Flame retardant and fireproof rock wool board and preparation method thereof

Abstract

The present invention relates to the technical field of rock wool boards and proposes a flame-retardant and fireproof rock wool board and a preparation method thereof. The raw materials of the rock wool board include the following components by weight: 100 parts basalt, 30-40 parts slag, 10-20 parts dolomite, 30-50 parts aluminum hydroxide, 10-15 parts iron ore, and 5-10 parts binder; the binder comprises dry powdered aluminum sol and water-based phenolic resin in a weight ratio of 1-9:1. This technical solution solves the problem of poor flame retardancy and fireproofing and tensile strength of rock wool boards in related technologies.

Description

Technical Field

[0001] The present invention relates to the technical field of rock wool boards, and in particular to a flame retardant and fireproof rock wool board and a preparation method thereof. Background Art

[0002] Rockwool board, a new building material, is widely used in building exterior wall insulation, roof insulation, and industrial equipment insulation. Made primarily from natural rocks such as basalt, it is melted at high temperatures and then processed using high-speed centrifugal equipment to produce inorganic fibers. Organic binders are then added, and the fibers are then formed and cut.

[0003] With rising awareness of fire safety, the market is placing stricter demands on the flame-retardant and fire-resistant properties of rock wool boards. While inorganic fibers offer high stability at high temperatures, organic binders have poor flame retardancy and often burn first in a fire, significantly weakening the overall flame-retardant and fire-resistant properties of the rock wool board. Furthermore, existing rock wool boards lack sufficient tensile strength, making them difficult to use in harsh environments for long periods. Therefore, developing a new flame-retardant and fire-resistant rock wool board is crucial to better meet market demands. Summary of the Invention

[0004] The present invention provides a flame retardant and fireproof rock wool board and a preparation method thereof, which solves the problem of poor flame retardant and fireproof performance and tensile strength of the rock wool board in the related art.

[0005] The technical solutions of the present invention are as follows:

[0006] The present invention provides a flame retardant and fireproof rock wool board, the raw materials of which include the following components in parts by weight: 100 parts of basalt, 30-40 parts of slag, 10-20 parts of dolomite, 30-50 parts of aluminum hydroxide, 10-15 parts of iron ore, and 5-10 parts of a binder;

[0007] The binder comprises aluminum sol dry powder and water-based phenolic resin in a weight ratio of 1 to 9:1.

[0008] As a further technical solution, the weight ratio of the aluminum sol dry powder to the water-based phenolic resin is 1-4:1.

[0009] In the present invention, when the weight ratio of the aluminum sol dry powder to the water-based phenolic resin is 1 to 4:1, it helps to further improve the tensile strength of the rock wool board.

[0010] As a further technical solution, the aluminum hydroxide is methyl MQ silicone resin modified aluminum hydroxide.

[0011] In this invention, the inventors discovered that modifying aluminum hydroxide with methyl MQ silicone resin can further improve the flame retardancy and fire resistance of rock wool boards. It is speculated that methyl MQ silicone resin can better fill the aluminum hydroxide into the rock wool board, thereby further improving the flame retardancy and fire resistance of the rock wool board.

[0012] As a further technical solution, the preparation method of the methyl MQ silicone resin modified aluminum hydroxide includes the following steps: dissolving the methyl MQ silicone resin in xylene, adding aluminum hydroxide, dispersing evenly, and drying to obtain the methyl MQ silicone resin modified aluminum hydroxide.

[0013] As a further technical solution, in the methyl MQ silicone resin modified aluminum hydroxide, the weight ratio of methyl MQ silicone resin to aluminum hydroxide is 1:19~24.

[0014] In the present invention, when the weight ratio of methyl MQ silicone resin to aluminum hydroxide in the methyl MQ silicone resin-modified aluminum hydroxide is 1:19-24, it helps to further improve the flame retardant and fireproof performance of the rock wool board.

[0015] As a further technical solution, the aluminum sol dry powder is a modified aluminum sol dry powder, and the components of the modified aluminum sol dry powder include zinc acetate and aluminum sol dry powder in a weight ratio of 1:4-9.

[0016] In this invention, the inventors discovered that modifying aluminum sol powder with zinc acetate can further improve the tensile strength of rock wool boards. It is speculated that the modified aluminum sol powder can interact with the hydroxymethyl groups in the water-based phenolic resin, further enhancing the rock wool board's ability to resist external forces and further increasing its tensile strength.

[0017] As a further technical solution, the preparation method of the modified aluminum sol dry powder includes the following steps: dissolving the aluminum sol dry powder in water, adding zinc acetate, dispersing evenly, and dehydrating to obtain the modified aluminum sol dry powder.

[0018] The present invention also provides a method for preparing the flame retardant and fireproof rock wool board, comprising the following steps:

[0019] S1. Adding a binder into water to obtain a binder solution;

[0020] S2. Mixing basalt, slag, dolomite and iron ore, crushing, melting, spinning, adding the binder solution to obtain rock wool fibers;

[0021] S3. Collect the rock wool fibers, add aluminum hydroxide, press, and solidify to obtain a flame retardant and fireproof rock wool board.

[0022] As a further technical solution, in step S1, the water content of the binder solution is 3wt%~5wt%.

[0023] As a further technical solution, in step S3, the curing temperature is 180-200°C.

[0024] The working principle and beneficial effects of the present invention are:

[0025] In the present invention, the binder includes aluminum sol dry powder and water-based phenolic resin. The combination of organic and inorganic binders can enhance the bonding effect and improve the tensile strength of the rock wool board. On the other hand, it can reduce the use of organic binders and reduce the risk of organic binder combustion, thereby improving the flame retardant and fireproof properties of the rock wool board. In addition, the addition of aluminum hydroxide as a flame retardant can also improve the flame retardant and fireproof properties of the rock wool board. DETAILED DESCRIPTION

[0026] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of the present invention.

[0027] In the following examples and comparative examples, unless otherwise specified, the content of silicon dioxide in the basalt is 45.2wt%, the content of silicon dioxide in the slag is 35.11wt%, the content of calcium oxide is 40.49wt%, the calcium oxide content in the dolomite is 30.4wt%, the magnesium oxide content is 21.9wt%, the particle size of aluminum hydroxide is 50μm, the iron content in the iron ore is 67.58wt%, the model of the aluminum sol dry powder is LA-30, purchased from Zibo Jinqi Chemical Technology Co., Ltd., the model of the water-based phenolic resin is HS-F101, purchased from Shandong Haoshun Chemical Co., Ltd., and the model of the methyl MQ silicone resin is SH-5204P.

[0028] Example 1

[0029] A method for preparing a flame retardant and fireproof rock wool board comprises the following steps:

[0030] S1. By weight, 4.5 parts of aluminum sol dry powder and 0.5 parts of water-based phenolic resin were added to water to obtain a binder solution with a water content of 3 wt %;

[0031] S2. 100 parts of basalt, 30 parts of slag, 10 parts of dolomite and 10 parts of iron ore are mixed, crushed, melted, spun, and a binder solution is added to obtain rock wool fibers;

[0032] S3. Collect the above rock wool fibers, add 30 parts of aluminum hydroxide, press, and cure at 180° C. to obtain a flame retardant and fireproof rock wool board.

[0033] Example 2

[0034] A method for preparing a flame retardant and fireproof rock wool board comprises the following steps:

[0035] S1. By weight, 9 parts of aluminum sol dry powder and 1 part of water-based phenolic resin were added to water to obtain a binder solution with a water content of 5 wt%;

[0036] S2. 100 parts of basalt, 40 parts of slag, 20 parts of dolomite and 15 parts of iron ore are mixed, crushed, melted, spun, and a binder solution is added to obtain rock wool fibers;

[0037] S3. Collect the above rock wool fibers, add 50 parts of aluminum hydroxide, press, and solidify at 200° C. to obtain a flame retardant and fireproof rock wool board.

[0038] Example 3

[0039] The only difference between this embodiment and embodiment 2 is that, in this embodiment, in step S1, the weight parts of the aluminum sol dry powder are 5 parts, and the weight parts of the water-based phenolic resin are 5 parts.

[0040] Example 4

[0041] The only difference between this embodiment and embodiment 2 is that, in this embodiment, in step S1, the weight parts of the aluminum sol dry powder are 8 parts, and the weight parts of the water-based phenolic resin are 2 parts.

[0042] Example 5

[0043] The only difference between this embodiment and Example 3 is that, in this embodiment, the aluminum hydroxide is methyl MQ silicone resin modified aluminum hydroxide. The preparation method of methyl MQ silicone resin modified aluminum hydroxide comprises the following steps: dissolving 1 part of methyl MQ silicone resin in 100 parts of xylene, adding 49 parts of aluminum hydroxide, dispersing evenly, and drying to obtain methyl MQ silicone resin modified aluminum hydroxide.

[0044] Example 6

[0045] The only difference between this embodiment and embodiment 5 is that, in this embodiment, when preparing methyl MQ silicone resin-modified aluminum hydroxide, the weight parts of methyl MQ silicone resin are 4 parts, and the weight parts of aluminum hydroxide are 46 parts.

[0046] Example 7

[0047] The only difference between this embodiment and embodiment 5 is that, in this embodiment, when preparing methyl MQ silicone resin-modified aluminum hydroxide, the weight parts of methyl MQ silicone resin are 2.5 parts, and the weight parts of aluminum hydroxide are 47.5 parts.

[0048] Example 8

[0049] The only difference between this embodiment and embodiment 5 is that, in this embodiment, when preparing methyl MQ silicone resin-modified aluminum hydroxide, the weight parts of methyl MQ silicone resin are 2 parts, and the weight parts of aluminum hydroxide are 48 parts.

[0050] Example 9

[0051] The only difference between this embodiment and Example 3 is that in this embodiment, the aluminum sol dry powder is a modified aluminum sol dry powder, and the preparation method of the modified aluminum sol dry powder includes the following steps: dissolving 4.9 parts of aluminum sol dry powder in 5 parts of water, adding 0.1 parts of zinc acetate, dispersing evenly, and dehydrating to obtain the modified aluminum sol dry powder.

[0052] Example 10

[0053] The only difference between this embodiment and embodiment 9 is that, in this embodiment, when preparing the modified aluminum sol dry powder, the weight parts of the aluminum sol dry powder are 3.5 parts, and the weight parts of zinc acetate are 1.5 parts.

[0054] Example 11

[0055] The only difference between this embodiment and embodiment 9 is that, in this embodiment, when preparing the modified aluminum sol dry powder, the weight portion of the aluminum sol dry powder is 4.5 parts, and the weight portion of zinc acetate is 0.5 parts.

[0056] Example 12

[0057] The only difference between this embodiment and embodiment 9 is that, in this embodiment, when preparing the modified aluminum sol dry powder, the weight parts of the aluminum sol dry powder are 4 parts, and the weight part of zinc acetate is 1 part.

[0058] Comparative Example 1

[0059] The only difference between this comparative example and Example 1 is that, in this comparative example, in step S1, 4.5 parts of aluminum sol dry powder and 0.5 parts of water-based phenolic resin are replaced by 5 parts of aluminum sol dry powder.

[0060] Comparative Example 2

[0061] The only difference between this comparative example and Example 1 is that, in this comparative example, in step S1, 4.5 parts of aluminum sol dry powder and 0.5 parts of water-based phenolic resin are replaced by 5 parts of water-based phenolic resin.

[0062] Comparative Example 3

[0063] The only difference between this comparative example and Example 1 is that in this comparative example, no aluminum hydroxide was added.

[0064] Experimental Example 1 Flame retardant fire performance test

[0065] ① Determination of Gross Calorific Value: The gross calorific value of the rock wool boards prepared in Examples 1-8 and Comparative Examples 2-3 was tested in accordance with GB / T 14402-2007, "Combustion Performance of Building Materials and Products - Determination of Calorific Value." The average of the results of the three samples was used as the final result. The test results are shown in Table 1 below.

[0066] Table 1 Flame retardant fire performance test results

[0067]

[0068] Comparison between Example 1 and Comparative Example 2 shows that the flame retardant and fireproofing properties of the rock wool board can be significantly improved by using aluminum sol dry powder and water-based phenolic resin as binders. Comparison between Example 1 and Comparative Example 3 shows that the addition of aluminum hydroxide can also improve the flame retardant and fireproofing properties of the rock wool board.

[0069] Comparison of Example 3 with Examples 5-8 shows that modifying aluminum hydroxide with methyl MQ silicone resin can further improve the flame retardancy and fire resistance of the rock wool board. Comparison of Examples 5-6 with Examples 7-8 shows that when the weight ratio of methyl MQ silicone resin to aluminum hydroxide in the methyl MQ silicone resin-modified aluminum hydroxide is 1:19-24, the flame retardancy and fire resistance of the rock wool board can be further improved.

[0070] ② Determination of Fire Resistance: The fire resistance of the rock wool board prepared in Example 8 was tested with reference to GB / T 9978.1-2008, "Fire resistance test methods for building components - Part 1: General requirements." The results showed that the rock wool board had a fire resistance of 120 minutes, meeting market demand.

[0071] Experimental Example 2 Tensile Strength Test

[0072] The tensile strength perpendicular to the surface of the rock wool boards prepared in Examples 1-4, Examples 9-12, and Comparative Examples 1-2 was tested in accordance with GB / T 30804-2014, "Determination of tensile strength perpendicular to the surface of thermal insulation products for building use." The average of the results of the three samples was used as the final result, and the results were rounded to one decimal place. The test results are shown in Table 2 below.

[0073] Table 2 Tensile strength test results

[0074]

[0075] Comparison of Example 1 and Comparative Examples 1-2 shows that by selecting aluminum sol dry powder and water-based phenolic resin as binders, the tensile strength of the rock wool board can be significantly improved. Comparison of Example 2 and Examples 3-4 shows that when the weight ratio of aluminum sol dry powder to water-based phenolic resin is 1-4:1, it helps to further improve the tensile strength of the rock wool board. Comparison of Example 3 and Examples 9-12 shows that by modifying the aluminum sol dry powder with zinc acetate, the tensile strength of the rock wool board can be further improved. Comparison of Examples 9-10 and Examples 11-12 shows that when the weight ratio of zinc acetate to aluminum sol dry powder in the modified aluminum sol dry powder is 1:4-9, it helps to further improve the tensile strength of the rock wool board.

[0076] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A flame retardant and fireproof rock wool board, characterized in that: The raw materials include the following components in parts by weight: 100 parts of basalt, 30-40 parts of slag, 10-20 parts of dolomite, 30-50 parts of aluminum hydroxide, 10-15 parts of iron ore, and 5-10 parts of binder; The binder comprises aluminum sol dry powder and water-based phenolic resin in a weight ratio of 1 to 9:1; The aluminum sol dry powder is a modified aluminum sol dry powder, and the components of the modified aluminum sol dry powder include zinc acetate and aluminum sol dry powder in a weight ratio of 1:4-9; The preparation method of the modified aluminum sol dry powder comprises the following steps: dissolving the aluminum sol dry powder in water, adding zinc acetate, dispersing evenly, and dehydrating to obtain the modified aluminum sol dry powder.

2. The flame retardant and fireproof rock wool board according to claim 1, characterized in that: The weight ratio of the aluminum sol dry powder to the water-based phenolic resin is 1-4:

1.

3. The flame retardant and fireproof rock wool board according to claim 1, characterized in that: The aluminum hydroxide is methyl MQ silicone resin modified aluminum hydroxide.

4. The flame retardant and fireproof rock wool board according to claim 3, characterized in that: The preparation method of the methyl MQ silicone resin modified aluminum hydroxide comprises the following steps: dissolving the methyl MQ silicone resin in xylene, adding aluminum hydroxide, dispersing uniformly, and drying to obtain the methyl MQ silicone resin modified aluminum hydroxide.

5. The flame retardant and fireproof rock wool board according to claim 3, characterized in that: In the methyl MQ silicone resin modified aluminum hydroxide, the weight ratio of methyl MQ silicone resin to aluminum hydroxide is 1:19-24.

6. A method for preparing the flame retardant and fireproof rock wool board according to claim 1, characterized in that: The following steps are involved: S1. Adding a binder into water to obtain a binder solution; S2. Mixing basalt, slag, dolomite and iron ore, crushing, melting, spinning, adding the binder solution, and obtaining rock wool fibers; S3. Collect the rock wool fibers, add aluminum hydroxide, press, and solidify to obtain a flame retardant and fireproof rock wool board.

7. The method for preparing a flame retardant and fireproof rock wool board according to claim 6, characterized in that: In step S1, the water content of the binder solution is 3 wt% to 5 wt%.

8. The method for preparing a flame retardant and fireproof rock wool board according to claim 6, characterized in that: In step S3, the curing temperature is 180-200°C.

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