A polymethacrylimide foam material for building sound insulation and its preparation process

Abstract

The invention relates to the field of foam material processing, in particular to a polymethacrylimide foam material for building sound insulation and a preparation process thereof, comprising the following steps: step one, polymer fiber preparation; step two, preparing a semi-finished product one; step three, preparing a foam board one; step four, repeating the steps; step five, preparing a semi-finished product two; step six, preparing a foam board two; step seven, hot pressing and forming; and step eight, cutting the finished product. In this process, special polymer fibers are skillfully added to raw materials such as methacrylic acid, methacrylonitrile, and methacrylamide. This structure not only significantly improves the overall density and strength of the foam material, but also greatly enhances its sound insulation performance. Secondly, two layers of foam boards one subjected to special polymerization and foaming treatment are compounded with a layer of foam board two containing polymer fibers. This multi-layer composite structure not only effectively improves the sound insulation performance of the foam material, but also makes the foam surface smoother and more beautiful, which is both practical and beautiful.

Description

Technical Field

[0001] The invention relates to the field of foam material processing, in particular to a polymethacrylimide foam material for building sound insulation and a preparation process thereof. Background Art

[0002] Foam has a wide range of applications in the construction field. With its light weight, heat insulation, sound insulation, shock absorption and other excellent properties, it has become one of the indispensable materials in modern construction. In terms of building thermal insulation, foam plastics, especially polyurethane foam, polystyrene foam, etc., are widely used in the insulation layer of walls, roofs and floors, effectively improving the energy efficiency of buildings and reducing energy consumption. These foam materials can form a continuous closed-cell structure, effectively blocking the transmission of cold and hot air from the outside and maintaining the stability of indoor temperature. At the same time, in some special architectural designs, such as stage sets and exhibition displays, foam is often used as model making and decorative materials because of its easy shaping and low cost, which is of great significance to the realization of green buildings and energy conservation and emission reduction.

[0003] However, in actual applications, traditional polymethacrylimide foam materials generally use methacrylic acid and methacrylonitrile as the main raw materials, resulting in low density or insufficient thickness of the finished product and limited sound insulation effect. Although it has certain sound insulation performance, it is difficult to achieve satisfactory sound insulation effect in scenes with high building noise.

[0004] Therefore, in view of the problem that the finished product density of the above-mentioned traditional polymethacrylimide foam material is low and the sound insulation performance needs to be improved, a polymethacrylimide foam material for building sound insulation and a preparation process thereof can be designed. Summary of the invention

[0005] In order to overcome the problem that the finished product density of traditional polymethacrylimide foam materials is low and the sound insulation performance needs to be improved.

[0006] The technical scheme of the present invention is: a polymethacrylimide foam material for building sound insulation, the starting raw material formula components of the material are calculated by weight: 80-150 parts of polymer fiber, 50-60 parts of methacrylic acid, 40-55 parts of methacrylonitrile, 1-32 parts of methacrylamide, 5-12 parts of 2,4,6-trinitrophenol, 3-5 parts of flame retardant, 5-20 parts of binder, 10-44 parts of water, 2-18 parts of foaming agent, and 0.1-0.7 parts of peroxide initiator.

[0007] Among them, the polymer fiber is a mixture of rock wool, mineral wool, glass wool, and asbestos fiber; the flame retardant is a mixture of one or more of aluminum hydroxide, magnesium hydroxide, red phosphorus trioxide, and antimony oxide; the binder is a mixture of one or more of polyvinyl alcohol, polyorthoester, polycaprolactone, and polysebacic acid glyceride; the foaming agent is a mixture of one or more of n-pentane, isopentane, n-hexane, cyclohexane, and petroleum ether; the thickener includes a mixture of one or more of methyl cellulose or carboxymethyl cellulose, polyacrylamide, polymethyl methacrylate, fatty alcohol polyoxyethylene ether sulfate, and PEG-150 distearate.

[0008] A process for preparing a polymethacrylimide foam material for building sound insulation, comprising the polymethacrylimide foam material for building sound insulation described above, and the steps are as follows:

[0009] Step 1: Take rock wool, mineral wool, glass wool and asbestos fibers in a ratio of 2-3:5-9:3-6:1-7, put them together in a special carding machine to loosen and mix them to make fluffy polymer fibers, and set them aside after they are fully fluffy;

[0010] Step 2: adding methacrylic acid, methacrylonitrile, methacrylamide, 2,4,6-trinitrophenol, a foaming agent, and a peroxide initiator into a special mixer and stirring and mixing them evenly to form a semi-finished product, and taking out a part of the semi-finished product for standby use;

[0011] Step 3: injecting a portion of the semi-finished product 1 into a cavity mold 1, and then placing the mold in a constant temperature water bath of 40-60° C. for polymerization and foaming, with the polymerization time controlled at 80-110 min, to obtain a foam board 1;

[0012] Step 4: Repeat step 3 to make two identical foam boards;

[0013] Step 5: Add polymer fiber, flame retardant, binder, and water with a pH value of 2.5-4.0 into a reaction kettle and stir. The stirring temperature is set to 80-85°C to prepare a slurry with a weight concentration of 2.5‰-1wt%. Then, add the slurry into a special mixer and stir and mix it with the remaining semi-finished product 1 to form a semi-finished product 2 for standby use.

[0014] Step 6: inject the spare semi-finished product 2 into the cavity mold 2, and then place the mold in a constant temperature water bath of 50-60°C for polymerization and foaming, and the polymerization time is controlled at 100-150 minutes to obtain the foam board 2;

[0015] Step 7: Lay the materials in the order of foam board 1, foam board 2, and foam board 1 from bottom to top, and then heat press them through a molding machine, with the heating temperature controlled at 180-200°C and the heating time at 150 seconds to 210 seconds, to compound the three structural layers into one;

[0016] Step 8: After the hot pressing process, the burrs are cut off by a special cutting device to form a product;

[0017] Preferably, in step 1, the fiber diameter of the polymer fiber is 3-12 μm.

[0018] Preferably, the licker-in roller speed of the carding machine in step 1 is 500 rpm-800 rpm.

[0019] Preferably, the stirring rate of the stirrer in step 2 is 300 rpm-1000 rpm.

[0020] Preferably, the thickness of the foam board 1 in step 3 is 0.8-1.2 cm.

[0021] Preferably, the stirring rate of the reactor in step 5 is 600 rpm-800 rpm.

[0022] Preferably, the stirring rate of the stirrer in step 5 is 500 rpm-1600 rpm.

[0023] Preferably, the thickness of the foam board 2 in step 6 is 2-3.5 cm.

[0024] Preferably, in step seven, the foam board 1 and the foam board 2 are bonded together using silica sol or PUR hot melt adhesive, and the upper and lower layers of colloid can be melted by hot pressing.

[0025] Beneficial effects of the present invention:

[0026] By ingeniously adding special polymer fibers to raw materials such as methacrylic acid, methacrylonitrile, and methacrylamide, and using a carding machine to loosen and mix the cotton and a mixer to fully mix and stir the cotton, the internal fiber structure of the foam material finally obtained is more fluffy and evenly distributed. This structure not only significantly improves the overall density and strength of the foam material, but also greatly enhances its sound insulation performance, so that the sound is more obstructed during the propagation process, thereby achieving better sound insulation effect. Secondly, this process designs a central sandwich structure to composite two layers of foam boards that have been specially polymerized and foamed with a layer of foam board containing polymer fibers. This multi-layer composite structure not only effectively improves the sound insulation performance of the foam material, but also makes the foam surface smoother and more beautiful, meeting the dual needs of modern buildings for sound insulation materials that are both practical and beautiful. DETAILED DESCRIPTION

[0027] The present invention will be further described below in conjunction with the embodiments.

[0028] Example

[0029] The present invention provides an embodiment: a polymethacrylimide foam material for building sound insulation, wherein the starting raw material formula components of the material are as follows by weight: 80-150 parts of polymer fiber, 50-60 parts of methacrylic acid, 40-55 parts of methacrylonitrile, 1-32 parts of methacrylamide, 5-12 parts of 2,4,6-trinitrophenol, 3-5 parts of flame retardant, 5-20 parts of binder, 10-44 parts of water, 2-18 parts of foaming agent, and 0.1-0.7 parts of peroxide initiator.

[0030] Among them, the polymer fiber is a mixture of rock wool, mineral wool, glass wool, and asbestos fiber; the flame retardant is a mixture of one or more of aluminum hydroxide, magnesium hydroxide, red phosphorus trioxide, and antimony oxide; the binder is a mixture of one or more of polyvinyl alcohol, polyorthoester, polycaprolactone, and polysebacic acid glyceride; the foaming agent is a mixture of one or more of n-pentane, isopentane, n-hexane, cyclohexane, and petroleum ether; the thickener includes a mixture of one or more of methyl cellulose or carboxymethyl cellulose, polyacrylamide, polymethyl methacrylate, fatty alcohol polyoxyethylene ether sulfate, and PEG-150 distearate.

[0031] A process for preparing a polymethacrylimide foam material for building sound insulation, comprising the polymethacrylimide foam material for building sound insulation described above, and the steps are as follows:

[0032] Step 1: Take rock wool, mineral wool, glass wool and asbestos fibers in a ratio of 2:6:4:3, adjust the licker-in speed of the carding machine to 600 rpm, and then put the materials into a special carding machine for loosening and mixing to make fluffy polymer fibers with a fiber diameter of 3-12μm, and fully fluff them for use;

[0033] Step 2: first adjust the stirring speed of the mixer to 600 rpm, then add methacrylic acid, methacrylonitrile, methacrylamide, 2,4,6-trinitrophenol, foaming agent, and peroxide initiator into a dedicated mixer and stir and mix them evenly to form a semi-finished product, and take out part of the semi-finished product for standby use;

[0034] Step 3: injecting a portion of the semi-finished product 1 into the cavity mold 1, and then placing the mold in a constant temperature water bath at 50° C. for polymerization and foaming, with the polymerization time controlled at 90 min, to obtain a foam board 1 with a thickness of 0.8 cm;

[0035] Step 4: Repeat step 3 to make two identical foam boards;

[0036] Step 5: First, the stirring rate of the reactor and the stirring rate of the mixer are adjusted to 800 rpm and 1400 rpm respectively, and then the polymer fiber, flame retardant, binder, and pH value = 3.5 water are added to the reactor and stirred, and the stirring temperature is set to 83°C to prepare a slurry with a weight concentration of 1wt%, and then the slurry is added to a special mixer and fully stirred and mixed with the remaining semi-finished product 1 to form a semi-finished product 2 for standby;

[0037] Step 6: inject the spare semi-finished product 2 into the cavity mold 2, and then place the mold in a constant temperature water bath at 60°C for polymerization and foaming, and the polymerization time is controlled at 120 minutes to obtain a foam board 2 with a thickness of 2 cm;

[0038] Step 7: Lay the materials in the order of foam board 1, foam board 2, and foam board 1 from bottom to top, and then heat press them through a molding machine. The heating temperature is controlled at 180°C and the heating time is 150 seconds. The silica sol between the board layers can be melted, so that the three structural layers are compounded into one;

[0039] Step 8: After the hot pressing process, the burrs are cut off by special cutting equipment to form the product.

[0040] The polymethacrylimide foam material prepared by the embodiment, in terms of performance, combines the toughness of polymer fibers with the advantages of a variety of chemical raw materials, forms a high-density, high-strength internal structure, and effectively improves its sound insulation performance. After a precise preparation process, especially through multi-layer composite and hot pressing treatment, the foam material not only has a significant sound insulation effect, but also has good flame retardant ability. In addition, by precisely controlling the raw material ratio and polymerization foaming conditions, the foam material exhibits a uniform microporous structure, which further enhances its sound insulation and thermal insulation performance. In terms of appearance, the foam material has a smooth surface and uniform color, and the edges are professionally cut without burrs and defects, which meets the requirements of modern buildings for the aesthetics of sound insulation materials. Therefore, the polymethacrylimide foam material can be widely used in building sound insulation, thermal insulation, sound absorption and noise reduction, etc., with its excellent sound insulation performance, good flame retardant performance and beautiful appearance.

Claims

1. A polymethacrylimide foam material for building sound insulation, characterized in that The starting raw material formula components of the material are calculated by weight as follows: 80-150 parts of high molecular fiber, 50-60 parts of methacrylic acid, 40-55 parts of methacrylonitrile, 1-32 parts of methacrylamide, 5-12 parts of 2,4,6-trinitrophenol, 3-5 parts of flame retardant, 5-20 parts of adhesive, 10-44 parts of water, 2-18 parts of foaming agent and 0.1-0.7 parts of peroxide initiator. Among them, the polymer fiber is a mixture of rock wool, mineral wool, glass wool, and asbestos fiber; the flame retardant is a mixture of one or more of aluminum hydroxide, magnesium hydroxide, red phosphorus trioxide, and antimony oxide; the binder is a mixture of one or more of polyvinyl alcohol, polyorthoester, polycaprolactone, and polysebacic acid glyceride; the foaming agent is a mixture of one or more of n-pentane, isopentane, n-hexane, cyclohexane, and petroleum ether; the thickener includes a mixture of one or more of methyl cellulose or carboxymethyl cellulose, polyacrylamide, polymethyl methacrylate, fatty alcohol polyoxyethylene ether sulfate, and PEG-150 distearate.

2. A process for preparing polymethacrylimide foam material for building sound insulation, characterized in that The method comprises the polymethacrylimide foam material for building sound insulation according to claim 1, wherein the steps are as follows: Step 1: Take rock wool, mineral wool, glass wool and asbestos fibers in a ratio of 2-3:5-9:3-6:1-7, put them together in a special carding machine to loosen and mix them to make fluffy polymer fibers, and set them aside after they are fully fluffy; Step 2: adding methacrylic acid, methacrylonitrile, methacrylamide, 2,4,6-trinitrophenol, a foaming agent, and a peroxide initiator into a special mixer and stirring and mixing them evenly to form a semi-finished product, and taking out a part of the semi-finished product for standby use; Step 3: injecting a portion of the semi-finished product 1 into a cavity mold 1, and then placing the mold in a constant temperature water bath of 40-60° C. for polymerization and foaming, with the polymerization time controlled at 80-110 min, to obtain a foam board 1; Step 4: Repeat step 3 to make two identical foam boards; Step 5: Add polymer fiber, flame retardant, binder, and water with a pH value of 2.5-4.0 into a reaction kettle and stir. The stirring temperature is set to 80-85°C to prepare a slurry with a weight concentration of 2.5‰-1wt%. Then, add the slurry into a special mixer and stir and mix it with the remaining semi-finished product 1 to form a semi-finished product 2 for standby use. Step 6: inject the spare semi-finished product 2 into the cavity mold 2, and then place the mold in a constant temperature water bath of 50-60°C for polymerization and foaming, and the polymerization time is controlled at 100-150 minutes to obtain the foam board 2; Step 7: Lay the materials in the order of foam board 1, foam board 2, and foam board 1 from bottom to top, and then heat press them through a molding machine, with the heating temperature controlled at 180-200°C and the heating time at 150 seconds to 210 seconds, to compound the three structural layers into one; Step 8: After the hot pressing process, the burrs are cut off by special cutting equipment to form the product.

3. The process for preparing a polymethacrylimide foam material for building sound insulation according to claim 2, characterized in that: The fiber diameter of the polymer fiber in step 1 is 3-12 μm.

4. The process for preparing a polymethacrylimide foam material for building sound insulation according to claim 2, characterized in that: In step 1, the licker-in roller speed of the carding machine is 500 rev / min-800 rev / min.

5. The process for preparing a polymethacrylimide foam material for building sound insulation according to claim 2, characterized in that: The stirring speed of the stirrer in step 2 is 300 rpm-1000 rpm.

6. The process for preparing a polymethacrylimide foam material for building sound insulation according to claim 2, characterized in that: The thickness of the foam board 1 in step 3 is 0.8-1.2 cm.

7. The process for preparing a polymethacrylimide foam material for building sound insulation according to claim 2, characterized in that: In step 5, the stirring rate of the reactor is 600 rpm-800 rpm.

8. The process for preparing a polymethacrylimide foam material for building sound insulation according to claim 2, characterized in that: The stirring speed of the stirrer in step 5 is 500 rpm-1600 rpm.

9. The process for preparing a polymethacrylimide foam material for building sound insulation according to claim 2, characterized in that: In step six, the thickness of the foam board 2 is 2-3.5 cm.

10. The process for preparing a polymethacrylimide foam material for building sound insulation according to claim 2, characterized in that: In step seven, the foam board 1 and the foam board 2 are bonded together using silica sol or PUR hot melt adhesive, and the upper and lower layers of colloid can be melted by hot pressing.