Basalt fiber composite fireproof thermal insulation board and manufacturing process thereof

Abstract

The invention discloses a basalt fiber composite fireproof thermal insulation board and a manufacturing process thereof, and belongs to the technical field of fireproof thermal insulation materials. Through the unique multi-layer structural design and the reasonable matching of the materials of all layers, the basalt fiber composite fireproof heat-insulating plate disclosed by the invention gives full play to the high-temperature-resistant and reinforcing effects of basalt fibers and the heat-insulating and fireproof advantages of other materials, so that the whole plate has excellent fireproof and heat-insulating performance, long fire endurance, low heat conductivity and good heat insulation performance. Flame and heat propagation can be effectively blocked, and safety of buildings and industrial places is guaranteed.

Description

Technical Field

[0001] The invention relates to the technical field of fireproof and heat-insulating materials, and in particular to a basalt fiber composite fireproof and heat-insulating board material and a manufacturing process thereof. Background Art

[0002] In the construction and industrial fields, with the improvement of safety standards and the enhancement of fire prevention awareness, the demand for high-efficiency fireproof and heat-insulating materials has become very urgent. This demand is not only reflected in the strict requirements for the fireproof performance of materials, but also involves comprehensive considerations of heat insulation effect, environmental protection, durability and other aspects.

[0003] Traditional fireproof insulation boards, such as some organic insulation boards, can meet the insulation requirements to a certain extent, but their fireproof performance is far from enough. When a fire occurs, these materials are easy to burn, not only can they not effectively prevent the spread of the fire, but they will also release toxic and harmful gases, causing great harm to people and the environment, and posing a great safety hazard. Therefore, this type of material has gradually failed to meet the high standards of fire safety in modern construction and industry.

[0004] On the other hand, although some inorganic fireproof panels have good fireproof performance, they have obvious deficiencies in other aspects. For example, they are usually brittle, have low strength, and are easily damaged during use; at the same time, their thermal insulation effect is often not ideal and cannot meet the requirements of high efficiency and energy saving. These defects limit the widespread application of inorganic fireproof panels, making the market in urgent need of higher-quality new fireproof and thermal insulation materials.

[0005] In this context, basalt fiber has entered people's field of vision with its outstanding performance. Basalt fiber has excellent characteristics such as high temperature resistance, strong chemical stability and low thermal conductivity. It is a fireproof and heat-insulating material with great potential. It can remain stable in high temperature environment and is not easy to burn. At the same time, its low thermal conductivity also means excellent thermal insulation performance. These characteristics make basalt fiber one of the ideal raw materials for preparing high-performance fireproof and heat-insulating materials.

[0006] However, there are still some technical challenges in applying basalt fiber to fireproof and heat-insulating panels. For example, in terms of the synergy between fiber and other materials, how to ensure the close combination and complementary performance between different materials is an issue that needs in-depth research. In addition, the optimization of the overall structure of the panel is also key, which directly affects the strength, durability and thermal insulation effect of the panel. The current technical level is still difficult to give full play to the full advantages of basalt fiber, resulting in the performance of the final product failing to reach the optimal state. Therefore, it is particularly important to develop a new basalt fiber composite fireproof and heat-insulating panel and its reasonable manufacturing process. Summary of the invention

[0007] The technical problem to be solved by the present invention is: to overcome the shortcomings of the prior art and provide a basalt fiber composite fireproof and heat-insulating board and its manufacturing process, which fully utilizes the high temperature resistance and reinforcement effect of basalt fiber and the heat insulation and fireproof advantages of other materials through a unique multi-layer structure design and a reasonable combination of materials of each layer, so that the board as a whole has excellent fireproof and heat-insulating properties, a long fire resistance limit, and low thermal conductivity, and can effectively block the spread of flames and heat, thereby ensuring the safety of buildings and industrial sites.

[0008] The technical solution of the present invention is:

[0009] In one aspect, the present invention provides a manufacturing process for a basalt fiber composite fireproof and heat-insulating board material, comprising the following steps:

[0010] S1 manufactures thermal insulation layer

[0011] The short-cut basalt fibers and hollow microspheres are uniformly dispersed in an inorganic binder to form a uniform mixed slurry, which is poured into a mold and subjected to an extrusion molding process to obtain a heat insulation layer with a hollow structure;

[0012] S2 core layer

[0013] The expanded perlite particles are immersed in a fire retardant solution and then dried; they are filled into the hollow structure of the heat insulation layer, and then another filled heat insulation layer is covered thereon, and through a hot pressing composite process, the core layer is sandwiched between two layers of heat insulation layers to form a structure in which the core layer is wrapped by the heat insulation layers; the purpose of this is to allow the expanded perlite particles to be inside the heat insulation layer blank to form a "sandwich" structure, making full use of the heat insulation performance of the expanded perlite particles, and also facilitating the subsequent composite between the layers and the stability of the overall structure;

[0014] S3 manufactures basalt fiber composite fireproof and heat insulation panels

[0015] Alumina, silica, dispersant and solvent are fully stirred to form a uniform coating slurry, and then the coating slurry is evenly coated on the surface of the structure in which the core layer is wrapped by the insulation layer in step S2 by spraying or roller coating, and then sintered and cured to obtain a basalt fiber composite fireproof insulation board.

[0016] Preferably, in step S1, the weight proportions of the components in the thermal insulation layer are: 250-300 parts of chopped basalt fibers, 150-200 parts of hollow microspheres, and 800-1000 parts of inorganic binder.

[0017] Preferably, in step S1, the length of the chopped basalt fibers is 6-12 mm; the hollow microspheres are ceramic hollow microspheres or hollow glass microspheres; and the inorganic binder is 25-30 wt. % water glass solution.

[0018] Preferably, in step S1, the chopped basalt fibers and hollow microspheres are uniformly dispersed in the inorganic binder by stirring and ultrasonication; and the pressure of the extrusion molding process is 5-10 MPa.

[0019] Preferably, in step S2, the weight proportions of the components in the core layer are: 400-500 parts of expanded perlite particles and 80-100 parts of fire retardant solution.

[0020] Preferably, in step S2, the fire retardant solution is a 15-30wt.% ammonium phosphate fire retardant solution or a 15-30wt.% ammonium polyphosphate fire retardant solution; the drying temperature is 100-120°C; the temperature of the hot pressing composite process is 200-300°C, and the pressure is 8-12MPa.

[0021] Among them, the ammonium phosphate in the ammonium phosphate fire retardant will produce acidic substances such as phosphoric acid and metaphosphoric acid when it is decomposed by heat. These substances can form a covering layer on the surface of the material, isolating oxygen and preventing further contact between combustible gas and oxygen. It is environmentally friendly and will not release toxic and harmful gases. At high temperatures, the phosphorus element in the ammonium polyphosphate fire retardant can generate a phosphate carbonization layer with an insulating effect, and the nitrogen element can absorb heat and produce inert gas, reducing the combustion rate and effectively preventing the spread of flames.

[0022] Preferably, in step S3, the weight proportions of the components in the coating slurry are: 50-60 parts of aluminum oxide, 40-50 parts of silicon dioxide, 3-5 parts of dispersant, and 100-200 parts of solvent; the dispersant is a methacrylic acid polycarboxylate dispersant or sodium polyacrylate, and the solvent is water.

[0023] Preferably, in step S3, the sintering and curing temperature is 800-1000° C. and the time is 1-2 hours.

[0024] On the other hand, the present invention provides a basalt fiber composite fireproof and heat-insulating board material manufactured by the manufacturing process of the above-mentioned basalt fiber composite fireproof and heat-insulating board material.

[0025] Preferably, the thickness of the heat insulation layer is 15-25 mm, the thickness of the core layer is 10-15 mm, and the coating thickness of the coating slurry is 1-2 mm.

[0026] Compared with the prior art, the present invention has the following beneficial effects:

[0027] 1. Through the unique multi-layer structure design and the reasonable matching of the materials of each layer, the basalt fiber composite fireproof and heat-insulating board of the present invention gives full play to the high temperature resistance and reinforcement effect of basalt fiber and the heat insulation and fireproof advantages of other materials, so that the board as a whole has excellent fireproof and heat-insulating properties, long fire resistance limit, low thermal conductivity, can effectively block the spread of flames and heat, and ensure the safety of buildings and industrial sites.

[0028] 2. Compared with traditional fireproof and heat-insulating panels, the basalt fiber composite fireproof and heat-insulating panels of the present invention have significantly improved mechanical properties, are less prone to cracking and breakage, can adapt to certain external forces during installation and use, extend service life, and reduce maintenance costs.

[0029] 3. The manufacturing process of the basalt fiber composite fireproof and heat-insulating board of the present invention is relatively simple and easy, the raw material source is wide, the cost is controllable, it is conducive to large-scale production and promotion, and can meet the market's growing demand for high-performance fireproof and heat-insulating boards. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a cross-sectional view of the basalt fiber composite fireproof and heat-insulating board material of the present invention.

[0031] In the figure, 1, thermal insulation layer; 2, core layer; 3, protective layer. DETAILED DESCRIPTION

[0032] In order to enable persons skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention.

[0033] Example 1

[0034] The manufacturing process of the basalt fiber composite fireproof and heat-insulating board of this embodiment is as follows:

[0035] S1 manufactures thermal insulation layer

[0036] First, 300 parts of 12mm chopped basalt fibers and 200 parts of ceramic hollow microspheres were mixed evenly, and then 1000 parts of 30wt.% water glass solution were slowly added, and mechanical stirring was performed at the same time, and the stirring speed was controlled at 800r / min, and the stirring time was 20min, so that the materials were initially mixed evenly. Then, the mixed material was subjected to ultrasonic dispersion treatment, and the ultrasonic power was set at 1500W, and the ultrasonic time was 10min, to further break up the agglomerated particles, ensure that the components were evenly dispersed, and obtain a uniform green body slurry.

[0037] Finally, the green body slurry is poured into the mold and formed by extrusion at a pressure of 8MPa. After demolding, a heat insulation layer with a length of 1000mm, a width of 1000mm and a thickness of 25mm is obtained. When designing the mold, a rectangular cavity is pre-planned. During the green body forming process, a removable partition is used as an auxiliary component. The partition is first placed in the green body slurry. After the green body is initially formed, the partition is pulled out to form a heat insulation layer with a cavity. The cavity is 40mm long, 40mm wide and 15mm thick.

[0038] S2 core layer

[0039] Immerse 500 parts of expanded perlite particles in 100 parts of a prepared 30wt.% ammonium polyphosphate fire retardant solution for 1 hour. Stir during the immersion to ensure that the particles fully absorb the fire retardant. Then put them into a drying device and dry them at 120°C until the particles are dry, so that the fire retardant is evenly attached to the surface of the particles, completing the pretreatment of the core layer.

[0040] Carefully fill the dried expanded perlite particles into the reserved cavity of the insulation layer. During the filling process, vibration can be used to ensure that the particles are filled densely and evenly without obvious gaps, so that the core layer can maximize its insulation and fireproofing effects in subsequent use. Take another identical insulation layer and accurately cover it on the insulation layer with the core layer filled, so that the expanded perlite particles are firmly sandwiched between the two insulation layers, forming a complete structure with the core layer wrapped by the insulation layer. At this point, the structure already has certain basic insulation and fireproofing properties, but it still needs further processing to make its layers tightly combined and have better integrity.

[0041] Put the two layers of insulation with the core layer sandwiched in the hot press, set the hot pressing temperature at 250℃, the pressure at 10MPa, and keep the hot pressing time for 2h. Through hot pressing, the two layers of insulation are tightly combined with the inner core layer, eliminating the tiny gaps that may be generated by filling and other operations, enhancing the stability of the entire structure and the continuity of the insulation performance, and forming a composite structure of the middle core layer and the insulation layer, which is an important intermediate structure of the basalt fiber composite fireproof insulation board.

[0042] S3 manufactures basalt fiber composite fireproof and heat insulation panels

[0043] Weigh 60 parts of aluminum oxide, 40 parts of silicon dioxide, and 5 parts of methacrylic acid polycarboxylate dispersant, add them to 200 parts of water, and stir them thoroughly at a speed of 1000r / min for 30 minutes to form a uniform coating slurry with good fluidity. The function of the coating slurry is to form a protective layer on the outer layer of the board that is resistant to high temperature, wear and corrosion, and can further block heat transfer, thereby improving the overall durability and fireproof and heat insulation properties of the board, so that it can adapt to more different use environments.

[0044] The coating slurry is evenly coated on the surface of the composite structure of the core layer and the thermal insulation layer after hot pressing by spraying. The coating thickness is controlled to be 2mm during coating to ensure that the entire surface can be covered and the thickness is uniform to avoid local over-thickness or over-thinness.

[0045] After coating, the board is placed in a high-temperature furnace for sintering and curing. The sintering temperature is controlled at 900°C and the time is set to 1.5 hours, so that the protective layer is firmly attached to the surface of the board. After this process, the components in the coating slurry undergo chemical reactions to form a dense protective layer structure, and finally a complete basalt fiber composite fireproof and heat-insulating board (such as Figure 1 shown).

[0046] According to tests, the basalt fiber composite fireproof and heat-insulating board of this embodiment has a fire resistance limit of more than 3h, a thermal conductivity of less than 0.05W / (m·K), and a compressive strength of 1.5MPa, and has excellent fireproof, heat-insulating and mechanical properties.

[0047] Example 2

[0048] The manufacturing process of the basalt fiber composite fireproof and heat-insulating board of this embodiment is as follows:

[0049] S1 manufactures thermal insulation layer

[0050] First, 250 parts of 8mm chopped basalt fibers and 150 parts of hollow glass microspheres were mixed evenly, and then 800 parts of 25wt.% water glass solution were slowly added, and mechanical stirring was performed at the same time, and the stirring speed was controlled at 600r / min, and the stirring time was 25min, so that the materials were initially mixed evenly. Then, the mixed material was subjected to ultrasonic dispersion treatment, and the ultrasonic power was set at 1200W, and the ultrasonic time was 12min, to further break up the agglomerated particles, ensure that the components were evenly dispersed, and obtain a uniform green body slurry.

[0051] Finally, the green body slurry is poured into the mold and formed by extrusion at a pressure of 10MPa. After demolding, a heat insulation layer with a length of 1000mm, a width of 1000mm and a thickness of 15mm is obtained. When designing the mold, a rectangular cavity is pre-planned. During the green body forming process, a removable partition is used as an auxiliary component. The partition is first placed in the green body slurry. After the green body is initially formed, the partition is pulled out to form a heat insulation layer with a cavity of 50mm in length, 50mm in width and 10mm in thickness.

[0052] S2 core layer

[0053] Immerse 400 parts of expanded perlite particles in 80 parts of a prepared 20wt.% ammonium polyphosphate fire retardant solution for 1 hour. Stir during the immersion to ensure that the particles fully absorb the fire retardant. Then put them into a drying device and dry them at 100°C until the particles are dry, so that the fire retardant is evenly attached to the surface of the particles, completing the pretreatment of the core layer.

[0054] Carefully fill the dried expanded perlite particles into the reserved cavity of the insulation layer. During the filling process, vibration can be used to ensure that the particles are filled densely and evenly without obvious gaps, so that the core layer can maximize its insulation and fireproofing effects in subsequent use. Take another identical insulation layer and accurately cover it on the insulation layer with the core layer filled, so that the expanded perlite particles are firmly sandwiched between the two insulation layers, forming a complete structure with the core layer wrapped by the insulation layer. At this point, the structure already has certain basic insulation and fireproofing properties, but it still needs further processing to make its layers tightly combined and have better integrity.

[0055] Put the two layers of insulation with the core layer sandwiched in the hot press, set the hot pressing temperature at 300℃, the pressure at 12MPa, and keep the hot pressing time for 1h. Through hot pressing, the two layers of insulation are tightly combined with the inner core layer, eliminating the tiny gaps that may be generated by filling and other operations, enhancing the stability of the entire structure and the continuity of the insulation performance, and forming a composite structure of the middle core layer and the insulation layer, which is an important intermediate structure of the basalt fiber composite fireproof insulation board.

[0056] S3 manufactures basalt fiber composite fireproof and heat insulation panels

[0057] Weigh 50 parts of aluminum oxide, 50 parts of silicon dioxide, and 3 parts of sodium polyacrylate dispersant, add them into 100 parts of water, and stir them thoroughly at a speed of 1000 r / min for 30 minutes to form a uniform coating slurry with good fluidity.

[0058] The coating slurry is evenly coated on the surface of the composite structure of the core layer and the thermal insulation layer after hot pressing by roller coating. The coating thickness is controlled to be 1.5mm during coating to ensure that the entire surface is covered and the thickness is uniform, avoiding the situation of local excessive thickness or excessive thinness.

[0059] After coating, the board is placed in a high-temperature furnace for sintering and curing. The sintering temperature is controlled at 1000°C and the time is set to 1 hour, so that the protective layer is firmly attached to the surface of the board. After this process, the components in the coating slurry undergo chemical reactions to form a dense protective layer structure, and finally a complete basalt fiber composite fireproof and heat-insulating board (such as Figure 1 shown).

[0060] After testing, the basalt fiber composite fireproof and heat-insulating board of this embodiment has a fire resistance limit of more than 2.5h, a thermal conductivity lower than 0.045W / (m·K), and a compressive strength of 1.2MPa, which meets the fireproof and heat-insulating requirements of most buildings.

[0061] Example 3

[0062] The manufacturing process of the basalt fiber composite fireproof and heat-insulating board of this embodiment is as follows:

[0063] S1 manufactures thermal insulation layer

[0064] First, 280 parts of 6mm chopped basalt fibers and 180 parts of ceramic hollow microspheres were mixed evenly, and then 900 parts of 28wt.% water glass solution were slowly added, and mechanical stirring was performed at the same time, and the stirring speed was controlled at 500r / min, and the stirring time was 30min, so that the materials were initially mixed evenly. Then, the mixed material was subjected to ultrasonic dispersion treatment, and the ultrasonic power was set at 1000W, and the ultrasonic time was 15min, to further break up the agglomerated particles, ensure that the components were evenly dispersed, and obtain a uniform green body slurry.

[0065] Finally, the green body slurry is poured into the mold and formed by extrusion at a pressure of 5MPa. After demolding, a heat insulation layer with a length of 1000mm, a width of 1000mm and a thickness of 20mm is obtained. When designing the mold, a rectangular cavity is pre-planned. During the green body forming process, a removable partition is used as an auxiliary component. The partition is first placed in the green body slurry. After the green body is initially formed, the partition is pulled out to form a heat insulation layer with a cavity. The cavity is 60mm long, 60mm wide and 12mm thick.

[0066] S2 core layer

[0067] Immerse 450 parts of expanded perlite particles in 90 parts of a prepared 15wt.% ammonium polyphosphate fire retardant solution for 1.2 hours. Stir during the immersion to ensure that the particles fully absorb the fire retardant. Then put them into a drying device and dry them at 110°C until the particles are dry, so that the fire retardant is evenly attached to the surface of the particles, completing the pretreatment of the core layer.

[0068] Carefully fill the dried expanded perlite particles into the reserved cavity of the insulation layer. During the filling process, vibration can be used to ensure that the particles are filled densely and evenly without obvious gaps, so that the core layer can maximize its insulation and fireproofing effects in subsequent use. Take another identical insulation layer and accurately cover it on the insulation layer with the core layer filled, so that the expanded perlite particles are firmly sandwiched between the two insulation layers, forming a complete structure with the core layer wrapped by the insulation layer. At this point, the structure already has certain basic insulation and fireproofing properties, but it still needs further processing to make its layers tightly combined and have better integrity.

[0069] Put the two layers of insulation with the core layer sandwiched in the hot press, set the hot pressing temperature at 200℃, the pressure at 8MPa, and keep the hot pressing time for 2h. Through hot pressing, the two layers of insulation are tightly combined with the inner core layer, eliminating the tiny gaps that may be generated by filling and other operations, enhancing the stability of the entire structure and the continuity of the insulation performance, and forming a composite structure of the middle core layer and the insulation layer, which is an important intermediate structure of the basalt fiber composite fireproof insulation board.

[0070] S3 manufactures basalt fiber composite fireproof and heat insulation panels

[0071] Weigh 55 parts of aluminum oxide, 45 parts of silicon dioxide, and 4 parts of sodium polymethacrylate dispersant, add them into 150 parts of water, and stir them thoroughly at a speed of 1000 r / min for 25 minutes to form a uniform coating slurry with good fluidity.

[0072] The coating slurry is evenly coated on the surface of the composite structure of the core layer and the thermal insulation layer after hot pressing by spraying. The coating thickness is controlled to be 1mm during coating to ensure that the entire surface can be covered and the thickness is uniform to avoid local over-thickness or over-thinness.

[0073] After coating, the board is placed in a high-temperature furnace for sintering and curing. The sintering temperature is controlled at 800°C and the time is set to 2 hours, so that the protective layer is firmly attached to the surface of the board. After this process, the components in the coating slurry undergo chemical reactions to form a dense protective layer structure, and finally a complete basalt fiber composite fireproof and heat-insulating board (such as Figure 1 shown).

[0074] After testing, the basalt fiber composite fireproof and heat-insulating board of this embodiment has a fire resistance limit of more than 2.8h, a thermal conductivity lower than 0.048W / (m·K), and a compressive strength of 1.3MPa, which meets the fireproof and heat-insulating requirements of most buildings.

[0075] Comparative Example 1

[0076] The difference from Example 1 is that in step S3, the coating slurry is not applied.

[0077] According to the test, the fireproof and heat-insulating board material of Comparative Example 1 has a fire resistance limit of about 2 hours, a thermal conductivity of 0.08 W / (m·K), and a compressive strength of 1 MPa.

[0078] Compared with Example 1, the performance of the fireproof and heat-insulating board material of Comparative Example 1 is reduced. This is because the coating slurry can block heat transfer and delay the damage of the board material by high temperature in a high temperature environment. Without the protective layer formed by the coating slurry, the heat is more likely to directly act on the internal structure, resulting in a shortened overall fire resistance time. At the same time, the protective layer of Example 1 has a lower thermal conductivity and can effectively block heat conduction. For the board material of Comparative Example 1 that has not undergone this protective treatment, heat is more likely to be conducted inside the board material, so the thermal conductivity value will increase. In addition, in addition to having fireproof and heat-insulating functions, the protective layer can also enhance the overall structural stability of the board material to a certain extent. Comparative Example 1 lacks this reinforcing structure. When squeezed by external force, it is more likely to experience structural deformation and damage, thereby reducing the compressive strength.

[0079] Comparative Example 2

[0080] The difference from Example 1 is that in step S1, an equal amount of ceramic hollow microspheres is used instead of short-cut basalt fibers.

[0081] According to the test, the fireproof and heat-insulating board material of Comparative Example 2 has a fire resistance limit of about 2 h, a thermal conductivity of about 0.07 W / (m·K), and a compressive strength of about 1 MPa.

[0082] Compared with Example 1, the fire resistance of the fireproof and heat-insulating board material of Comparative Example 2 decreases. This is because the chopped basalt fibers and ceramic hollow microspheres coexist and cooperate with each other, exerting a synergistic enhancement effect, while Comparative Example 2 uses an equal amount of ceramic hollow microspheres instead of chopped basalt fibers, breaking this synergistic effect. Although ceramic hollow microspheres have a certain heat-insulating effect, they lack the network structure formed by the chopped basalt fibers interweaving in the material, and cannot achieve the network structure to increase the degree of tortuosity of the heat transfer path and share external forces. This results in that when facing high temperatures, heat is more likely to break through the relatively weak insulation "defense line", which reduces the fire resistance limit. In terms of thermal conductivity, due to the lack of effective resistance to heat conduction by chopped basalt fibers, heat is more easily transferred inside the board, and the thermal conductivity value increases accordingly. In terms of compressive strength, short-cut basalt fiber can enhance the overall mechanical properties of the material. It can share external pressure and enhance the structural stability of the board like "tendons and bones". Therefore, without the structural reinforcement effect of short-cut basalt fiber, the board is more likely to deform and be damaged when subjected to external force, which reduces the compressive strength.

[0083] Comparative Example 3

[0084] The difference from Example 1 is that in step S1, an equal amount of chopped basalt fibers are used instead of ceramic hollow microspheres.

[0085] According to the test, the fireproof and heat-insulating board material of Comparative Example 3 has a fire resistance limit of about 2.5 h, a thermal conductivity of about 0.06 W / (m·K), and a compressive strength of about 1.8 MPa.

[0086] Compared with Example 1, the fire resistance of the fireproof and heat-insulating board material of Comparative Example 3 decreases. This is because Comparative Example 3 uses an equal amount of chopped basalt fibers instead of ceramic hollow microspheres, which also destroys the synergistic reinforcement effect between the chopped basalt fibers and the ceramic hollow microspheres. Although the chopped basalt fibers themselves have certain high temperature resistance and good mechanical reinforcement properties, they lack the efficient "air insulation layer" effect brought by the unique hollow structure of ceramic hollow microspheres, and the heat barrier inside the board becomes less ideal, causing the heat to diffuse more easily inside the board, the fire resistance limit decreases, and the thermal conductivity increases due to the smaller heat conduction obstacles. In addition, the chopped basalt fibers have good mechanical reinforcement properties, and the network structure formed by their interweaving can better share the external pressure, making the overall structure of the board more stable and the ability to withstand external forces enhanced, so the compressive strength will be improved.

[0087] Comparative Example 4

[0088] The difference from Example 1 is that no cavity is reserved in the heat insulation layer and no core layer is provided subsequently.

[0089] According to the test, the fireproof and heat-insulating board material of Comparative Example 4 has a fire resistance limit of about 2 h, a thermal conductivity of about 0.07 W / (m·K), and a compressive strength of about 1 MPa.

[0090] Compared with Example 1, the fire resistance of the fireproof and heat-insulating board of Comparative Example 4 is reduced. This is because the core layer has a unique role in fireproofing, heat insulation and structural support in the entire board structure. Although the simple insulation layer can play a certain insulation effect, it is not as good as the role played by the core layer and other structures in comprehensive fireproof performance, so the fire resistance limit will be reduced. In addition to the insulation material itself, the core layer structure cooperates with other layers through specific impregnation, filling and hot pressing composite processes to more effectively block the heat conduction path; while the insulation layer is set separately, the barrier effect on heat conduction is relatively weakened, making it easier for heat to transfer inside the board, and the thermal conductivity is correspondingly increased. In addition, the core layer not only has the function of heat insulation and fire prevention in the board, but also plays a certain supporting and filling role in the overall structure, which helps to disperse external pressure and improve the compressive resistance of the board. The single insulation layer is relatively weak in structural support, which makes the board more prone to deformation and damage when subjected to external force, resulting in a decrease in compressive strength.

Claims

1. The manufacturing process of basalt fiber composite fireproof and heat-insulating board material is characterized in that: The following steps are involved: S1 manufactures thermal insulation layer The short-cut basalt fibers and hollow microspheres are uniformly dispersed in an inorganic binder to form a uniform mixed slurry, which is poured into a mold and subjected to an extrusion molding process to obtain a heat insulation layer with a hollow structure; S2 core layer The expanded perlite particles are immersed in a fire retardant solution and then dried; they are filled into the hollow structure of the heat insulation layer, and then another filled heat insulation layer is covered thereon, and through a hot pressing composite process, the core layer is sandwiched between the two heat insulation layers to form a structure in which the core layer is wrapped by the heat insulation layer; S3 manufactures basalt fiber composite fireproof and heat insulation panels Alumina, silica, dispersant and solvent are fully stirred to form a uniform coating slurry, and then the coating slurry is evenly coated on the surface of the structure in which the core layer is wrapped by the insulation layer in step S2 by spraying or roller coating, and then sintered and cured to obtain a basalt fiber composite fireproof insulation board.

2. The manufacturing process of the basalt fiber composite fireproof and heat-insulating board material according to claim 1, characterized in that: In step S1, the weight proportions of the components in the thermal insulation layer are: 250-300 parts of chopped basalt fibers, 150-200 parts of hollow microspheres, and 800-1000 parts of inorganic binder.

3. The manufacturing process of the basalt fiber composite fireproof and heat-insulating board material according to claim 1 or 2, characterized in that: In step S1, the length of the chopped basalt fibers is 6-12 mm; the hollow microspheres are ceramic hollow microspheres or hollow glass microspheres; and the inorganic binder is 25-30 wt. % water glass solution.

4. The manufacturing process of the basalt fiber composite fireproof and heat-insulating board material according to claim 1, characterized in that: In step S1, the chopped basalt fibers and hollow microspheres are uniformly dispersed in the inorganic binder by stirring and ultrasonication; the pressure of the extrusion molding process is 5-10 MPa.

5. The manufacturing process of the basalt fiber composite fireproof and heat-insulating board material according to claim 1, characterized in that: In step S2, the weight proportions of the components in the core layer are: 400-500 parts of expanded perlite particles and 80-100 parts of fire retardant solution.

6. The manufacturing process of the basalt fiber composite fireproof and heat-insulating board material according to claim 1 or 5, characterized in that: In step S2, the fire retardant solution is a 15-30wt.% ammonium phosphate fire retardant solution or a 15-30wt.% ammonium polyphosphate fire retardant solution; the drying temperature is 100-120°C; the temperature of the hot pressing composite process is 200-300°C, and the pressure is 8-12MPa.

7. The manufacturing process of the basalt fiber composite fireproof and heat-insulating board material according to claim 1, characterized in that: In step S3, the weight proportions of the components in the coating slurry are: 50-60 parts of aluminum oxide, 40-50 parts of silicon dioxide, 3-5 parts of dispersant, and 100-200 parts of solvent; the dispersant is a methacrylic acid polycarboxylate dispersant or sodium polyacrylate, and the solvent is water.

8. The manufacturing process of the basalt fiber composite fireproof and heat-insulating board material according to claim 1, characterized in that: In step S3, the sintering and curing temperature is 800-1000° C. and the time is 1-2 hours.

9. The basalt fiber composite fireproof and heat-insulating board material manufactured by the manufacturing process of the basalt fiber composite fireproof and heat-insulating board material according to any one of claims 1 to 8.

10. The basalt fiber composite fireproof and heat-insulating board material according to claim 9, characterized in that: The thickness of the heat insulation layer is 15-25 mm, the thickness of the core layer is 10-15 mm, and the coating thickness of the coating slurry is 1-2 mm.

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