A high-density rock wool board for construction and its manufacturing method

Abstract

The invention relates to the technical field of building materials and discloses a high-density rock wool board for construction and a manufacturing method thereof. The method comprises the following steps: step 1: grinding and sieving basalt, diabase, quartz sand, limestone, slag and waste incineration fly ash respectively, uniformly mixing the grinding and smelting ...

Description

Technical Field

[0001] The present invention relates to the technical field of building materials, in particular to a high-density rock wool board for construction and a manufacturing method thereof. Background Art

[0002] Rock wool board for construction is a material widely used in building insulation, fire prevention and sound insulation. It is mainly made of mineral fibers such as basalt that are solidified after high-temperature melting. Rock wool boards are often used for the exterior walls of high-rise buildings, industrial plants, etc. However, in most parts of my country, there are seasonal temperature changes and temperature differences between day and night. In this long-term environment, building walls made of rock wool boards will crack and fall off.

[0003] High-density rock wool boards are made of mineral fibers such as basalt. They are inorganic materials that do not burn when exposed to fire and can effectively prevent the spread of fire. They are suitable for high-rise buildings and places with strict fire protection requirements. However, in areas with large temperature changes, cracks will appear in the rock wool boards, which will affect the life of the rock wool boards.

[0004] In order to solve the above problems, a high-density rock wool board for construction is of great significance. Summary of the Invention

[0005] The object of the present invention is to provide a high-density rock wool board for construction and a method for manufacturing the same, so as to solve the problems raised in the prior art.

[0006] To achieve the above object, the present invention provides the following technical solutions:

[0007] A method for manufacturing a high-density rock wool board for construction, comprising the following steps:

[0008] Step 1: Grind and sieve basalt, diabase, quartz sand, limestone, slag, and waste incineration fly ash, mix them evenly, melt them at 1400-1500°C for 2-3 hours, and then perform fiberization by centrifugal flight to obtain high-density fibers.

[0009] Step 2: Spray silane modifier and epoxy resin adhesive on high-density fiber to obtain cotton felt; transfer the cotton felt to a mold, spread it with a pendulum, pre-press at a pressure of 2~3MPa and a temperature of 80~100℃ for 30~35 minutes, increase the pressure to 8~10MPa, increase the temperature to 160~170℃ and press and cure for 1.5~2.5 hours, cool to obtain a high-density rock wool board.

[0010] In the scheme, the waste incineration fly ash is screened with a sieve with an aperture of 3 mm, the iron-based impurities are removed by magnetic attraction, and the ash is pickled with a dilute hydrochloric acid solution with a mass concentration of 1%, and then dried for later use.

[0011] More optimally, the raw materials of the high-density rock wool board include the following components: 70-90 parts by mass of high-density fiber, 5-10 parts by mass of silane modifier, and 12-17 parts by mass of epoxy resin adhesive.

[0012] More optimally, the raw materials of the epoxy resin adhesive include the following components: 70-80 parts of epoxy resin, 15-20 parts of modified nano-silica, 30-35 parts of curing agent, 7-10 parts of epoxy diluent, and 1-3 parts of defoaming agent.

[0013] A more optimized preparation method of the modified nano-silica is as follows: 2,5-furandicarboxylic acid is added to acetone and mixed evenly, epoxidized nano-silica and triphenylphosphine are added, and stirred at 110-115°C for 1-2 hours, bisphenol A diglycidyl ether and triphenylphosphine are added, and stirring is continued for 1-3 hours. After removing the solvent, the mixture is purified and dried to obtain the modified nano-silica.

[0014] More optimally, the mass ratio of the 2,5-furandicarboxylic acid, epoxidized nano-silica, and bisphenol A diglycidyl ether is 0.82:1:(2.5-3).

[0015] The more optimized preparation method of the silane modifier is as follows: (1) KH550, diphenylsilanediol, and barium hydroxide are added to xylene and mixed uniformly, and the mixture is heated to 80-85°C and stirred for 5-6 hours under a nitrogen atmosphere to obtain a branched aminopolysiloxane; (2) under nitrogen protection, the branched aminopolysiloxane and KH560 are added to N-methylpyrrolidone and mixed uniformly, and the mixture is stirred at 80-90°C for 4-6 hours, the solvent is removed, the mixture is purified and dried, and the mixture is added to an ethanol aqueous solution and mixed uniformly to obtain a silane modifier for standby use.

[0016] More optimally, the mass ratio of the KH550 to diphenylsilanediol is 1:(1.5-2); the mass ratio of the branched aminopolysiloxane to KH560 is 1:(0.2-0.3).

[0017] More optimally, the raw materials of the high-density fiber include the following components: by mass, 40-50 parts of basalt, 20-30 parts of diabase, 10-15 parts of quartz sand, 8-12 parts of limestone, 10-20 parts of slag, and 5-10 parts of waste incineration fly ash.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] In the present application, basalt, diabase, quartz sand, limestone, slag, and waste incineration fly ash are ground, sieved, and uniformly mixed, melted, and then fiberized by a centrifugal flight method to obtain high-density fibers; a silane modifier and an epoxy resin binder are sprayed on the high-density fibers to obtain cotton felt; the cotton felt is transferred to a mold, felted by a pendulum, and cured to produce a high-density rock wool board;

[0020] Basalt and diabase are high-density minerals that form a high-strength, high-temperature-resistant fiber skeleton, enhancing the heat resistance and strength of the rock wool board. Quartz sand, primarily composed of silicon dioxide, forms a three-dimensional network (Si-O-Si bonds) in its molten state, enhancing the fiber's chemical stability and high-temperature resistance, preventing softening and deformation at high temperatures. Limestone generates calcium oxide at high temperatures, which reacts with quartz sand to form a low-melting eutectic calcium silicate, reducing melt viscosity and making the fibers easier to stretch and form during centrifugal spinning. Slag provides calcium oxide and aluminum oxide, which react with silicon dioxide to form low-melting eutectic phases such as grossonite, further reducing melting energy consumption. Fine particles from waste incineration fly ash fill the gaps between fibers, increasing the density and compressive strength of the rock wool board.

[0021] In order to enhance the strength and crack resistance of high-density rock wool boards, modified silica is added to the epoxy resin adhesive in the scheme. The two carboxyl groups in the 2,5-furandicarboxylic acid molecule can undergo ring-opening esterification reaction with the epoxy groups in bisphenol A diglycidyl ether and epoxidized nano-silica, and participate in the construction of the epoxy resin network as a cross-linking agent.

[0022] Among them, the modified nano-silica has a multi-functional cross-linked network structure; its good density can reduce the penetration of water molecules, and the hydrolysis resistance of the furan ring further improves the water resistance; and the rigid structure of the furan ring can improve the rigidity and thermal stability of the cured network, while its aromatic properties enhance the intermolecular π-π interaction and improve the bonding strength; bisphenol A diglycidyl ether and silica are integrated into the network to form an organic-inorganic hybrid structure, which improves the overall thermal stability; and the flexible chain segments of the bisphenol A structure can balance the brittleness of the rigid furan ring and silica, improve the strength and adhesion to the rock wool fiber, so as to enhance the crack resistance of the high-density rock wool board.

[0023] In order to further improve the bonding strength between the epoxy resin binder and the rock wool fiber, KH550 reacts with diphenylsilanediol under alkaline conditions to form a branched aminopolysiloxane. The branched aminopolysiloxane is then reacted with KH560 at a molar ratio of 1:2 under certain conditions to obtain a silane modifier containing silane groups and amino groups.

[0024] Among them, the introduction of phenyl groups increases the rigidity and aromatic structure of the molecular chain, improving the heat resistance and strength of the material; under alkaline conditions, the silanol groups on diphenylsilanediol condense with the siloxy groups of KH550 to form a branched structure. The branched structure gives the silane modifier higher flexibility, enhances the cross-linking density of the siloxane network, reduces the thermal expansion coefficient, and thus improves crack resistance; KH560 reacts with the -NH2 of aminopolysiloxane to form a cross-linked structure, enhancing the rigidity of the material and inhibiting high-temperature deformation.

[0025] The rock wool fiber is mixed with a silane modifier; the surface of the rock wool fiber is treated with the silane modifier to enhance the interfacial bonding strength between the rock wool fiber and the epoxy resin adhesive, reduce interfacial debonding, and enhance the strength and crack resistance of the high-density rock wool board.

[0026] The amino group on the modified agent reacts with the epoxy group on the epoxy resin binder under certain conditions to form a three-dimensional cured network on the surface of the rock wool fiber, thereby improving the density of the high-density rock wool board and thus improving the crack resistance and strength of the rock wool board. DETAILED DESCRIPTION

[0027] 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 creative efforts are within the scope of protection of the present invention.

[0028] In the following specific embodiments, parts are by mass. In this embodiment, it should be noted that the purchase manufacturers of all raw materials involved in the present invention are not subject to any special restrictions. Examples include: KH560 (3-(2,3-epoxypropoxy)propyltrimethoxysilane) CAS No. 2530-83-8; KH550 (3-aminopropyltriethoxysilane) CAS No. 919-30-2; epoxy resin model E-51; curing agent is 4,4'-diaminodiphenyl sulfone, CAS No. 8 0-08-0; the defoamer comes from Foshan Nanhai Datian Chemical Co., Ltd., model AT-86S; the epoxy diluent is propylene oxide butyl ether, CAS number 2426-08-6; the CAS number of 2,5-furandicarboxylic acid is 3238-40-2; the CAS number of bisphenol A diglycidyl ether is 1675-54-3; the product number of nano-silica is XH-SiO2-50, and there are a large number of hydroxyl groups in different bonding states on the surface; the CAS number of diphenylsilanediol is 947-42-2.

[0029] The preparation method of epoxidized nano-silica is as follows: 0.6 parts of KH560 are added to an ethanol aqueous solution (65 wt%) and mixed evenly for 40 minutes, 1 part of nano-silica is added and mixed evenly, and the mixture is heated to 70°C and stirred for 5 hours to obtain epoxidized nano-silica;

[0030] Example 1: A method for manufacturing a high-density rock wool board for construction, comprising the following steps:

[0031] Step 1: 40 parts of basalt, 20 parts of diabase, 10 parts of quartz sand, 8 parts of limestone, 10 parts of slag, and 5 parts of waste incineration fly ash are ground, sieved, and evenly mixed, then melted at 1500°C for 3 hours and fiberized by centrifugal flight to obtain high-density fibers;

[0032] Step 2: (1) 70 parts of epoxy resin, 15 parts of modified nano-silica, 30 parts of curing agent, 7 parts of epoxy diluent, and 2 parts of defoaming agent are uniformly mixed to obtain epoxy resin binder; (2) 5 parts of silane modifier and 12 parts of epoxy resin binder are sprayed on 70 parts of high-density fiber to obtain cotton felt; the cotton felt is transferred to a mold, and is spread by a pendulum, pre-pressed at a pressure of 2.5 MPa and a temperature of 100°C for 30 minutes, the pressure is increased to 10 MPa, the temperature is increased to 160°C, and pressed and cured for 2 hours, and cooled to obtain a high-density rock wool board;

[0033] The modified nano-silica is prepared by weighing 2,5-furandicarboxylic acid, epoxidized nano-silica, and bisphenol A diglycidyl ether in a mass ratio of 0.82:1:2.6; adding 2,5-furandicarboxylic acid to acetone and uniformly mixing; adding epoxidized nano-silica and triphenylphosphine; stirring at 110° C. for 2 hours; adding bisphenol A diglycidyl ether and triphenylphosphine; continuing to stir for 1.5 hours; removing the solvent; precipitating with anhydrous ether; filtering, washing, and drying to obtain the modified nano-silica;

[0034] The preparation method of the silane modifier is as follows: (1) KH550 and diphenylsilanediol are weighed in a mass ratio of 1:1.6; KH550, diphenylsilanediol and barium hydroxide are added to xylene and mixed uniformly, and the mixture is heated to 80°C and stirred for 6 hours under a nitrogen atmosphere to obtain a branched aminopolysiloxane; (2) branched aminopolysiloxane and KH560 are weighed in a mass ratio of 1:0.25; the branched aminopolysiloxane and KH560 are added to N-methylpyrrolidone under nitrogen protection and mixed uniformly, and the mixture is stirred at 85°C for 5 hours, the solvent is removed, the mixture is purified and dried, and the mixture is added to an ethanol aqueous solution (ethanol concentration is 80wt%) and mixed uniformly to obtain a silane modifier with a concentration of 70wt%.

[0035] Example 2: A method for manufacturing a high-density rock wool board for construction, comprising the following steps:

[0036] Step 1: Grind and sieve 50 parts of basalt, 25 parts of diabase, 12 parts of quartz sand, 10 parts of limestone, 15 parts of slag, and 8 parts of waste incineration fly ash, mix them uniformly, melt them at 1500°C for 3 hours, and fiberize them by centrifugal flight to obtain high-density fibers;

[0037] Step 2: (1) Evenly mix 70 parts of epoxy resin, 20 parts of modified nano-silica, 30 parts of curing agent, 7 parts of epoxy diluent, and 2 parts of defoaming agent to obtain epoxy resin binder; (2) Spray 8 parts of silane modifier and 15 parts of epoxy resin binder on 80 parts of high-density fiber to obtain cotton felt; Transfer the cotton felt to a mold, spread it with a pendulum, pre-press at a pressure of 2.5 MPa and a temperature of 100°C for 30 minutes, increase the pressure to 10 MPa, increase the temperature to 160°C, press and cure for 2 hours, and cool to obtain a high-density rock wool board;

[0038] The modified nano-silica is prepared by weighing 2,5-furandicarboxylic acid, epoxidized nano-silica, and bisphenol A diglycidyl ether in a mass ratio of 0.82:1:2.6; adding 2,5-furandicarboxylic acid to acetone and uniformly mixing; adding epoxidized nano-silica and triphenylphosphine; stirring at 110° C. for 2 hours; adding bisphenol A diglycidyl ether and triphenylphosphine; continuing to stir for 1.5 hours; removing the solvent; precipitating with anhydrous ether; filtering, washing, and drying to obtain the modified nano-silica;

[0039] The preparation method of the silane modifier is as follows: (1) KH550 and diphenylsilanediol are weighed in a mass ratio of 1:1.6; KH550, diphenylsilanediol and barium hydroxide are added to xylene and mixed uniformly, and the mixture is heated to 80°C and stirred for 6 hours under a nitrogen atmosphere to obtain a branched aminopolysiloxane; (2) branched aminopolysiloxane and KH560 are weighed in a mass ratio of 1:0.25; the branched aminopolysiloxane and KH560 are added to N-methylpyrrolidone under nitrogen protection and mixed uniformly, and the mixture is stirred at 85°C for 5 hours, the solvent is removed, the mixture is purified and dried, and the mixture is added to an ethanol aqueous solution (ethanol concentration is 80wt%) and mixed uniformly to obtain a silane modifier with a concentration of 70wt%.

[0040] Example 3: A method for manufacturing a high-density rock wool board for construction, comprising the following steps:

[0041] Step 1: Grind and sieve 50 parts of basalt, 25 parts of diabase, 12 parts of quartz sand, 10 parts of limestone, 15 parts of slag, and 8 parts of waste incineration fly ash, mix them uniformly, melt them at 1500°C for 3 hours, and fiberize them by centrifugal flight to obtain high-density fibers;

[0042] Step 2: (1) 80 parts of epoxy resin, 15 parts of modified nano-silica, 30 parts of curing agent, 7 parts of epoxy diluent, and 2 parts of defoaming agent are uniformly mixed to obtain epoxy resin binder; (2) 7 parts of silane modifier and 17 parts of epoxy resin binder are sprayed on 90 parts of high-density fiber to obtain cotton felt; the cotton felt is transferred to a mold, and is laid with a pendulum, pre-pressed at a pressure of 2.5 MPa and a temperature of 100°C for 30 minutes, the pressure is increased to 10 MPa, the temperature is increased to 160°C, and pressed and cured for 2 hours, and cooled to obtain a high-density rock wool board;

[0043] The modified nano-silica is prepared by weighing 2,5-furandicarboxylic acid, epoxidized nano-silica, and bisphenol A diglycidyl ether in a mass ratio of 0.82:1:2.6; adding 2,5-furandicarboxylic acid to acetone and uniformly mixing; adding epoxidized nano-silica and triphenylphosphine; stirring at 110° C. for 2 hours; adding bisphenol A diglycidyl ether and triphenylphosphine; continuing to stir for 1.5 hours; removing the solvent; precipitating with anhydrous ether; filtering, washing, and drying to obtain the modified nano-silica;

[0044] The preparation method of the silane modifier is as follows: (1) KH550 and diphenylsilanediol are weighed in a mass ratio of 1:1.6; KH550, diphenylsilanediol and barium hydroxide are added to xylene and mixed uniformly, and the mixture is heated to 80°C and stirred for 6 hours under a nitrogen atmosphere to obtain a branched aminopolysiloxane; (2) branched aminopolysiloxane and KH560 are weighed in a mass ratio of 1:0.25; the branched aminopolysiloxane and KH560 are added to N-methylpyrrolidone under nitrogen protection and mixed uniformly, and the mixture is stirred at 85°C for 5 hours, the solvent is removed, the mixture is purified and dried, and the mixture is added to an ethanol aqueous solution (ethanol concentration is 80wt%) and mixed uniformly to obtain a silane modifier with a concentration of 70wt%.

[0045] Comparative Example 1 is based on Example 2; the modified silica is replaced with epoxidized nano-silica;

[0046] Step 1: Grind and sieve 50 parts of basalt, 25 parts of diabase, 12 parts of quartz sand, 10 parts of limestone, 15 parts of slag, and 8 parts of waste incineration fly ash, mix them uniformly, melt them at 1500°C for 3 hours, and fiberize them by centrifugal flight to obtain high-density fibers;

[0047] Step 2: (1) 70 parts of epoxy resin, 20 parts of epoxidized nano-silica, 30 parts of curing agent, 7 parts of epoxy diluent, and 2 parts of defoaming agent are uniformly mixed to obtain epoxy resin binder; (2) 80 parts of high-density fiber are sprayed with 8 parts of silane modifier and 15 parts of epoxy resin binder to obtain cotton felt; the cotton felt is transferred to a mold, and is laid with a pendulum, pre-pressed at a pressure of 2.5 MPa and a temperature of 100°C for 30 minutes, the pressure is increased to 10 MPa, the temperature is increased to 160°C, and pressed and cured for 2 hours, and cooled to obtain a high-density rock wool board;

[0048] The preparation method of the silane modifier is as follows: (1) KH550 and diphenylsilanediol are weighed in a mass ratio of 1:1.6; KH550, diphenylsilanediol and barium hydroxide are added to xylene and mixed uniformly, and the mixture is heated to 80°C and stirred for 6 hours under a nitrogen atmosphere to obtain a branched aminopolysiloxane; (2) branched aminopolysiloxane and KH560 are weighed in a mass ratio of 1:0.25; the branched aminopolysiloxane and KH560 are added to N-methylpyrrolidone under nitrogen protection and mixed uniformly, and the mixture is stirred at 85°C for 5 hours, the solvent is removed, the mixture is purified and dried, and the mixture is added to an ethanol aqueous solution (ethanol concentration is 80wt%) and mixed uniformly to obtain a silane modifier with a concentration of 70wt%.

[0049] Comparative Example 2 is based on Example 2; bisphenol A diglycidyl ether is not added;

[0050] Step 1: Grind and sieve 50 parts of basalt, 25 parts of diabase, 12 parts of quartz sand, 10 parts of limestone, 15 parts of slag, and 8 parts of waste incineration fly ash, mix them uniformly, melt them at 1500°C for 3 hours, and fiberize them by centrifugal flight to obtain high-density fibers;

[0051] Step 2: (1) Evenly mix 70 parts of epoxy resin, 20 parts of modified nano-silica, 30 parts of curing agent, 7 parts of epoxy diluent, and 2 parts of defoaming agent to obtain epoxy resin binder; (2) Spray 8 parts of silane modifier and 15 parts of epoxy resin binder on 80 parts of high-density fiber to obtain cotton felt; Transfer the cotton felt to a mold, spread it with a pendulum, pre-press at a pressure of 2.5 MPa and a temperature of 100°C for 30 minutes, increase the pressure to 10 MPa, increase the temperature to 160°C, press and cure for 2 hours, and cool to obtain a high-density rock wool board;

[0052] The modified nano-silica is prepared by weighing 2,5-furandicarboxylic acid and epoxidized nano-silica at a mass ratio of 0.82:1; adding 2,5-furandicarboxylic acid to acetone and uniformly mixing; adding epoxidized nano-silica and triphenylphosphine; stirring at 110° C. for 3 hours; removing the solvent; precipitating with anhydrous ether; filtering, washing, and drying to obtain the modified nano-silica;

[0053] The preparation method of the silane modifier is as follows: (1) KH550 and diphenylsilanediol are weighed in a mass ratio of 1:1.6; KH550, diphenylsilanediol and barium hydroxide are added to xylene and mixed uniformly, and the mixture is heated to 80°C and stirred for 6 hours under a nitrogen atmosphere to obtain a branched aminopolysiloxane; (2) branched aminopolysiloxane and KH560 are weighed in a mass ratio of 1:0.25; the branched aminopolysiloxane and KH560 are added to N-methylpyrrolidone under nitrogen protection and mixed uniformly, and the mixture is stirred at 85°C for 5 hours, the solvent is removed, the mixture is purified and dried, and the mixture is added to an ethanol aqueous solution (ethanol concentration is 80wt%) and mixed uniformly to obtain a silane modifier with a concentration of 70wt%.

[0054] Comparative Example 3 is based on Example 2; 2,5-furandicarboxylic acid is replaced with succinic acid;

[0055] Step 1: Grind and sieve 50 parts of basalt, 25 parts of diabase, 12 parts of quartz sand, 10 parts of limestone, 15 parts of slag, and 8 parts of waste incineration fly ash, mix them uniformly, melt them at 1500°C for 3 hours, and fiberize them by centrifugal flight to obtain high-density fibers;

[0056] Step 2: (1) 70 parts of epoxy resin, 20 parts of modified nano-silica, 30 parts of curing agent, 7 parts of epoxy diluent, and 2 parts of defoaming agent are uniformly mixed to obtain epoxy resin adhesive; (2) 8 parts of silane modifier (concentration of 70wt%, solvent is 80wt% ethanol aqueous solution) and 15 parts of epoxy resin adhesive are sprayed on 80 parts of high-density fiber to obtain cotton felt; the cotton felt is transferred to a mold, and is spread by a pendulum, pre-pressed at a pressure of 2.5MPa and a temperature of 100℃ for 30 minutes, the pressure is increased to 10MPa, the temperature is increased to 160℃, and pressed and cured for 2 hours, and cooled to obtain a high-density rock wool board;

[0057] The modified nano-silica is prepared by weighing succinic acid, epoxidized nano-silica, and bisphenol A diglycidyl ether in a mass ratio of 0.82:1:2.6; adding 2,5-furandicarboxylic acid to acetone and uniformly mixing; adding epoxidized nano-silica and triphenylphosphine; stirring at 110° C. for 2 hours; adding bisphenol A diglycidyl ether and triphenylphosphine; continuing to stir for 1.5 hours; removing the solvent; precipitating with anhydrous ether; filtering, washing, and drying to obtain the modified nano-silica;

[0058] The preparation method of the silane modifier is as follows: (1) KH550 and diphenylsilanediol are weighed in a mass ratio of 1:1.6; KH550, diphenylsilanediol and barium hydroxide are added to xylene and mixed uniformly, and the mixture is heated to 80°C and stirred for 6 hours under a nitrogen atmosphere to obtain a branched aminopolysiloxane; (2) branched aminopolysiloxane and KH560 are weighed in a mass ratio of 1:0.25; the branched aminopolysiloxane and KH560 are added to N-methylpyrrolidone under nitrogen protection and mixed uniformly, and the mixture is stirred at 85°C for 5 hours, the solvent is removed, the mixture is purified and dried, and the mixture is added to an ethanol aqueous solution (ethanol concentration is 80wt%) and mixed uniformly to obtain a silane modifier with a concentration of 70wt%.

[0059] Comparative Example 4 is based on Example 2; the silane modifier is replaced by KH550 and KH560;

[0060] Step 1: Grind and sieve 50 parts of basalt, 25 parts of diabase, 12 parts of quartz sand, 10 parts of limestone, 15 parts of slag, and 8 parts of waste incineration fly ash, mix them uniformly, melt them at 1500°C for 3 hours, and fiberize them by centrifugal flight to obtain high-density fibers;

[0061] Step 2: (1) Evenly mix 70 parts of epoxy resin, 20 parts of modified nano-silica, 30 parts of curing agent, 7 parts of epoxy diluent, and 2 parts of defoaming agent to obtain epoxy resin binder; (2) Spray 8 parts of silane modifier and 15 parts of epoxy resin binder on 80 parts of high-density fiber to obtain cotton felt; Transfer the cotton felt to a mold, spread it with a pendulum, pre-press at a pressure of 2.5 MPa and a temperature of 100°C for 30 minutes, increase the pressure to 10 MPa, increase the temperature to 160°C, press and cure for 2 hours, and cool to obtain a high-density rock wool board;

[0062] The silane modifier was prepared by adding KH550 and KH560 in a mass ratio of 1:1 to an 80 wt % ethanol aqueous solution and uniformly mixing to obtain a silane modifier with a concentration of 70 wt %;

[0063] The preparation method of the modified nano-silica is as follows: 2,5-furandicarboxylic acid, epoxidized nano-silica, and bisphenol A diglycidyl ether are weighed in a mass ratio of 0.82:1:2.6; 2,5-furandicarboxylic acid is added to acetone and mixed uniformly, epoxidized nano-silica and triphenylphosphine are added, and the mixture is stirred at 110° C. for 2 hours, bisphenol A diglycidyl ether and triphenylphosphine are added, and the mixture is stirred for 1.5 hours. After removing the solvent, the mixture is precipitated with anhydrous ether, filtered, washed, and dried to obtain the modified nano-silica.

[0064] Test: (1) Heat resistance: Examples 1 to 3 and Comparative Examples 1 to 4 were tested by thermogravimetric analyzer. Nitrogen was introduced at a flow rate of 10 mL / min, the temperature range was 25 to 800 °C, the heating rate was 5 °C / min, and the temperature Td at which the heat loss was 5% was recorded. 5% ;

[0065] (2) Temperature and humidity cycle test: The high-density rock wool boards prepared in Examples 1 to 3 and Comparative Examples 1 to 4 were placed in a variable temperature test chamber for 30 days. The temperature in the chamber was cycled between -16°C and 60°C at a rate of 0.2°C / min and the relative humidity was 100%. This simulated the climate fluctuations in actual use and observed whether the surface cracked. The compressive strength was also tested.

[0066] Table 1

[0067]

[0068] Conclusion: Comparative Example 1 is based on Example 2; the modified silica is replaced with epoxidized nano-silica; resulting in a decrease in the performance of the high-density rock wool board; Comparative Example 2 is based on Example 2; bisphenol A diglycidyl ether is not added; resulting in increased rigidity of the modified silica and inability to release stress; because the flexible chain segments of the bisphenol A structure can balance the brittleness of the rigid furan ring and silica, improving strength and adhesion to rock wool fibers, the rock wool board prepared in Example 2 cracks during the temperature and humidity cycle, thus leading to The performance of the high-density rock wool board is reduced; Comparative Example 3 is based on Example 2; 2,5-furandicarboxylic acid is replaced with succinic acid; because the furan group has certain heat resistance, the heat resistance of the modified nano-silica is reduced, thereby reducing the performance of the high-density rock wool board; Comparative Example 4 is based on Example 2; KH550 and KH560 are used to replace the silane modifier; because diphenylsilanediol reacts with KH550 to obtain branched aminopolysiloxane; therefore, the performance of the rock wool board prepared in Comparative Example 4 is reduced.

[0069] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations that come within the meaning and range of equivalents of the claims be embraced therein.

Claims

1. A method for manufacturing a high-density rock wool board for construction, characterized in that: The following steps are included: Step 1: Grind and sieve basalt, diabase, quartz sand, limestone, slag, and waste incineration fly ash, mix them evenly, melt them at 1400-1500°C for 2-3 hours, and then perform fiberization by centrifugal flight to obtain high-density fibers. Step 2: Spray silane modifier and epoxy resin binder on high-density fiber to obtain cotton felt; transfer the cotton felt to a mold, spread it by a pendulum, pre-press at a pressure of 2-3 MPa and a temperature of 80-100°C for 30-35 minutes, increase the pressure to 8-10 MPa, increase the temperature to 160-170°C, press and cure for 1.5-2.5 hours, and cool to obtain a high-density rock wool board; The raw materials of the epoxy resin adhesive include the following components: 70-80 parts of epoxy resin, 15-20 parts of modified nano-silicon dioxide, 30-35 parts of curing agent, 7-10 parts of epoxy diluent, and 1-3 parts of defoaming agent; The preparation method of the modified nano-silica comprises: adding 2,5-furandicarboxylic acid to acetone and uniformly mixing, adding epoxidized nano-silica and triphenylphosphine, stirring at 110-115° C. for 1-2 hours, adding bisphenol A diglycidyl ether and triphenylphosphine, continuing stirring for 1-3 hours, removing the solvent, purifying, and drying to obtain the modified nano-silica; The preparation method of the silane modifier is as follows: (1) adding KH550, diphenylsilanediol and barium hydroxide to xylene and uniformly mixing, heating to 80-85°C and stirring for 5-6 hours under a nitrogen atmosphere to obtain a branched aminopolysiloxane; (2) adding the branched aminopolysiloxane and KH560 to N-methylpyrrolidone under nitrogen protection and uniformly mixing, stirring at 80-90°C for 4-6 hours, removing the solvent, purifying and drying, adding to an ethanol aqueous solution and uniformly mixing to obtain a silane modifier.

2. The method for manufacturing a high-density rock wool board for construction according to claim 1, characterized in that: The raw materials of the high-density rock wool board include the following components: 70-90 parts by mass of high-density fiber, 5-10 parts by mass of silane modifier, and 12-17 parts by mass of epoxy resin adhesive.

3. The method for manufacturing a high-density rock wool board for construction according to claim 1, characterized in that: The mass ratio of the 2,5-furandicarboxylic acid, epoxidized nano-silica, and bisphenol A diglycidyl ether is 0.82:1:(2.5-3).

4. The method for manufacturing a high-density rock wool board for construction according to claim 1, wherein: The mass ratio of the KH550 to diphenylsilanediol is 1:(1.5-2); the mass ratio of the branched aminopolysiloxane to KH560 is 1:(0.2-0.3).

5. The method for manufacturing a high-density rock wool board for construction according to claim 1, wherein: The raw materials of the high-density fiber include the following components: 40-50 parts of basalt, 20-30 parts of diabase, 10-15 parts of quartz sand, 8-12 parts of limestone, 10-20 parts of slag, and 5-10 parts of waste incineration fly ash, calculated by mass.

6. A high-density rock wool board prepared according to the method for manufacturing a high-density rock wool board for construction according to any one of claims 1 to 5.

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