High-strength rock wool board and preparation method thereof

Abstract

The invention relates to the technical field of rock wool boards, and provides a high-strength rock wool board and a preparation method thereof.The high-strength rock wool board comprises a heat preservation layer, a bonding layer and a facing layer which are sequentially arranged from top to bottom, and the heat preservation layer is prepared from, by weight, 70-80 parts of rock wool fibers, 10-15 parts of special-shaped polyester fibers, 10-20 parts of phenolic resin, 1-3 parts of a water repellent and 10-20 parts of water; the bonding layer is prepared from the following raw materials: an ethylene-vinyl acetate emulsion, a styrene-acrylate copolymer, a defoaming agent, a thickening agent, a coupling agent and water; the facing layer is prepared from the following raw materials: Portland cement, cellulose ether, quartz sand and water. According to the technical scheme, the problems of low compression strength and low tensile strength of the rock wool board in the prior art are solved.

Description

Technical Field

[0001] The invention relates to the technical field of rock wool boards, and in particular to a high-strength rock wool board and a preparation method thereof. Background Art

[0002] In today's construction and industrial fields, the performance requirements for materials are increasing day by day. As a widely used thermal insulation, heat insulation and sound absorption material, the importance of rock wool board is self-evident. However, traditional rock wool board often has certain limitations in strength.

[0003] With the continuous development of building structures and the increasing complexity of industrial application scenarios, higher requirements are placed on the strength of rock wool boards. In the construction field, higher compression strength can ensure that the rock wool board is not easily deformed when subjected to a certain pressure, thereby ensuring the structural stability of the building and the durability of the thermal insulation performance. The tensile strength is essential for resisting external impact and preventing the board from delamination and falling off. In industrial applications, such as in some high temperature and high pressure environments, rock wool boards are required to have sufficient strength to withstand various mechanical and thermal stresses. Therefore, the development of a high-strength rock wool board and its preparation method can not only meet the current market demand for high-performance materials, but also provide strong support for the sustainable development of the construction and industrial fields. Summary of the invention

[0004] The present invention provides a high-strength rock wool board and a preparation method thereof, which solves the problem of low compression strength and low tensile strength of the rock wool board in the related art.

[0005] The technical solution of the present invention is as follows: The present invention provides a high-strength rock wool board, comprising an insulation layer, an adhesive layer and a finishing layer arranged in sequence from top to bottom, wherein the raw materials of the insulation layer comprise the following components by weight: 70-80 parts of rock wool fiber, 10-15 parts of special-shaped polyester fiber, 10-20 parts of phenolic resin, 1-3 parts of water repellent, and 10-20 parts of water; The raw materials of the bonding layer include ethylene-vinyl acetate emulsion, styrene-acrylate copolymer, defoamer, thickener, coupling agent and water; The raw materials of the finishing layer include silicate cement, cellulose ether, quartz sand and water.

[0006] As a further technical solution, the special-shaped polyester fiber is composed of trilobal fiber and dumbbell fiber, and the mass ratio of the trilobal fiber to the dumbbell fiber is 2:1-3.

[0007] In the present invention, trilobal fibers and dumbbell fibers are added simultaneously, and by reasonably adjusting the mass ratio of the trilobal fibers and the dumbbell fibers, the synergistic effect of the two is brought into play to form complementary mechanical properties, thereby improving the compressive strength and tensile strength of the rock wool board.

[0008] As a further technical solution, the mass ratio of the trilobal fiber to the dumbbell fiber is 1:1.

[0009] As a further technical solution, the water repellent is a silicone water repellent.

[0010] As a further technical solution, the bonding layer raw materials include the following components in parts by weight: 20 to 30 parts of ethylene-vinyl acetate emulsion, 10 to 20 parts of styrene-acrylate copolymer, 0.5 to 1.5 parts of defoaming agent, 1 to 3 parts of thickener, 2 to 4 parts of coupling agent, and 70 to 80 parts of water.

[0011] As a further technical solution, the mass ratio of the ethylene-vinyl acetate emulsion to the styrene-acrylate copolymer is 2:2-3.

[0012] In the present invention, the mass ratio of ethylene-vinyl acetate emulsion and styrene-acrylate copolymer is adjusted to improve the cohesive strength of the rock wool board, maintain the structural integrity of the rock wool board, and enhance the compression strength and tensile strength of the rock wool board.

[0013] As a further technical solution, the thickness of the bonding layer is 2 to 3 mm.

[0014] As a further technical solution, the defoamer includes one or more of an organosilicon defoamer, a polyether defoamer, and a mineral oil defoamer.

[0015] As a further technical solution, the thickener includes one or both of polyvinyl alcohol and polyacrylamide.

[0016] As a further technical solution, the coupling agent includes one or more of silane coupling agent KH-155, silane coupling agent A-151, and silane coupling agent KH-602.

[0017] As a further technical solution, the raw materials of the finishing layer include the following components in parts by weight: 40-60 parts of Portland cement, 10-20 parts of styrene-acrylate copolymer, 10-20 parts of cellulose ether, 30-50 parts of quartz sand, and 10-15 parts of water.

[0018] The present invention also provides a method for preparing a high-strength rock wool board, comprising the following steps: S1, weighing the raw materials of the thermal insulation layer, mixing them evenly, and curing and forming them to obtain the thermal insulation layer; S2, weigh the bonding layer raw materials, mix them evenly, and apply them on one side of the thermal insulation layer to obtain the bonding layer; S3, weigh the raw materials of the finishing layer, mix them evenly, extrude them onto the bonding layer, and obtain the high-strength rock wool board after curing.

[0019] The working principle and beneficial effects of the present invention are: In the present invention, adding special-shaped polyester fibers to the insulation layer can not only enhance the stability and strength of the insulation layer in the tensile direction, but also play a role in dispersing pressure. The mixed structure formed by the special-shaped polyester fibers and the rock wool fibers can make the pressure more evenly distributed in the entire insulation layer, avoiding the rock wool board from being crushed due to excessive pressure in some parts, thereby improving the compression strength and tensile strength of the rock wool board. DETAILED DESCRIPTION

[0020] 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 described embodiments 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 creative work are within the scope of protection of the present invention.

[0021] In the following examples and comparative examples: Organic silicon defoamer: model number is CI-0560, manufacturer is Guangdong Nanhui New Materials Co., Ltd.; Insulation layer thickness: 60mm; Finishing layer thickness: 8mm; Adhesive layer thickness: 2~3mm; Polyvinyl alcohol: model PVA-2488; Silicone water repellent: solid content is 30wt%, the manufacturer is Jinan Shouyue Chemical Technology Co., Ltd.; Styrene-acrylate copolymer: specific gravity 1.07g / cm 3 , melt index is 0.50g / 10min; Ethylene-vinyl acetate emulsion: active substance content 55wt%, manufacturer is Shenzhen Yuanyijia Technology Co., Ltd.; Phenolic resin: model PF-2124; Trilobal fiber: fineness is 1.5D~2.5D, length is 32~102nm; Dumbbell fiber: fineness is 7.0D~12.0D, length is 32~102nm.

[0022] Example 1 S1, weigh 70 parts of rock wool fiber, 10 parts of special-shaped polyester fiber, 10 parts of phenolic resin, 1 part of silicone water repellent, and 10 parts of water, mix them evenly, and obtain the thermal insulation layer after curing and forming, wherein the special-shaped polyester fiber is a trilobal fiber; S2, weigh 20 parts of ethylene-vinyl acetate emulsion, 10 parts of styrene-acrylate copolymer, 0.5 parts of silicone defoamer, 1 part of polyvinyl alcohol, 2 parts of silane coupling agent KH-155, and 70 parts of water, mix them evenly, and apply them on one side of the insulation layer to obtain a bonding layer, the thickness of the bonding layer is 2 mm; S3. Weigh 40 parts of Portland cement, 10 parts of cellulose ether, 30 parts of quartz sand and 10 parts of water, mix them evenly, extrude them onto the bonding layer, and cure them for 7 days to obtain a high-strength rock wool board.

[0023] Example 2 S1, weigh 75 parts of rock wool fiber, 12 parts of special-shaped polyester fiber, 15 parts of phenolic resin, 2 parts of silicone water repellent, and 15 parts of water, mix them evenly, and obtain the thermal insulation layer after curing and forming, wherein the special-shaped polyester fiber is a trilobal fiber; S2, weigh 24 parts of ethylene-vinyl acetate emulsion, 12 parts of styrene-acrylate copolymer, 1 part of silicone defoamer, 2 parts of polyvinyl alcohol, 3 parts of silane coupling agent A-151, and 75 parts of water, mix them evenly, and apply them on one side of the insulation layer to obtain a bonding layer with a thickness of 2.5 mm; S3. Weigh 50 parts of Portland cement, 15 parts of cellulose ether, 40 parts of quartz sand and 12 parts of water, mix them evenly, extrude them onto the bonding layer, and cure them for 7 days to obtain a high-strength rock wool board.

[0024] Example 3 S1, weigh 80 parts of rock wool fiber, 15 parts of special-shaped polyester fiber, 20 parts of phenolic resin, 3 parts of silicone water repellent, and 20 parts of water, mix them evenly, and obtain the thermal insulation layer after curing and forming, wherein the special-shaped polyester fiber is a trilobal fiber; S2, weigh 30 parts of ethylene-vinyl acetate emulsion, 15 parts of styrene-acrylate copolymer, 1.5 parts of silicone defoamer, 3 parts of polyvinyl alcohol, 4 parts of silane coupling agent KH-602, and 80 parts of water, mix them evenly, and apply them on one side of the insulation layer to obtain a bonding layer with a thickness of 3 mm; S3. Weigh 60 parts of Portland cement, 20 parts of cellulose ether, 50 parts of quartz sand and 15 parts of water, mix them evenly, extrude them onto the bonding layer, and cure them for 7 days to obtain a high-strength rock wool board.

[0025] Example 4 Compared with Example 1, the difference of Example 4 is that 10 parts of the shaped polyester fibers are dumbbell fibers.

[0026] Example 5 Compared with Example 1, the difference of Example 5 is that 10 parts of the shaped polyester fibers are composed of trilobal fibers and dumbbell fibers in a mass ratio of 3:1.

[0027] Example 6 Compared with Example 1, the difference of Example 6 is that 10 parts of the shaped polyester fibers are composed of trilobal fibers and dumbbell fibers in a mass ratio of 2:1.

[0028] Example 7 Compared with Example 1, the difference of Example 7 is that 10 parts of the shaped polyester fibers are composed of trilobal fibers and dumbbell fibers in a mass ratio of 1:1.

[0029] Example 8 Compared with Example 1, the difference of Example 8 is that 10 parts of the shaped polyester fibers are composed of trilobal fibers and dumbbell fibers in a mass ratio of 2:3.

[0030] Example 9 Compared with Example 1, the difference of Example 9 is that 10 parts of the shaped polyester fibers are composed of trilobal fibers and dumbbell fibers in a mass ratio of 1:2.

[0031] Example 10 Compared with Example 7, Example 10 is different in that 20 parts of ethylene-vinyl acetate emulsion and 10 parts of styrene-acrylate copolymer are replaced with 15 parts of ethylene-vinyl acetate emulsion and 15 parts of styrene-acrylate copolymer.

[0032] Embodiment 11 Compared with Example 7, Example 11 is different in that 20 parts of ethylene-vinyl acetate emulsion and 10 parts of styrene-acrylate copolymer are replaced with 12 parts of ethylene-vinyl acetate emulsion and 18 parts of styrene-acrylate copolymer.

[0033] Example 12 Compared with Example 7, Example 12 is different in that 20 parts of ethylene-vinyl acetate emulsion and 10 parts of styrene-acrylate copolymer are replaced with 10 parts of ethylene-vinyl acetate emulsion and 20 parts of styrene-acrylate copolymer.

[0034] Comparative Example 1 Compared with Example 1, the difference of Comparative Example 1 is that the special-shaped polyester fiber is replaced by an equal amount of rock wool fiber.

[0035] The high-strength rock wool boards prepared in Examples 1 to 12 and Comparative Example 1 were tested according to the following method: 1. Compression strength: Test the compression strength of the sample according to the test method specified in GB / T25975-2018 "Rock wool products for external insulation of building exterior walls".

[0036] 2. Tensile strength perpendicular to the surface: According to the test method specified in GB / T25975-2018 "Rock wool products for external insulation of building exterior walls", the tensile strength of the test sample perpendicular to the surface is tested.

[0037] The test results are shown in the following table: Table 1 Performance test results of high-strength rock wool boards prepared in Examples 1 to 12 and Comparative Example 1

[0038] Compared with Comparative Example 1, Example 1 adds shaped polyester fibers. As a result, the compressive strength and the tensile strength perpendicular to the surface of Example 1 are greater than those of Comparative Example 1, indicating that the addition of shaped polyester fibers can improve the compressive strength and the tensile strength perpendicular to the surface of the rock wool board.

[0039] Compared with Examples 1 and 4, Examples 5 to 9 simultaneously added trilobal fibers and dumbbell fibers, and the compressive strength and tensile strength perpendicular to the surface of Examples 5 to 9 were greater than those of Examples 1 and 4, indicating that the trilobal fibers and dumbbell fibers play a synergistic role and can enhance the compressive strength and tensile strength perpendicular to the surface of the rock wool board. In Examples 5 to 9, trilobal fibers and dumbbell fibers of different mass ratios were added, and the compressive strength and tensile strength perpendicular to the surface of Examples 6 to 8 were greater than those of Examples 5 and 9, indicating that when the mass ratio of trilobal fibers to dumbbell fibers is 2:1 to 3, and the preferred ratio is 1:1, the compressive strength and tensile strength perpendicular to the surface of the obtained rock wool board are better.

[0040] Compared with Example 7, ethylene-vinyl acetate emulsion and styrene-acrylate copolymer were added to the bonding layer of Examples 10 to 12 in different mass ratios. As a result, the compressive strength and tensile strength perpendicular to the surface of Examples 10 to 11 were greater than those of Examples 9 and 12, indicating that when the mass ratio of ethylene-vinyl acetate emulsion and styrene-acrylate copolymer was 2:2 to 3, the compressive strength and tensile strength perpendicular to the surface of the obtained rock wool board were better.

[0041] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A high-strength rock wool board, characterized in that: It includes an insulation layer, a bonding layer and a finishing layer arranged in sequence from top to bottom, wherein the raw materials of the insulation layer include the following components by weight: 70-80 parts of rock wool fiber, 10-15 parts of special-shaped polyester fiber, 10-20 parts of phenolic resin, 1-3 parts of water repellent, and 10-20 parts of water; The raw materials of the bonding layer include ethylene-vinyl acetate emulsion, styrene-acrylate copolymer, defoamer, thickener, coupling agent and water; The raw materials of the finishing layer include silicate cement, cellulose ether, quartz sand and water.

2. A high-strength rock wool board according to claim 1, characterized in that: The special-shaped polyester fiber consists of trilobal fiber and dumbbell fiber, and the mass ratio of the trilobal fiber to the dumbbell fiber is 2:1-3.

3. A high-strength rock wool board according to claim 1, characterized in that: The bonding layer raw material comprises the following components in parts by weight: 20-30 parts of ethylene-vinyl acetate emulsion, 10-20 parts of styrene-acrylate copolymer, 0.5-1.5 parts of defoamer, 1-3 parts of thickener, 2-4 parts of coupling agent and 70-80 parts of water.

4. A high-strength rock wool board according to claim 1, characterized in that: The mass ratio of the ethylene-vinyl acetate emulsion to the styrene-acrylate copolymer is 2:2-3.

5. The high-strength rock wool board according to claim 1, characterized in that: The thickness of the bonding layer is 2-3 mm.

6. The high-strength rock wool board according to claim 1, characterized in that: The defoamer includes one or more of an organosilicon defoamer, a polyether defoamer, and a mineral oil defoamer.

7. The high-strength rock wool board according to claim 1, characterized in that: The thickener includes one or both of polyvinyl alcohol and polyacrylamide.

8. The high-strength rock wool board according to claim 1, characterized in that: The coupling agent includes one or more of silane coupling agent KH-155, silane coupling agent A-151, and silane coupling agent KH-602.

9. The high-strength rock wool board according to claim 1, characterized in that: The raw materials of the finishing layer include the following components in parts by weight: 40-60 parts of silicate cement, 10-20 parts of cellulose ether, 30-50 parts of quartz sand, and 10-15 parts of water.

10. A method for preparing a high-strength rock wool board according to any one of claims 1 to 9, characterized in that: The following steps are involved: S1, weighing the raw materials of the thermal insulation layer, mixing them evenly, and curing and forming them to obtain the thermal insulation layer; S2, weigh the bonding layer raw materials, mix them evenly, and apply them on one side of the thermal insulation layer to obtain the bonding layer; S3, weigh the raw materials of the finishing layer, mix them evenly, extrude them onto the bonding layer, and obtain the high-strength rock wool board after curing.

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