Composite foam fireproof door and manufacturing method

Abstract

The invention provides a composite foam fireproof door and a manufacturing method thereof, and the composite foam fireproof door comprises a door leaf and a door frame, and comprises the following components by weight: 30-45 parts of a glue solution; 5 to 13 parts of wood fiber; 12 to 20 parts of phenolic resin; 1-3 parts of methyl silicone oil; 4 parts of perlite foam particles; 2-3 parts of a curing agent; 1-2 parts of a silane coupling agent; the preparation method comprises the following steps: firstly, fully mixing and stirring the components in a high-speed mixer according to a corresponding proportion, and then mixing the other components into paste; further blending, stirring, uniformly mixing and extruding the mixed material through a horizontal rotary mixer, molding in a forming mold, and inputting into a microwave drying tunnel for high-temperature drying; the mixture passing through the microwave drying tunnel and water molecules of the electromagnetic wave glue solution vibrate at a high speed, are catalyzed, cross-linked and foamed in friction heating, then are fed into a graphene hot drying rack and a drying room to be dried and cured at a low temperature, and are finally assembled into a door leaf and a door frame after surface finishing. The cost is low, the weight is light, and standardized, batched and automatic manufacturing can be achieved.

Description

Technical Field

[0001] The present invention relates to the field of fire doors, in particular to a composite foam fire door and a manufacturing method thereof. Background Art

[0002] It is known that existing fire doors are mainly divided into two categories: wooden fire doors and metal fire doors. It is difficult to meet the requirements of the new standard GB12955-2024. This is because wooden fire doors are made of wood as the frame and covered with fireproof panels, which are flammable materials. Metal fire doors are exposed to high temperatures at the fire scene, which can cause welds to fall off, metal deformation, and burns. According to statistics, 82% of deaths in fires are caused by quality problems of fireproof materials and fire doors.

[0003] The traditional production process has the problem of unscientific selection of fireproof materials. Wooden fire doors are difficult to prevent fire due to the flammable nature of wood. They can only be made of wood as the inner frame, with fireproof materials filled in the middle and sealed on the outside. This adds many production processes and the labor of many skilled workers, including wood molding and processing, flame retardant liquid impregnation, secondary drying and drying. Traditional woodworking technology is used, with low output, many processes, high labor costs, and difficulty in standardized mass production and lightweight assembly.

[0004] The use of steel fire doors is equally unscientific. Not only is the cost high, but the steel's characteristics are strictly speaking not suitable for making fire doors. First, the steel welding points will produce higher temperatures under the high temperature of the fire and will break; second, the steel material will burn red in the fire, generating heat, increasing the hot temperature, and will burn the victims and rescuers. Summary of the Invention

[0005] In view of the shortcomings of the existing technology, the present invention provides a composite foam fire door and a manufacturing method thereof, which has the advantages of low cost, fireproofing and heat insulation, lightweight, and can realize standardized, batch and automated production.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solutions: A composite foam fireproof door, comprising a door leaf and a door frame, characterized in that, in parts by weight, it comprises the following components: 30-45 parts of glue solution; 5-13 parts of wood fiber; 12-20 parts of phenolic resin; 1-3 parts of methyl silicone oil; 4 parts perlite foam particles; 2-3 parts of curing agent; 1-2 parts of silane coupling agent.

[0007] Preferably, it further comprises 8-10 parts of sepiolite fiber, 8-12 parts of silicon powder, 10-20 parts of magnesium oxide and 3-5 parts of sodium bicarbonate.

[0008] Preferably, it further comprises 8-10 parts of sepiolite fiber, 2-3 parts of oxalic acid and 6-8 parts of PVA.

[0009] Preferably, it also includes 2-3 parts of catalyst and 2-3 parts of foaming agent; Preferably, the adhesive solution is silica sol and polyvinyl alcohol. Silica sol has the characteristics of high temperature resistance of 1500-1600°C, high viscosity, and porosity. Functional materials can be added to implement reinforcement modification and toughening modification.

[0010] A method for manufacturing a composite foam fire door, characterized by the following steps: S1. First, the silica powder, sepiolite fiber, wood fiber, and coupling agent are fully stirred in a high-speed mixer according to the corresponding proportions. The stirring temperature is controlled within 90 degrees. S2, adding phenolic resin, PVA, perlite foam particles, oxalic acid and curing agent to the glue solution and mixing into a paste; S3, further blending and stirring the mixed materials of S1 and S2 by a horizontal rotary mixer; S4, then enter the vacuum clay mill for mixing and extrusion into a clay shape, and then use a three-axis vacuum clay mill to knead and extrude it into a molding mold for shaping, or use a double roller press to form it, and at the same time, press the high-temperature resistant asbestos fiber mesh or glass fiber silicone mesh into the mixed clay material and input it into a microwave drying channel for heating and drying; S5. The electromagnetic waves generated by the microwave drying tunnel cause the water molecules in the mixed glue material to vibrate at high speed, catalyze, foam, and cross-link during the friction and heat generation. After foaming, the material is sent to the graphene hot drying rack and drying room for low-temperature drying and solidification. After surface finishing, it is finally assembled into door leaves and door frames.

[0011] Preferably, the forming mold is a non-metal mold.

[0012] Preferred: non-metallic molds use phenolic molds; Preferably: in step S4, the microwave oven is used for high temperature drying and the temperature is controlled within 80-200 degrees. Preferably, in step S5, the low-temperature drying and curing temperature is controlled between 30-60° C. until absolutely dry.

[0013] Preferably, in step S5, phenolic foaming agent or perlite foam particles are used for foaming.

[0014] Beneficial effects: The composite foam material has a reduced specific gravity, ensuring that the fire door does not sag during use, the joints have great smoke resistance, and the toughness and high temperature resistance are enhanced, making the material strong, with a nail holding force similar to hardwood, and as light as paulownia wood. The fire resistance reaches over 1000 degrees, the material produces little smoke, is heat-insulating, self-extinguishing, and non-combustible. It also has waterproof and moisture-proof functions, and can be produced automatically to reduce labor costs. DETAILED DESCRIPTION

[0015] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with 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. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0016] Example 1 A composite foam fireproof door, comprising a door leaf and a door frame, comprising the following components in parts by weight: 42 parts of silica sol; 5 parts of wood fiber; 20 parts of phenolic resin; 1 part methyl silicone oil; 4 parts perlite foam particles; 2 parts of curing agent; 2 parts of silane coupling agent; 9 parts of sepiolite fiber; 10 parts of silicon micropowder; 12 parts of magnesium oxide; 3 parts of sodium bicarbonate.

[0017] Example 2 A composite foam fireproof door, comprising a door leaf and a door frame, comprising the following components in parts by weight: 35 parts of silica sol; 8 parts of wood fiber; 14 parts of phenolic resin; 3 parts of methyl silicone oil; 4 parts perlite foam particles; 2 parts of curing agent; 2 parts of silane coupling agent; 8 parts of sepiolite fiber; 2 parts of oxalic acid; 6 parts of PVA; Example 3 A composite foam fireproof door, comprising a door leaf and a door frame, comprising the following components in parts by weight: 30 parts of silicone glue; 5 parts of wood fiber; 16 parts of phenolic resin; 2 parts of methyl silicone oil; 4 parts perlite foam particles; 2 parts of curing agent; 1 part of silane coupling agent; 8 parts of sepiolite fiber; 3 parts of catalyst; 3 parts of foaming agent; Example 4 A method for manufacturing a composite foam fire door, characterized by the following steps: S1. First, 10 parts of silica powder, 8 parts of sepiolite fiber, 5 parts of wood fiber and 3 parts of coupling agent are fully mixed in a high-speed mixer, and the stirring temperature is controlled within 90 degrees; S2, add 16 parts of phenolic resin, 6 parts of PVA, 4 parts of perlite foam particles, 3 parts of oxalic acid, and 2 parts of curing agent to 35 parts of silica sol and mix into a paste; S3, further blending and stirring the mixed materials of S1 and S2 by a horizontal rotary mixer; S4, then enter the vacuum clay mill for mixing and extrusion into a clay shape, and then use a three-axis vacuum clay mill to knead and extrude it into a molding mold for shaping, or use a double roller press to form it, and at the same time, press the high-temperature resistant asbestos fiber mesh or glass fiber silicone mesh into the mixed clay material and input it into a microwave oven for drying at 150 degrees for 8 minutes; S5. The electromagnetic waves generated by the microwave drying tunnel cause the water molecules in the mixed glue material to vibrate at high speed, catalyze, foam, and cross-link during the friction and heat generation. After foaming, the material is sent to the graphene hot drying rack and drying room for low-temperature drying and solidification. After surface finishing, it is finally assembled into door leaves and door frames.

[0018] In this embodiment, the non-metallic mold is a phenolic mold.

[0019] In this embodiment, when oxalic acid is not added in step S2, 12 parts of magnesium oxide and 3 parts of sodium bicarbonate can be added as a replacement.

[0020] In this embodiment, the high-temperature drying in the microwave oven in step S4 is carried out at a temperature controlled within 80-200 degrees, for example, 100 degrees, and the time is controlled within 10 minutes. When 200 degrees is used, the time is controlled within 6 minutes. The drying time may vary.

[0021] In this embodiment, the low-temperature drying and curing temperature in step S5 is controlled between 30-60° C., for example, 30° C., 40° C. or 60° C., until absolutely dry.

[0022] Test Example 1 Example Material specific gravity Fire performance Refractory time Water gun shock one <![CDATA[500kg / m 3 ]]> 1200 degrees 2 hours Unbreakable two <![CDATA[600kg / m 3 ]]> 1100 degrees 1.5 hours Unbreakable three <![CDATA[450kg / m 3 ]]> 1050 degrees 1 hour Unbreakable To sum up, the effect achieved by the present invention is that the specific gravity of the composite foam material is reduced, which ensures that the fire door does not sag during use, the joints have great smoke resistance, and the toughness and high temperature resistance are enhanced, making the material strong, with a nail holding force similar to hardwood, and as light as paulownia wood, with a fire resistance of more than 1000 degrees. The material produces little smoke, is self-extinguishing and does not burn, and also has the functions of being waterproof and moisture-proof. It can be produced automatically, can be directly formed, punched and assembled, and reduces labor costs.

[0023] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A composite foam fire door, comprising a door leaf and a door frame, characterized in that: According to parts by weight, it includes the following ingredients: 30-45 parts of glue solution; 5-13 parts of wood fiber; 12-20 parts of phenolic resin; 1-3 parts of methyl silicone oil; 4 parts perlite foam particles; 2-3 parts of curing agent; 1-2 parts of silane coupling agent.

2. A composite foam fire door according to claim 1, characterized in that: It also includes 8-10 parts of sepiolite fiber, 8-12 parts of silicon powder, 10-20 parts of magnesium oxide and 3-5 parts of sodium bicarbonate.

3. The composite foam fire door according to claim 1, characterized in that: It also includes 8-10 parts of sepiolite fiber, 2-3 parts of oxalic acid and 6-8 parts of PVA.

4. A composite foam fire door according to claim 1 or 2, characterized in that: It also includes 2-3 parts of catalyst and 2-3 parts of foaming agent.

5. The composite foam fire door according to claim 1, characterized in that: The glue solution adopts silica sol and polyvinyl alcohol.

6. A method for manufacturing a composite foam fire door, characterized by: S1. First, the silica powder, sepiolite fiber, wood fiber, and coupling agent are fully mixed in a high-speed mixer according to the corresponding proportions, and the stirring temperature is controlled within 90 degrees; S2, adding phenolic resin, PVA, perlite foam particles, oxalic acid and curing agent to the glue solution and mixing into a paste; S3, further blending and stirring the mixed materials of S1 and S2 by a horizontal rotary mixer; S4, then enter the vacuum clay mill for mixing and extrusion into a clay shape, and then use a three-axis vacuum clay mill to knead and extrude it into a molding mold for shaping, or use a double roller press to form it, and at the same time, press the high-temperature resistant asbestos fiber mesh or glass fiber silicone mesh into the mixed clay material and input it into a microwave drying channel for heating and drying; S5. The electromagnetic waves generated by the microwave drying tunnel cause the water molecules in the mixed glue material to vibrate at high speed, catalyze, foam, and cross-link during the friction and heat generation. After foaming, the material is sent to the graphene hot drying rack and drying room for low-temperature drying and solidification. After surface finishing, it is finally assembled into door leaves and door frames.

7. The method for manufacturing a composite foam fire door according to claim 6, characterized in that: The molding mold adopts a non-metal mold.

8. The method for manufacturing a composite foam fire door according to claim 6, characterized in that: The non-metal mold uses a phenolic mold.

9. The method for manufacturing a composite foam fire door according to claim 6, characterized in that: In step S4, the high-temperature drying in the microwave oven is controlled at a temperature between 80 and 200 degrees Celsius, and in step S5, the low-temperature drying and curing temperature is controlled at a temperature between 30 and 60 degrees Celsius.

10. The composite foam fire door according to claim 6, characterized in that: In step S5, phenolic foaming agent or perlite foam particles are used for foaming.