Composite waterproof coiled material of butyl rubber and basalt fiber cloth and preparation method of composite waterproof coiled material

Abstract

The invention discloses a butyl rubber and basalt fiber cloth composite waterproof coiled material and a preparation method thereof, and the method comprises the following steps: pretreating butyl rubber, mixing the butyl rubber raw material, adding a proper amount of a vulcanizing agent, a plasticizer and other assistants, and preparing a butyl rubber material with good fluidity and bonding performance; carrying out cleaning pretreatment on the basalt fiber cloth; the butyl rubber material and the basalt fiber cloth are tightly combined through a hot-pressing compounding technology; compared with the prior art, the mechanical property of the waterproof coiled material can be remarkably improved, the coiled material has super-strong tear resistance and puncture resistance, the waterproof failure risk is reduced, butyl rubber serves as a bonding and waterproof layer of a composite structure, a continuous and compact waterproof barrier can be formed in the coiled material, and the waterproof performance of the coiled material is improved. The overall waterproof effect is further improved, the corrosion resistance and the anti-aging performance are improved, the service life is prolonged, and the cable is suitable for waterproof protection engineering in severe environments.

Description

Technical Field

[0001] This invention relates to the field of waterproof membranes, and more particularly to a composite waterproof membrane of butyl rubber and basalt fiber cloth and its preparation method. Background Technology

[0002] Waterproof membranes, as the core functional material in building waterproofing projects, are widely used in waterproofing protection systems for various building structures such as roofs, basements, tunnels, bridges, and water conservancy projects. With modern architecture developing towards higher durability, higher safety, and adaptability to complex environments, the construction industry has placed more stringent requirements on the comprehensive performance of waterproof membranes, highlighting the increasingly prominent performance deficiencies of traditional waterproof membranes.

[0003] Currently, the mainstream waterproof membranes on the market mainly include three categories: bitumen-based waterproof membranes, ordinary rubber waterproof membranes, and polymer waterproof membranes. However, all of them have significant performance shortcomings: bitumen-based waterproof membranes have low tensile strength (usually ≤500MPa), poor tear resistance, and insufficient aging resistance, and are prone to cracking, delamination, leakage, and other failures after long-term service; ordinary rubber waterproof membranes have basic waterproofing capabilities, but their puncture resistance is generally lower than 300N, making them easily punctured and damaged by sharp objects in complex construction scenarios or during later use, leading to failure of the waterproofing function; polymer waterproof membranes generally have problems such as low adhesion strength to the substrate (peel strength ≤1.5N / mm) and limited corrosion resistance, making it difficult to meet the long-term waterproofing requirements in harsh environments such as acids, alkalis, and salts.

[0004] Therefore, developing a composite waterproof membrane that combines excellent waterproof sealing, ultra-high mechanical strength, strong puncture resistance, and long-lasting corrosion resistance and aging resistance has become a pressing technical challenge in the field of waterproof building materials. Summary of the Invention

[0005] The purpose of this invention is to provide a high-strength composite waterproof membrane of butyl rubber and basalt fiber cloth. By rationally combining butyl rubber and basalt fiber cloth, the excellent properties of the two materials are fully utilized, achieving a synergistic improvement in waterproof performance, mechanical properties and durability, and solving the problems of weak tear resistance, puncture resistance and insufficient aging and corrosion resistance of existing waterproof membranes.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0007] A method for preparing a composite waterproof membrane of butyl rubber and basalt fiber cloth includes the following steps:

[0008] S1, Butyl Rubber Pretreatment

[0009] Butyl rubber raw materials are mixed and appropriate amounts of vulcanizing agents, plasticizers and other additives are added to produce butyl rubber compounds with good flowability and adhesion properties.

[0010] S2, Basalt Fiber Cloth Pretreatment

[0011] The surface of the basalt fiber cloth is cleaned to remove impurities, and surface activation treatment is performed if necessary to improve its bonding strength with butyl rubber.

[0012] S3, Composite Molding

[0013] According to the designed layer structure, butyl rubber compound and basalt fiber cloth are laid sequentially on the molding equipment, and each layer is tightly bonded by hot pressing composite process.

[0014] S4. Finished Product Processing

[0015] The composite-molded roll is cooled, shaped, cut, and trimmed to obtain the finished butyl rubber-basalt fiber composite waterproof roll.

[0016] Preferably, in step S1, the butyl rubber raw material is mixed evenly with the vulcanizing agent and the plasticizer, with the amount of vulcanizing agent being 2% of the mass of the rubber raw material and the amount of plasticizer being 5% of the mass of the rubber raw material. The mixture is then mixed at 140°C for 20 minutes to produce the butyl rubber compound.

[0017] Preferably, in step S2, the basalt fiber cloth is placed in an ultrasonic cleaner for 10 minutes to remove surface dust and impurities, and then dried at 80°C for 30 minutes.

[0018] Preferably, in step S3, a butyl rubber base layer is evenly laid on the lower template of the flat vulcanizing machine, then a pretreated basalt fiber cloth is laid on top, and then a butyl rubber surface layer is laid on the fiber cloth. Finally, the upper template is covered and hot-pressed.

[0019] As a preferred option, in step S3, the hot pressing process parameters are: hot pressing temperature 120-160℃, hot pressing pressure 2-5MPa, and heat and pressure holding time 5-15min; preferably, the hot pressing temperature is 140-150℃, the pressure is 3-4MPa, and the heat and pressure holding time is 10-12min, to ensure that the interlayer bonding strength is ≥2.0N / mm.

[0020] A composite waterproof membrane of butyl rubber and basalt fiber cloth, the composite waterproof membrane includes a composite layer, the composite layer is composed of alternating layers of butyl rubber and multiple layers of basalt fiber cloth, the butyl rubber layer is made of modified butyl rubber material and has a thickness of 0.5-2mm, the basalt fiber cloth is a continuous fiber woven fabric, and the upper and lower surfaces of the composite layer are provided with waterproof layers.

[0021] The butyl rubber layer serves both adhesive and waterproof functions. This material has excellent corrosion resistance, aging resistance, and waterproof performance, as well as good adhesive properties, which allows it to be tightly bonded to the basalt fiber cloth, ensuring the stability of the composite structure.

[0022] The basalt fiber cloth plays a role in enhancing performance, possessing extremely high tensile strength, excellent corrosion resistance, and anti-aging properties.

[0023] Preferably, the waterproof layer is a butyl rubber waterproof layer, which is made of the same material as the butyl rubber layer in the composite layer, to ensure the continuity and sealing of the overall waterproof system.

[0024] Preferably, the number of layers in the composite layer can be adjusted according to actual usage requirements, preferably 3-5 layers, wherein the number of basalt fiber cloth layers is 2-4 layers, the number of butyl rubber layers is 1-3 layers, and adjacent basalt fiber cloth layers are bonded and fixed by butyl rubber layers, with an interlayer peel strength ≥2.0N / mm.

[0025] Preferably, the basalt fiber cloth has a fiber diameter of 5-15 μm and a fabric density of 200-600 g / m³. 2 It has a fracture strength ≥1500MPa and possesses extremely high tensile strength, excellent corrosion resistance and aging resistance.

[0026] Compared with the prior art, the advantages of the present invention are as follows:

[0027] (1) Excellent tear and puncture resistance: The tensile strength of basalt fiber cloth is ≥1500MPa. After being combined with butyl rubber, the tensile strength of the roll can reach 1800-2200MPa, the tear strength is ≥80kN / m, and the puncture resistance is ≥500N, which is more than 50% higher than that of traditional products. It can effectively resist the puncture damage of sharp objects during construction and the tensile force generated by structural deformation during use, greatly reducing the risk of waterproof failure.

[0028] (2) Excellent waterproof performance: Butyl rubber itself has excellent waterproof performance and is not breathable or water-permeable. As the bonding and waterproof layer of the composite structure, it can form a continuous and dense waterproof barrier inside the roll material. At the same time, the butyl rubber is tightly bonded to the basalt fiber cloth, avoiding the phenomenon of water seepage between layers. The overall waterproof performance meets the first-class waterproof standard of GB / T18242-2008 "Elastomer Modified Bituminous Waterproof Roll Material", and some indicators are better than the standard requirements.

[0029] (3) Excellent durability: Butyl rubber and basalt fiber cloth have excellent corrosion resistance and anti-aging properties, which can resist the erosion of harsh environmental media such as acids, alkalis and salts, and resist the influence of natural environmental factors such as ultraviolet rays and high and low temperatures. The service life can reach more than 20 years, which is twice as long as traditional products, and significantly reduces the later maintenance cost.

[0030] (4) Good adhesion performance: The interfacial bonding strength of butyl rubber is ≥2.0N / mm, which enables the basalt fiber cloth and the rubber layer to form a strong integrated structure, avoids interlayer peeling, and ensures the structural integrity of the roll material during construction and long-term use.

[0031] (5) Wide range of applications: This composite waterproof membrane has excellent comprehensive performance and can be widely used in various scenarios with high waterproof requirements, such as roofs, basements, tunnels, bridges, and water conservancy projects. It is especially suitable for waterproof protection projects in harsh environments. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the composite waterproof membrane structure of butyl rubber-basalt fiber cloth of the present invention.

[0033] In the diagram: 1. Butyl rubber layer; 2. Basalt fiber cloth layer; 3. Waterproof layer. Detailed Implementation

[0034] A composite waterproof membrane made of butyl rubber and basalt fiber cloth, see [link to relevant documentation]. Figure 1 The composite waterproof membrane includes a composite layer, which is composed of an alternating butyl rubber layer 1 and multiple layers of basalt fiber cloth 2. The butyl rubber layer 1 is made of modified butyl rubber material with a thickness of 0.5-2mm. The basalt fiber cloth 2 is a continuous fiber woven fabric. The upper and lower surfaces of the composite layer are provided with waterproof layers 3, which are butyl rubber waterproof layers.

[0035] Example 1: A composite waterproof membrane of butyl rubber and basalt fiber cloth, wherein the composite layer has a three-layer structure, from bottom to top: a butyl rubber bottom layer (1mm thick), a basalt fiber cloth layer (400g / m² density). 2 (Fiber diameter 10μm) and butyl rubber surface layer (thickness 1mm).

[0036] The preparation process is as follows:

[0037] Butyl rubber pretreatment: Mix butyl rubber raw material with vulcanizing agent (2% of the mass of rubber raw material) and plasticizer (5% of the mass of rubber raw material) evenly, and knead at 140℃ for 20 minutes to prepare butyl rubber compound;

[0038] Basalt fiber cloth pretreatment: Put the basalt fiber cloth into an ultrasonic cleaner for 10 minutes to remove surface dust and impurities, and then dry it at 80℃ for 30 minutes.

[0039] Composite molding: The bottom layer of butyl rubber is evenly laid on the lower template of the flat vulcanizing machine, then the pretreated basalt fiber cloth is laid on it, and the top layer of butyl rubber is laid on the fiber cloth. The upper template is then covered, and the hot pressing temperature is set to 140℃, the pressure to 3MPa, and the heat and pressure holding time to 10min.

[0040] Post-processing: Remove the hot-pressed composite roll and allow it to cool naturally to room temperature. Then cut it into finished products of the corresponding specifications according to requirements.

[0041] Testing showed that the composite waterproof membrane prepared in this embodiment has a tensile strength of 1800 MPa, a tear strength of 80 kN / m, and a puncture resistance of 500 N. After immersion in acid and alkali solutions for 30 days, the performance retention rate is ≥90%. After a UV aging test of 1000 h, the performance retention rate is ≥85%. The waterproof performance meets the Class I waterproof standard in GB / T18242-2008 "Elastomer Modified Bituminous Waterproof Membranes".

[0042] Example 2

[0043] A butyl rubber-basalt fiber composite waterproof membrane has a 5-layer structure, consisting of a butyl rubber bottom layer (0.8 mm thick), a first basalt fiber fabric layer (300 g / m² density), and a basalt fiber cloth layer. 2 The structure consists of a fiber diameter of 8 μm, a butyl rubber interlayer (thickness of 0.8 mm), and a second basalt fiber cloth layer (cloth surface density of 300 g / m³). 2 (Fiber diameter 8μm), butyl rubber surface layer (thickness 0.8mm).

[0044] The preparation process was the same as in Example 1, except that the hot pressing temperature was adjusted to 150°C, the pressure to 4 MPa, and the holding time to 12 min.

[0045] Testing showed that the composite waterproof membrane prepared in this embodiment has a tensile strength of 2200MPa, a tear strength of 95kN / m, and a puncture resistance of 650N. After immersion in acid and alkali solutions for 30 days, the performance retention rate is ≥92%. After UV aging test for 1000h, the performance retention rate is ≥88%. The waterproof performance is better than the Class I waterproof standard in GB / T18242-2008 "Elastomer Modified Bituminous Waterproof Membrane".

[0046] The present invention provides a detailed description of a composite waterproof membrane of butyl rubber and basalt fiber cloth and its preparation method. Specific examples have been used to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. At the same time, for those skilled in the art, based on the ideas of the present invention, there will be changes in the specific implementation methods and application scope. Modifications and improvements to the present invention are possible without exceeding the concept and scope specified in the appended claims. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A method for preparing a composite waterproof membrane of butyl rubber and basalt fiber cloth, characterized in that: Includes the following steps: S1, Butyl Rubber Pretreatment Butyl rubber raw materials are mixed and appropriate amounts of vulcanizing agents, plasticizers and other additives are added to produce butyl rubber compounds with good flowability and adhesion properties. S2, Basalt Fiber Cloth Pretreatment The surface of the basalt fiber cloth is cleaned to remove impurities, and surface activation treatment is performed if necessary to improve its bonding strength with butyl rubber. S3, Composite Molding According to the designed layer structure, butyl rubber compound and basalt fiber cloth are laid sequentially on the molding equipment, and each layer is tightly bonded through hot pressing composite process. S4. Finished Product Processing The composite-molded roll is cooled, shaped, cut, and trimmed to obtain the finished butyl rubber-basalt fiber composite waterproof roll.

2. The method for preparing the composite waterproof membrane of butyl rubber and basalt fiber cloth according to claim 1, characterized in that: In step S1, the butyl rubber raw material is mixed evenly with vulcanizing agent and plasticizer. The amount of vulcanizing agent is 2% of the mass of the rubber raw material, and the amount of plasticizer is 5% of the mass of the rubber raw material. The mixture is then mixed at 140°C for 20 minutes to produce butyl rubber compound.

3. The method for preparing the composite waterproof membrane of butyl rubber and basalt fiber cloth according to claim 1, characterized in that: In step S2, the basalt fiber cloth is placed in an ultrasonic cleaner for 10 minutes to remove surface dust and impurities, and then dried at 80°C for 30 minutes.

4. The method for preparing the composite waterproof membrane of butyl rubber and basalt fiber cloth according to claim 1, characterized in that: In step S3, butyl rubber base material is evenly laid on the lower template of the flat vulcanizing machine, then pretreated basalt fiber cloth is laid on top, and then butyl rubber surface material is laid on the fiber cloth. Finally, the upper template is covered and hot-pressed.

5. The method for preparing the composite waterproof membrane of butyl rubber and basalt fiber cloth according to claim 1, characterized in that: In step S3, the hot pressing temperature is 120-160℃, the pressure is 2-5MPa, and the heat and pressure holding time is 5-15min.

6. The composite waterproof membrane prepared by the method for preparing the composite waterproof membrane of butyl rubber and basalt fiber cloth according to claim 1, characterized in that: The composite waterproof membrane includes a composite layer, which is composed of alternating layers of butyl rubber and multiple layers of basalt fiber cloth. The butyl rubber layer is made of modified butyl rubber material with a thickness of 0.5-2mm. The basalt fiber cloth is a continuous fiber woven fabric. The upper and lower surfaces of the composite layer are provided with waterproof layers.

7. The composite waterproof membrane of butyl rubber and basalt fiber cloth according to claim 6, characterized in that: The waterproof layer is a butyl rubber waterproof layer.

8. The composite waterproof membrane of butyl rubber and basalt fiber cloth according to claim 1, characterized in that: The composite layer consists of 3-5 layers, of which basalt fiber cloth consists of 2-4 layers and butyl rubber layer consists of 1-3 layers. Adjacent basalt fiber cloth layers are bonded and fixed together by butyl rubber layer.

9. The composite waterproof membrane of butyl rubber and basalt fiber cloth according to claim 1, characterized in that: The basalt fiber cloth has a fiber diameter of 5-15 μm and a fabric density of 200-600 g / m³. 2 The fracture strength is ≥1500MPa.

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