, a bending strength of 207MPa to 266MPa at 150°C, a tensile strength of 336MPa to 372MPa, and a notched impact strength of 65KJ / m 2 ~75KJ / m 2 , insulation resistance is greater than or equal to 10 8 MΩ, flame retardancy reaches UL94 V-0 level, thermal conductivity (25℃) is less than 0.2w / m·k and density is 1.52g / cm 3 ~1.75g / cm 3 , especially suitable for use in the field of lightweight thermal insulation.

[0178] Example 20:

[0179] A lightweight melamine insulation board, which is made by hot-pressing multiple layers of overlapping modified melamine insulation resin fiber fabric prepreg (the number of layers of the modified melamine insulation resin fiber fabric prepreg is not limited and can be any one of 1 to 500 layers as required);

[0180] The modified melamine thermal insulation resin fiber fabric prepreg is obtained by coating a modified melamine thermal insulation resin adhesive on a basalt fiber fabric and then baking it;

[0181] The modified melamine thermal insulation resin adhesive is composed of 100 parts by weight of melamine resin, 35 parts by weight of silicone resin, 35 parts by weight of polyether modified epoxy resin, 25 parts by weight of melamine salt, 40 parts by weight of nano-modifier, 0.06 parts by weight of modification treatment agent, 13 parts by weight of curing agent, 0.1 parts by weight of accelerator and 400 parts by weight of solvent;

[0182] The basalt fiber fabric is any one of basalt fiber plain cloth, basalt fiber twill cloth, basalt fiber woven cloth, basalt fiber multi-axial cloth, and basalt fiber composite cloth.

[0183] Example 21:

[0184] A lightweight melamine insulation board, which is made by hot-pressing multiple layers of overlapping modified melamine insulation resin fiber fabric prepreg (the number of layers of the modified melamine insulation resin fiber fabric prepreg is not limited and can be any one of 1 to 500 layers as required);

[0185] The modified melamine thermal insulation resin fiber fabric prepreg is obtained by coating a modified melamine thermal insulation resin adhesive on a basalt fiber fabric and then baking it;

[0186] The modified melamine thermal insulation resin adhesive is composed of 100 parts by weight of melamine resin, 15 parts by weight of silicone resin, 5 parts by weight of polyether modified epoxy resin, 5 parts by weight of melamine salt, 10 parts by weight of nano-modifier, 0.01 parts by weight of modification treatment agent, 0.2 parts by weight of curing agent, 0.005 parts by weight of accelerator and 60 parts by weight of solvent;

[0187] The basalt fiber fabric is any one of basalt fiber plain cloth, basalt fiber twill cloth, basalt fiber woven cloth, basalt fiber multi-axial cloth, and basalt fiber composite cloth.

[0188] Example 22:

[0189] A lightweight melamine insulation board, which is made by hot-pressing multiple layers of overlapping modified melamine insulation resin fiber fabric prepreg (the number of layers of the modified melamine insulation resin fiber fabric prepreg is not limited and can be any one of 1 to 500 layers as required);

[0190] The modified melamine thermal insulation resin fiber fabric prepreg is obtained by coating a modified melamine thermal insulation resin adhesive on a basalt fiber fabric and then baking it;

[0191] The modified melamine thermal insulation resin adhesive is composed of 100 parts by weight of melamine resin, 25 parts by weight of silicone resin, 20 parts by weight of polyether modified epoxy resin, 15 parts by weight of melamine salt, 25 parts by weight of nano-modifier, 0.035 parts by weight of modification treatment agent, 6.6 parts by weight of curing agent, 0.05 parts by weight of accelerator and 230 parts by weight of solvent;

[0192] The basalt fiber fabric is any one of basalt fiber plain cloth, basalt fiber twill cloth, basalt fiber woven cloth, basalt fiber multi-axial cloth, and basalt fiber composite cloth.

[0193] The foregoing description is merely a preferred embodiment of the present invention. It should be understood that the present invention is not limited to the form disclosed herein and should not be construed as excluding other embodiments. Rather, the present invention can be used in various other combinations, modifications, and environments and can be modified within the scope of the concept described herein through the above teachings or techniques or knowledge in the relevant field. Modifications and variations made by those skilled in the art that do not depart from the spirit and scope of the present invention are intended to be protected by the appended claims.

[0194] In the above embodiments, the percentages used, unless otherwise specified, are all weight (mass) percentages or percentages known to those skilled in the art; the ratios used, unless otherwise specified, are all weight (mass) ratios; and the weight parts may be grams or kilograms.

[0195] In the above embodiments, the process parameters (temperature, pressure, time, vehicle speed, rotation speed, etc.) and the amounts of the components in each step are ranges, and any point can be applied.

[0196] The technical contents not specifically described in the present invention and the above embodiments are the same as the prior art, and the raw materials are all commercially available products.

[0197] The present invention is not limited to the above embodiments, and all of the contents of the present invention can be implemented and have the above good effects.

Claims

1. A lightweight melamine insulation board, characterized by: The lightweight melamine insulation board is a lightweight melamine insulation board made by hot pressing multiple layers of overlapping modified melamine insulation resin fiber fabric prepreg; The modified melamine thermal insulation resin fiber fabric prepreg is obtained by coating a modified melamine thermal insulation resin adhesive on a basalt fiber fabric and then baking it; The modified melamine thermal insulation resin adhesive is composed of 100 parts by weight of melamine resin, 15-35 parts by weight of silicone resin, 5-35 parts by weight of polyether modified epoxy resin, 5-25 parts by weight of melamine salt, 10-40 parts by weight of nano-modifier, 0.01-0.06 parts by weight of modification treatment agent, 0.2-13 parts by weight of curing agent, 0.005-0.1 parts by weight of accelerator and 60-400 parts by weight of solvent; The basalt fiber fabric is at least one of basalt fiber plain cloth, basalt fiber twill cloth, basalt fiber woven cloth, basalt fiber multi-axial cloth, and basalt fiber composite cloth; In the modified melamine thermal insulation resin adhesive: The melamine resin is a highly etherified melamine formaldehyde resin; The melamine salt is any one of ammonium polyphosphate, dimelamine pyrophosphate, and melamine cyanurate, or a mixture of two or more thereof; The curing agent is a mixture of two or more of diaminodiphenyl sulfone, dicyandiamide, and diaminodiphenylmethane; The nano-modifier is one or a mixture of fumed silica and hollow glass microspheres; The modifying agent is any one of 3-aminopropyltriethoxysilane and 3-glycidoxypropyltrimethoxysilane or a mixture of the two; The accelerator is any one of imidazole, acetyl metal complex, boron trifluoride ethylamine, p-toluenesulfonic acid, and methanesulfonic acid, or a mixture of two or more thereof; The solvent is any one of toluene, xylene, acetone, butanone, ethanol, ethylene glycol methyl ether, and N,N-dimethylformamide, or a mixture of two or more thereof.

2. The lightweight melamine insulation board according to claim 1, characterized in that: The hot pressing molding is as follows: after preheating the template at 105°C to 155°C, the modified melamine thermal insulation resin fiber fabric prepreg is overlapped and placed in the template, and after closing the mold, hot pressing molding is performed under the conditions of temperature 130°C to 175°C and pressure 1MPa to 25MPa, and the hot pressing time is 0.5h to 50h.

3. The lightweight melamine insulation board according to claim 1 or 2, characterized in that: The baking method comprises the following steps: placing a basalt fiber fabric coated with a modified melamine thermal insulation resin adhesive into a drying tunnel, wherein the drying tunnel is 50 meters long and divided into four sections, each section being 12.5 meters long; and the baking temperature ranges from 75°C to 175°C, wherein the first section is 75°C to 95°C, the second section is 105°C to 135°C, the third section is 135°C to 175°C, and the fourth section is 85°C to 110°C. The speed of the gluing machine is 5m / min to 25m / min.

4. The lightweight melamine insulation board according to claim 1 or 2, characterized in that: The preparation method of the modified melamine thermal insulation resin adhesive is as follows: at a temperature of 50°C to 85°C, the nano-modifier, the modification treatment agent, the polyether-modified epoxy resin and the silicone resin are stirred and mixed, after stirring for 1 hour to 3 hours, a curing agent is added, and the mixture is stirred at room temperature, after stirring for 0.5 hour to 2.5 hours, melamine resin and melamine salt are added, and the mixture is stirred at room temperature, after stirring for 0.75 hour to 1.5 hours, a solvent and an accelerator are added, and the mixture is stirred and mixed at room temperature to obtain the modified melamine thermal insulation resin adhesive.

5. The lightweight melamine insulation board according to claim 1 or 2, characterized in that: In the modified melamine thermal insulation resin fiber fabric prepreg, the weight percentage of the modified melamine thermal insulation resin adhesive is 25% to 50%, and the weight percentage of the basalt fiber fabric is 50% to 75%.

6. The method for preparing a lightweight melamine insulation board according to claim 1, characterized in that The following steps are involved: a. Ingredients: Prepare the raw materials of each component according to the ratio of 100 parts by weight of melamine resin, 15-35 parts by weight of silicone resin, 5-35 parts by weight of polyether modified epoxy resin, 5-25 parts by weight of melamine salt, 10-40 parts by weight of nano-modifier, 0.01-0.06 parts by weight of modification treatment agent, 0.2-13 parts by weight of curing agent, 0.005-0.1 parts by weight of accelerator and 60-400 parts by weight of solvent; The melamine resin is a highly etherified melamine formaldehyde resin; The melamine salt is any one of ammonium polyphosphate, dimelamine pyrophosphate, and melamine cyanurate, or a mixture of two or more thereof; The curing agent is a mixture of two or more of diaminodiphenyl sulfone, dicyandiamide, and diaminodiphenylmethane; The nano-modifier is one or a mixture of fumed silica and hollow glass microspheres; The modifying agent is any one of 3-aminopropyltriethoxysilane and 3-glycidoxypropyltrimethoxysilane or a mixture of the two; The accelerator is any one of imidazole, acetyl metal complex, boron trifluoride ethylamine, p-toluenesulfonic acid, and methanesulfonic acid, or a mixture of two or more thereof; The solvent is any one of toluene, xylene, acetone, butanone, ethanol, ethylene glycol methyl ether, N,N-dimethylformamide, or a mixture of two or more thereof; b. Preparation of modified melamine thermal insulation resin adhesive: at a temperature of 50° C. to 85° C., the nano-modifier, the modifying agent, the polyether-modified epoxy resin and the silicone resin are stirred and mixed, and after stirring for 1 h to 3 h, a curing agent is added and mixed at room temperature, and after stirring for 0.5 h to 2.5 h, melamine resin and melamine salt are added, and mixed and stirred at room temperature, and after stirring for 0.75 h to 1.5 h, a solvent and an accelerator are added, and after stirring and mixing at room temperature, a modified melamine thermal insulation resin adhesive is obtained; c. Preparing a modified melamine thermal insulation resin fiber fabric prepreg: coating the modified melamine thermal insulation resin adhesive prepared in step b on a basalt fiber fabric, and then baking to obtain a modified melamine thermal insulation resin fiber fabric prepreg; The basalt fiber fabric is at least one of basalt fiber plain cloth, basalt fiber twill cloth, basalt fiber woven cloth, basalt fiber multi-axial cloth, and basalt fiber composite cloth; d. Preparation of lightweight melamine insulation board: preheating the template at 105°C to 155°C, overlapping the modified melamine insulation resin fiber fabric prepreg and placing it in the template, closing the mold and hot pressing it at a temperature of 130°C to 175°C and a pressure of 1MPa to 25MPa for 0.5h to 50h to obtain a lightweight melamine insulation board.

7. The method for preparing the lightweight melamine insulation board according to claim 6, characterized in that: The baking method comprises placing the basalt fiber fabric coated with a modified melamine thermal insulation resin adhesive into a drying tunnel. The drying tunnel is 50 meters long and divided into four sections, each section being 12.5 meters long. The baking temperature range is 75°C to 175°C, wherein the first section is 75°C to 95°C, the second section is 105°C to 135°C, the third section is 135°C to 175°C, and the fourth section is 85°C to 110°C. The speed of the gluing machine is 5m / min to 25m / min.

8. The method for preparing the lightweight melamine insulation board according to claim 6 or 7, characterized in that: The performance parameters of the prepared lightweight melamine insulation board are: bending strength at room temperature is 350MPa ～ 420MPa, flexural strength 207MPa at 150℃ ～ 266MPa, tensile strength 336MPa~372MPa, notched impact strength 65KJ / m 2 ～ 75KJ / m 2 , insulation resistance is greater than or equal to 10 8 MΩ, flame retardancy reaches UL94 V-0 level, thermal conductivity is less than 0.2w / m•k at 25℃, density is 1.52g / cm 3 ~1.75g / cm 3 .

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