Rock wool felt and production method

Abstract

The invention discloses a rock wool felt and a production method, and belongs to the field of rock wool felts.The rock wool felt comprises a rock wool layer, and an outer protection layer is arranged outside the rock wool layer; the rock wool layer comprises the following substances in parts by weight: 60-70 parts of basalt, 15-20 parts of dolomite, 8-12 parts of wollastonite and 12-15 parts of a composite adhesive. By arranging the outer protective layer, the gas barrier, waterproof and weather-resistant properties of the rock wool felt can be effectively improved while the effects of heat preservation, flame retardance, sound insulation and the like of the rock wool felt are ensured, so that the rock wool felt can be stably used for a long time.

Description

Technical Field

[0001] This invention belongs to the field of rock wool felt, specifically a rock wool felt and its production method. Background Technology

[0002] Rock wool felt is a commonly used thermal insulation and flame retardant material with excellent thermal insulation, fireproofing and sound insulation effects. Due to its low cost, it is widely used in many fields such as construction, chemical industry and shipbuilding.

[0003] However, the following problems exist in actual use: However, traditional rock wool felt has the following inherent drawbacks: Rock wool has poor gas barrier properties. Its interwoven fiber structure contains a large number of micropores, which are beneficial for heat insulation, but air, water vapor and other gases can pass through freely. Therefore, it cannot meet the requirements when used in clean rooms, cold storage or building envelopes that require airtightness. It has poor waterproof performance. If it is exposed to a humid environment for a long time or soaked in liquid water, moisture may seep into and be absorbed on the fiber surface, causing the thermal conductivity to rise sharply and the insulation performance to drop. In severe cases, it may even cause fiber settling and structural damage. With poor weather resistance, when rock wool felt is used in exterior wall insulation thin plastering systems or for wrapping exposed pipes, its surface is directly or indirectly exposed to ultraviolet radiation. Ultraviolet radiation will accelerate the aging and degradation of rock wool felt, leading to material pulverization, reduced strength, and a decrease in corresponding thermal insulation effects. Summary of the Invention

[0004] This invention provides a rock wool felt and a production method thereof, in order to overcome the deficiencies in the prior art.

[0005] This invention is achieved through the following technical solution: A rock wool felt includes a rock wool layer, and an outer protective layer is provided on the outside of the rock wool layer; The rock wool layer comprises the following materials in parts by weight: 60-70 parts basalt, 15-20 parts dolomite, 8-12 parts wollastonite, and 12-15 parts composite adhesive. The outer protective layer spray emulsion comprises the following substances in parts by weight: 30-40 parts of 2-ethyl-2-butyl-1,3-propanediol, 20-30 parts of n-hexyltrimethoxysilane, 10-15 parts of perfluorohexylethyl acrylate, 6-10 parts of alkynyl alcohol polyether modified siloxane, 4-6 parts of sodium sulfate of fatty alcohol polyoxyethylene ether, 1-2 parts of fatty alcohol polyoxyethylene ether, 1-2 parts of γ-methacryloyloxypropyltrimethoxysilane, 30-40 parts of hydroxyethyl acrylate, 20-30 parts of hydroxyethyl methacrylate, 20-30 parts of perfluorohexylethyl acrylate, 2-4 parts of disodium ethoxylated cashew phenol sulfosuccinate half ester, 4-6 parts of benzophenone, 2-4 parts of methyl diethanolamine, and 500-600 parts of deionized water.

[0006] The rock wool felt described above has a rock wool layer thickness of 30-100mm and an outer protective layer thickness of 2-4mm.

[0007] The rock wool felt described above, wherein the composite adhesive comprises the following substances in parts by weight: 15-20 parts sodium silicate, 10-15 parts aluminum sol, 5-8 parts polyvinyl alcohol, 3-5 parts modified starch, 2-3 parts borax, and 30-40 parts deionized water. The preparation method is as follows: weigh sodium silicate, aluminum sol, polyvinyl alcohol, modified starch, borax, and deionized water according to the formula. Then, mix sodium silicate and aluminum sol and add deionized water. Heat to 50-60℃ and stir at 150-200r / min for 15-20min. Then add polyvinyl alcohol, modified starch, and borax and continue stirring for 20-25min to obtain the composite adhesive.

[0008] The rock wool felt described above is prepared as follows: basalt, dolomite, wollastonite, and composite adhesive are weighed according to the specified ratio. The basalt, dolomite, and wollastonite are added to a melting furnace and heated to 1500-1600℃ to melt into magma. The magma is then rotated at high speed through a centrifuge to form fibers. Next, the composite adhesive is evenly sprayed onto the surface of the rock wool fibers. The fibers are collected by a cotton collector to form a preliminary blank. The preliminary blank is sent to a curing furnace and cured at 200-220℃ for 20-30 minutes. After curing, it is cut and trimmed to obtain the rock wool layer.

[0009] The preparation process of the outer protective layer of the rock wool felt described above includes the following steps: Step 1: Weigh out the following ingredients according to the specified ratio: 2-ethyl-2-butyl-1,3-propanediol, n-hexyltrimethoxysilane, perfluorohexylethyl acrylate, alkynyl alcohol polyether modified siloxane, sodium fatty alcohol polyoxyethylene ether sulfate, fatty alcohol polyoxyethylene ether, γ-methacryloyloxypropyltrimethoxysilane, hydroxyethyl acrylate, hydroxyethyl methacrylate, perfluorohexylethyl acrylate, ethoxylated cashew phenol sulfosuccinate half ester disodium salt, benzophenone, methyl diethanolamine, and deionized water. Step 2: Add 2-ethyl-2-butyl-1,3-propanediol, n-hexyltrimethoxysilane, perfluorohexylethyl acrylate, alkynyl alcohol polyether modified siloxane, sodium fatty alcohol polyoxyethylene ether sulfate, fatty alcohol polyoxyethylene ether, and γ-methacryloyloxypropyltrimethoxysilane to two-thirds of the weight of deionized water and mix to obtain an emulsion. Step 3: Add hydroxyethyl acrylate, hydroxyethyl methacrylate, perfluorohexyl ethyl acrylate, ethoxylated cashew phenol sulfosuccinate disodium salt, benzophenone, and methyl diethanolamine to the remaining one-third of the weight of deionized water and mix to obtain the dropping solution. Step 4: Add the liquid obtained in Step 3 to the emulsion obtained in Step 2 and mix. Step 5: After mixing, irradiate with ultraviolet light, and after irradiation, dispense the outer protective layer spray emulsion.

[0010] In the rock wool felt described above, the reaction temperature in step 2 is 60-70℃, the stirring speed is 200-300r / min, the mixing time is 3-4h, and nitrogen gas is introduced for protection during the mixing process.

[0011] In the rock wool felt described above, the stirring speed in step 3 is 200-300 r / min, the mixing time is 20-30 min, and the mixing is carried out at room temperature.

[0012] In the rock wool felt described above, the dripping time of the dripping liquid obtained in step 4 is 2-3 hours, the temperature during the dripping process is 50-70℃, the stirring speed is 100-130 r / min, and nitrogen gas is introduced for protection during the dripping process.

[0013] In the rock wool felt described above, in steps 4 and 5, the ultraviolet lamp irradiation time is 1.5-2 hours, the ultraviolet lamp irradiation intensity is 1500-2000 μW / cm², the stirring speed during ultraviolet lamp irradiation is 80-100 r / min, and nitrogen gas is introduced for protection during ultraviolet lamp irradiation.

[0014] A method for producing rock wool felt includes the following steps: Step 1: The rock wool layer is transported by rollers. Before transport, multiple high-pressure nozzles spray an outer protective emulsion onto the rock wool layer. Step 2: After spraying, the coating is directly placed in the heating chamber set in the middle and rear section of the transport, and initially cured at a temperature of 150-170℃ for 2-3 minutes; Step 3: The rock wool felt of the outer protective layer is initially cured and placed in a curing oven to cure at a temperature of 70-90℃ for 1.5-2 hours. After curing, it is cooled to room temperature to obtain the finished product.

[0015] The advantages of this invention are: In this invention, by setting an outer protective layer, the rock wool felt can not only be kept warm, flame retardant and soundproof, but also effectively improve its gas barrier, waterproof and weather resistance properties, thereby ensuring that the rock wool felt can be used stably for a long time. The outer protective layer of this invention employs a core-shell structure in its spray emulsion production. In this invention, 2-ethyl-2-butyl-1,3-propanediol, n-hexyltrimethoxysilane, perfluorohexylethyl acrylate, and alkynyl alcohol polyether-modified siloxane serve as functional monomers for the core. 2-ethyl-2-butyl-1,3-propanediol possesses excellent heat resistance and stability, providing a solid structural foundation for the core. n-Hexyltrimethoxysilane enhances the compatibility and interfacial bonding between the core and other components, improving the overall structural stability. Perfluorohexylethyl acrylate imparts excellent weather resistance and chemical inertness to the core, effectively... It resists external environmental erosion; alkynyl alcohol polyether modified siloxane can improve the fluidity and dispersibility of the core, ensuring uniform mixing of each component in the subsequent emulsion preparation process; sodium fatty alcohol polyoxyethylene ether sulfate and fatty alcohol polyoxyethylene ether play an emulsifying role, which can reduce the interfacial tension between core components and promote the uniform dispersion of each monomer to form a stable core structure; γ-methacryloyloxypropyltrimethoxysilane chemically combines with silane monomers in the core through the silicon-oxygen bond in its molecular structure, and the carbon-carbon double bond can participate in the subsequent polymerization reaction, further enhancing the structural integrity of the core and its connection with the shell. The shell layer of this invention uses hydroxyethyl acrylate, hydroxyethyl methacrylate, and perfluorohexyl ethyl acrylate as functional monomers. The hydroxyl groups in the molecules of hydroxyethyl acrylate and hydroxyethyl methacrylate provide good reactivity, facilitating cross-linking with the core and other additives, thereby improving the density of the shell layer. The introduction of perfluorohexyl ethyl acrylate endows the shell layer with outstanding waterproof, oil-proof, and chemical corrosion-resistant properties, complementing the function of the core. Ethoxylated cashew phenol sulfosuccinate disodium salt can play a dispersing and emulsifying role in the shell layer, which helps to stably disperse the shell layer monomers in the aqueous phase and ensures the smooth progress of the shell layer formation process. In this invention, benzophenone and methyl diethanolamine work synergistically to generate free radicals under ultraviolet light irradiation, which can initiate the polymerization reaction of shell monomers and improve the resistance to ultraviolet radiation, thereby improving the weather resistance of rock wool felt.

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a bar chart illustrating the thermal conductivity of the verification test results of this invention; Figure 2 This is a bar chart of the oxygen index from the verification test of this invention; Figure 3 This is a bar chart illustrating the sound insulation performance of the verification test of this invention; Figure 4 This is a bar graph showing the water vapor transmission rate in the verification test of this invention; Figure 5 This is a bar chart showing the water absorption rate of the verification test of this invention. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Example

[0019] A method for producing rock wool felt includes the following steps: The preparation process of the rock wool layer is as follows: 60 parts of basalt, 15 parts of dolomite, 8 parts of wollastonite, and 12 parts of composite adhesive are weighed according to the ratio. The basalt, dolomite, and wollastonite are added to the melting furnace and heated to 1500℃ to melt into magma. The magma is then rotated at high speed through a centrifuge to form fibers. The composite adhesive is then evenly sprayed onto the surface of the rock wool fibers and collected by a cotton collecting machine to form a preliminary blank. The preliminary blank is sent to a curing furnace and cured at 200℃ for 30 minutes. After curing, it is cut and trimmed to obtain a rock wool layer with a thickness of 50mm. The composite adhesive comprises the following components in parts by weight: 15 parts sodium silicate, 10 parts aluminum sol, 5 parts polyvinyl alcohol, 3 parts modified starch, 2 parts borax, and 30 parts deionized water. The preparation method is as follows: Sodium silicate, aluminum sol, polyvinyl alcohol, modified starch, borax, and deionized water are weighed according to the formula. Then, sodium silicate and aluminum sol are mixed and deionized water is added. The temperature is raised to 50°C and stirred at 150 r / min for 20 min. Then, polyvinyl alcohol, modified starch, and borax are added and stirred for another 25 min to obtain the composite adhesive. The preparation process of the outer protective layer includes the following steps: Step 1: Weigh out the following ingredients according to the specified ratio: 30 parts of 2-ethyl-2-butyl-1,3-propanediol, 20 parts of n-hexyltrimethoxysilane, 10 parts of perfluorohexylethyl acrylate, 6 parts of alkynyl alcohol polyether modified siloxane, 4 parts of sodium sulfate of fatty alcohol polyoxyethylene ether, 1 part of fatty alcohol polyoxyethylene ether, 1 part of γ-methacryloyloxypropyltrimethoxysilane, 30 parts of hydroxyethyl acrylate, 20 parts of hydroxyethyl methacrylate, 20 parts of perfluorohexylethyl acrylate, 2 parts of ethoxylated cashew phenol sulfosuccinate half ester disodium salt, 4 parts of benzophenone, 2 parts of methyl diethanolamine, and 500 parts of deionized water. Step 2: Add 2-ethyl-2-butyl-1,3-propanediol, n-hexyltrimethoxysilane, perfluorohexylethyl acrylate, alkynyl alcohol polyether modified siloxane, sodium fatty alcohol polyoxyethylene ether sulfate, fatty alcohol polyoxyethylene ether, and γ-methacryloyloxypropyltrimethoxysilane to two-thirds of the weight of deionized water. Mix and stir at 60°C and 200 r / min for 4 hours. Nitrogen gas is introduced for protection during the mixing process. After the reaction is complete, an emulsion is obtained. Step 3: Add hydroxyethyl acrylate, hydroxyethyl methacrylate, perfluorohexyl ethyl acrylate, ethoxylated cashew phenol sulfosuccinate disodium salt, benzophenone, and methyl diethanolamine to the remaining one-third of the weight of deionized water and mix. During the mixing process, the stirring speed is 200 r / min and the mixing time is 30 min. Stir at room temperature. After the mixing is completed, the droplet solution is obtained. Step 4: Add the drop solution obtained in Step 3 to the emulsion obtained in Step 2 and mix. The drop solution is added over a period of 2 hours. The temperature during the drop addition process is 70°C, the stirring speed is 130 r / min, and nitrogen gas is introduced for protection during the drop addition process. Step 5: After mixing, irradiate with a UV lamp for 2 hours at an intensity of 1500 μW / cm². Stirring speed is 80 r / min during UV irradiation. Nitrogen gas is introduced for protection during UV irradiation. After irradiation, the outer protective layer spray emulsion is dispensed. Step 1: The rock wool layer is transported by rollers. Before transport, multiple high-pressure nozzles spray an outer protective emulsion onto the rock wool layer. Step 2: After spraying, the coating is directly placed in the heating chamber set in the middle and rear section of the transport, and initially cured at a temperature of 150-170℃ for 2-3 minutes; Step 3: The rock wool felt for the initial curing of the outer protective layer is placed in a curing oven and cured at 70-90℃ for 1.5-2 hours. After curing, it is cooled to room temperature to obtain the finished product, with an outer protective layer thickness of 2.3±0.2mm. Example

[0020] A method for producing rock wool felt includes the following steps: The preparation process of the rock wool layer is as follows: 70 parts of basalt, 20 parts of dolomite, 12 parts of wollastonite, and 15 parts of composite adhesive are weighed according to the ratio. The basalt, dolomite, and wollastonite are added to the melting furnace and heated to 1600℃ to melt into magma. The magma is then rotated at high speed through a centrifuge to form fibers. The composite adhesive is then evenly sprayed onto the surface of the rock wool fibers and collected by a cotton collector to form a preliminary blank. The preliminary blank is sent to a curing furnace and cured at 220℃ for 20 minutes. After curing, it is cut and trimmed to obtain a rock wool layer with a thickness of 50mm. The composite adhesive comprises the following components in parts by weight: 20 parts sodium silicate, 15 parts aluminum sol, 8 parts polyvinyl alcohol, 5 parts modified starch, 3 parts borax, and 40 parts deionized water. The preparation method is as follows: Sodium silicate, aluminum sol, polyvinyl alcohol, modified starch, borax, and deionized water are weighed according to the formula. Then, sodium silicate and aluminum sol are mixed and deionized water is added. The temperature is raised to 60°C and stirred at 200 r / min for 15 min. Then, polyvinyl alcohol, modified starch, and borax are added and stirred for another 20 min to obtain the composite adhesive. The preparation process of the outer protective layer includes the following steps: Step 1: Weigh out the following ingredients according to the specified ratio: 40 parts of 2-ethyl-2-butyl-1,3-propanediol, 30 parts of n-hexyltrimethoxysilane, 15 parts of perfluorohexylethyl acrylate, 10 parts of alkynyl alcohol polyether modified siloxane, 6 parts of sodium sulfate of fatty alcohol polyoxyethylene ether, 2 parts of fatty alcohol polyoxyethylene ether, 2 parts of γ-methacryloyloxypropyltrimethoxysilane, 40 parts of hydroxyethyl acrylate, 30 parts of hydroxyethyl methacrylate, 30 parts of perfluorohexylethyl acrylate, 4 parts of ethoxylated cashew phenol sulfosuccinate half ester disodium salt, 6 parts of benzophenone, 4 parts of methyl diethanolamine, and 600 parts of deionized water. Step 2: Add 2-ethyl-2-butyl-1,3-propanediol, n-hexyltrimethoxysilane, perfluorohexylethyl acrylate, alkynyl alcohol polyether modified siloxane, sodium fatty alcohol polyoxyethylene ether sulfate, fatty alcohol polyoxyethylene ether, and γ-methacryloyloxypropyltrimethoxysilane to two-thirds of the weight of deionized water. Mix and stir at 70°C and 300 r / min for 3 hours. Nitrogen gas is introduced for protection during the mixing process. After the reaction is complete, an emulsion is obtained. Step 3: Add hydroxyethyl acrylate, hydroxyethyl methacrylate, perfluorohexyl ethyl acrylate, ethoxylated cashew phenol sulfosuccinate disodium salt, benzophenone, and methyl diethanolamine to the remaining one-third of the weight of deionized water and mix. During the mixing process, the stirring speed is 300 r / min and the mixing time is 20 min. Stir at room temperature. After the mixing is completed, the droplet solution is obtained. Step 4: Add the drop solution obtained in Step 3 to the emulsion obtained in Step 2 and mix. The drop solution is added over a period of 2 hours. The temperature during the drop addition process is 70°C, the stirring speed is 130 r / min, and nitrogen gas is introduced for protection during the drop addition process. Step 5: After mixing, irradiate with a UV lamp for 1.5 hours at an intensity of 2000 μW / cm². Stirring speed is 100 r / min during irradiation. Nitrogen gas is introduced for protection during irradiation. After irradiation, the outer protective layer spray emulsion is dispensed. Step 1: The rock wool layer is transported by rollers. Before transport, multiple high-pressure nozzles spray an outer protective emulsion onto the rock wool layer. Step 2: After spraying, the coating is directly placed in the heating chamber set in the middle and rear of the transportation process, and initially cured at 170℃ for 2 minutes; Step 3: The rock wool felt for the initial curing of the outer protective layer is placed in a curing oven and cured at 90℃ for 1.5 hours. After curing, it is cooled to room temperature to obtain the finished product, with an outer protective layer thickness of 2.3±0.2mm. Example

[0021] A method for producing rock wool felt includes the following steps: The preparation process of the rock wool layer is as follows: 65 parts of basalt, 17 parts of dolomite, 10 parts of wollastonite, and 14 parts of composite adhesive are weighed according to the ratio. The basalt, dolomite, and wollastonite are added to the melting furnace and heated to 1550℃ to melt into magma. The magma is then rotated at high speed through a centrifuge to form fibers. The composite adhesive is then evenly sprayed onto the surface of the rock wool fibers and collected by a cotton collecting machine to form a preliminary blank. The preliminary blank is sent to a curing furnace and cured at 210℃ for 25 minutes. After curing, it is cut and trimmed to obtain a rock wool layer with a thickness of 50mm. The composite adhesive comprises the following components in parts by weight: 18 parts sodium silicate, 12 parts aluminum sol, 7 parts polyvinyl alcohol, 4 parts modified starch, 2.5 parts borax, and 35 parts deionized water. The preparation method is as follows: Sodium silicate, aluminum sol, polyvinyl alcohol, modified starch, borax, and deionized water are weighed according to the formula. Then, sodium silicate and aluminum sol are mixed and deionized water is added. The temperature is raised to 55°C and stirred at 180 r / min for 17 min. Then, polyvinyl alcohol, modified starch, and borax are added and stirred for another 22 min to obtain the composite adhesive. The preparation process of the outer protective layer includes the following steps: Step 1: Weigh out the following ingredients according to the specified ratio: 35 parts of 2-ethyl-2-butyl-1,3-propanediol, 25 parts of n-hexyltrimethoxysilane, 13 parts of perfluorohexylethyl acrylate, 8 parts of alkynyl alcohol polyether modified siloxane, 5 parts of sodium fatty alcohol polyoxyethylene ether sulfate, 1.5 parts of fatty alcohol polyoxyethylene ether, 1.5 parts of γ-methacryloyloxypropyltrimethoxysilane, 35 parts of hydroxyethyl acrylate, 25 parts of hydroxyethyl methacrylate, 25 parts of perfluorohexylethyl acrylate, 3 parts of ethoxylated cashew nut sulfosuccinate half ester disodium salt, 5 parts of benzophenone, 3 parts of methyl diethanolamine, and 550 parts of deionized water. Step 2: Add 2-ethyl-2-butyl-1,3-propanediol, n-hexyltrimethoxysilane, perfluorohexylethyl acrylate, alkynyl alcohol polyether modified siloxane, sodium fatty alcohol polyoxyethylene ether sulfate, fatty alcohol polyoxyethylene ether, and γ-methacryloyloxypropyltrimethoxysilane to two-thirds of the weight of deionized water. Mix and stir at 65°C and 250 r / min for 3.5 h. Nitrogen gas is introduced for protection during the mixing process. After the reaction is complete, an emulsion is obtained. Step 3: Add hydroxyethyl acrylate, hydroxyethyl methacrylate, perfluorohexyl ethyl acrylate, ethoxylated cashew phenol sulfosuccinate disodium salt, benzophenone, and methyl diethanolamine to the remaining one-third of the weight of deionized water and mix. During the mixing process, the stirring speed is 250 r / min and the mixing time is 25 min. Stirring is carried out at room temperature. After the mixing is completed, the droplet solution is obtained. Step 4: Add the drop solution obtained in Step 3 to the emulsion obtained in Step 2 and mix. The drop solution is added over a period of 2.5 hours. The temperature during the drop addition is 60°C, the stirring speed is 120 r / min, and nitrogen gas is introduced for protection during the drop addition process. Step 5: After mixing, irradiate with a UV lamp for 1.8 hours at an intensity of 1800 μW / cm². Stirring speed is 90 r / min during irradiation. Nitrogen gas is introduced for protection during irradiation. After irradiation, the outer protective layer spray emulsion is dispensed. Step 1: The rock wool layer is transported by rollers. Before transport, multiple high-pressure nozzles spray an outer protective emulsion onto the rock wool layer. Step 2: After spraying, the coating is directly placed in the heating chamber set in the middle and rear section of the transport, and initially cured at 160℃ for 2.5 minutes; Step 3: The rock wool felt for the initial curing of the outer protective layer is placed in a curing oven and cured at 80℃ for 1.8 hours. After curing, it is cooled to room temperature to obtain the finished product, with an outer protective layer thickness of 2.3±0.2mm.

[0022] Comparative Example 1 A method for producing rock wool felt includes the following steps: The preparation process of the rock wool layer is as follows: 60 parts of basalt, 15 parts of dolomite, 8 parts of wollastonite, and 12 parts of composite adhesive are weighed according to the ratio. The basalt, dolomite, and wollastonite are added to the melting furnace and heated to 1500℃ to melt into magma. The magma is then rotated at high speed through a centrifuge to form fibers. The composite adhesive is then evenly sprayed onto the surface of the rock wool fibers and collected by a cotton collecting machine to form a preliminary blank. The preliminary blank is sent to a curing furnace and cured at 200℃ for 30 minutes. After curing, it is cut and trimmed to obtain a rock wool layer with a thickness of 50mm. The composite adhesive comprises the following components in parts by weight: 15 parts sodium silicate, 10 parts aluminum sol, 5 parts polyvinyl alcohol, 3 parts modified starch, 2 parts borax, and 30 parts deionized water. The preparation method is as follows: Sodium silicate, aluminum sol, polyvinyl alcohol, modified starch, borax, and deionized water are weighed according to the formula. Then, sodium silicate and aluminum sol are mixed and deionized water is added. The temperature is raised to 50°C and stirred at 150 r / min for 20 min. Then, polyvinyl alcohol, modified starch, and borax are added and stirred for another 25 min to obtain the composite adhesive.

[0023] Comparative Example 2 A method for producing rock wool felt includes the following steps: The preparation process of the rock wool layer is as follows: 70 parts of basalt, 20 parts of dolomite, 12 parts of wollastonite, and 15 parts of composite adhesive are weighed according to the ratio. The basalt, dolomite, and wollastonite are added to the melting furnace and heated to 1600℃ to melt into magma. The magma is then rotated at high speed through a centrifuge to form fibers. The composite adhesive is then evenly sprayed onto the surface of the rock wool fibers and collected by a cotton collector to form a preliminary blank. The preliminary blank is sent to a curing furnace and cured at 220℃ for 20 minutes. After curing, it is cut and trimmed to obtain a rock wool layer with a thickness of 50mm. The composite adhesive comprises the following components in parts by weight: 20 parts sodium silicate, 15 parts aluminum sol, 8 parts polyvinyl alcohol, 5 parts modified starch, 3 parts borax, and 40 parts deionized water. The preparation method is as follows: Sodium silicate, aluminum sol, polyvinyl alcohol, modified starch, borax, and deionized water are weighed according to the formula. Then, sodium silicate and aluminum sol are mixed and deionized water is added. The temperature is raised to 60°C and stirred at 200 r / min for 15 min. Then, polyvinyl alcohol, modified starch, and borax are added and stirred for another 20 min to obtain the composite adhesive.

[0024] Comparative Example 3 A method for producing rock wool felt includes the following steps: The preparation process of the rock wool layer is as follows: 65 parts of basalt, 17 parts of dolomite, 10 parts of wollastonite, and 14 parts of composite adhesive are weighed according to the ratio. The basalt, dolomite, and wollastonite are added to the melting furnace and heated to 1550℃ to melt into magma. The magma is then rotated at high speed through a centrifuge to form fibers. The composite adhesive is then evenly sprayed onto the surface of the rock wool fibers and collected by a cotton collecting machine to form a preliminary blank. The preliminary blank is sent to a curing furnace and cured at 210℃ for 25 minutes. After curing, it is cut and trimmed to obtain a rock wool layer with a thickness of 50mm. The composite adhesive comprises the following components in parts by weight: 18 parts sodium silicate, 12 parts aluminum sol, 7 parts polyvinyl alcohol, 4 parts modified starch, 2.5 parts borax, and 35 parts deionized water. The preparation method is as follows: Sodium silicate, aluminum sol, polyvinyl alcohol, modified starch, borax, and deionized water are weighed according to the formula. Then, sodium silicate and aluminum sol are mixed and deionized water is added. The temperature is raised to 55°C and stirred at 180 r / min for 17 min. Then, polyvinyl alcohol, modified starch, and borax are added and stirred for another 22 min to obtain the composite adhesive.

[0025] The rock wool felts prepared in Examples 1-3 and Comparative Examples 1-3 were tested for their thermal insulation (expressed as thermal conductivity, with the national standard for testing being GB / T 10294-2008), flame retardancy (expressed as oxygen index, with the national standard for testing being GB / T 2406.2-2009), sound insulation (sound insulation amount recorded at a frequency of 1000Hz, with the national standard for testing being GB 50118-2010), gas barrier properties (expressed as water vapor transmission rate, with the national standard for testing being GB / T 30801-2014), waterproof properties (expressed as water absorption rate, with the national standard for testing being GB / T 25975), and resistance to ultraviolet radiation (GB / T 18244-2022, using fluorescent ultraviolet lamps for artificial climate accelerated aging, with a test time of 1000h).

[0026] Depend on Figure 1-5It can be seen that the rock wool felt prepared in Examples 1-3 of the present invention is slightly better than the rock wool felt prepared in Comparative Examples 1-3 in terms of thermal conductivity, oxygen index, and sound insulation. However, the rock wool felt prepared in Examples 1-3 of the present invention is significantly better than the rock wool felt prepared in Comparative Examples 1-3 in terms of water vapor transmission rate and water absorption rate. After aging test, the rock wool felt prepared in Examples 1-3 of the present invention does not show cracking or pulverization, while the rock wool felt prepared in Comparative Examples 1-3 all show severe cracking and pulverization on the surface, and the area of ​​cracked and pulverized areas exceeds 30% of the total surface area. Based on the above data, it can be seen that the rock wool felt prepared in the present invention can effectively improve the gas barrier, waterproof and weather resistance of rock wool felt while ensuring the thermal insulation, flame retardant and sound insulation effects of rock wool felt, thereby ensuring that rock wool felt can be used stably for a long time.

[0027] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A rock wool felt, characterized in that: Includes a rock wool layer, and an outer protective layer is provided on the outside of the rock wool layer; The rock wool layer comprises the following materials in parts by weight: 60-70 parts basalt, 15-20 parts dolomite, 8-12 parts wollastonite, and 12-15 parts composite adhesive. The outer protective layer spray emulsion comprises the following substances in parts by weight: 30-40 parts of 2-ethyl-2-butyl-1,3-propanediol, 20-30 parts of n-hexyltrimethoxysilane, 10-15 parts of perfluorohexylethyl acrylate, 6-10 parts of alkynyl alcohol polyether modified siloxane, 4-6 parts of sodium sulfate of fatty alcohol polyoxyethylene ether, 1-2 parts of fatty alcohol polyoxyethylene ether, 1-2 parts of γ-methacryloyloxypropyltrimethoxysilane, 30-40 parts of hydroxyethyl acrylate, 20-30 parts of hydroxyethyl methacrylate, 20-30 parts of perfluorohexylethyl acrylate, 2-4 parts of disodium ethoxylated cashew phenol sulfosuccinate half ester, 4-6 parts of benzophenone, 2-4 parts of methyl diethanolamine, and 500-600 parts of deionized water.

2. The rock wool felt according to claim 1, characterized in that: The thickness of the rock wool layer is 30-100mm, and the thickness of the outer protective layer is 2-4mm.

3. The rock wool felt according to claim 1, characterized in that: The composite adhesive comprises the following components in parts by weight: 15-20 parts sodium silicate, 10-15 parts aluminum sol, 5-8 parts polyvinyl alcohol, 3-5 parts modified starch, 2-3 parts borax, and 30-40 parts deionized water. The preparation method is as follows: weigh sodium silicate, aluminum sol, polyvinyl alcohol, modified starch, borax, and deionized water according to the formula. Then, mix sodium silicate and aluminum sol and add deionized water. Heat to 50-60℃ and stir at 150-200r / min for 15-20min. Then add polyvinyl alcohol, modified starch, and borax and continue stirring for 20-25min to obtain the composite adhesive.

4. The rock wool felt according to claim 1, characterized in that: The preparation process of the rock wool layer is as follows: basalt, dolomite, wollastonite and composite adhesive are weighed according to the formula. Basalt, dolomite and wollastonite are added to a melting furnace and heated to 1500-1600℃ to melt into magma. The magma is then rotated at high speed through a centrifuge to form fibers. Next, the composite adhesive is evenly sprayed onto the surface of the rock wool fibers and collected by a cotton collector to form a preliminary blank. The preliminary blank is sent to a curing furnace and cured at 200-220℃ for 20-30 minutes. After curing, it is cut and trimmed to obtain the rock wool layer.

5. The rock wool felt according to claim 1, characterized in that: The preparation process of the outer protective layer includes the following steps: Step 1: Weigh out the following ingredients according to the specified ratio: 2-ethyl-2-butyl-1,3-propanediol, n-hexyltrimethoxysilane, perfluorohexylethyl acrylate, alkynyl alcohol polyether modified siloxane, sodium fatty alcohol polyoxyethylene ether sulfate, fatty alcohol polyoxyethylene ether, γ-methacryloyloxypropyltrimethoxysilane, hydroxyethyl acrylate, hydroxyethyl methacrylate, perfluorohexylethyl acrylate, ethoxylated cashew phenol sulfosuccinate half ester disodium salt, benzophenone, methyl diethanolamine, and deionized water. Step 2: Add 2-ethyl-2-butyl-1,3-propanediol, n-hexyltrimethoxysilane, perfluorohexylethyl acrylate, alkynyl alcohol polyether modified siloxane, sodium fatty alcohol polyoxyethylene ether sulfate, fatty alcohol polyoxyethylene ether, and γ-methacryloyloxypropyltrimethoxysilane to two-thirds of the weight of deionized water and mix to obtain an emulsion. Step 3: Add hydroxyethyl acrylate, hydroxyethyl methacrylate, perfluorohexyl ethyl acrylate, ethoxylated cashew phenol sulfosuccinate disodium salt, benzophenone, and methyl diethanolamine to the remaining one-third of the weight of deionized water and mix to obtain the dropping solution. Step 4: Add the liquid obtained in Step 3 to the emulsion obtained in Step 2 and mix. Step 5: After mixing, irradiate with ultraviolet light, and after irradiation, dispense the outer protective layer spray emulsion.

6. The rock wool felt according to claim 5, characterized in that: The reaction temperature in step 2 is 60-70℃, the stirring speed is 200-300r / min, the mixing time is 3-4h, and nitrogen gas is introduced for protection during the mixing process.

7. A rock wool felt according to claim 5, characterized in that: In step 3, the stirring speed is 200-300 r / min, the mixing time is 20-30 min, and the mixing is carried out at room temperature.

8. A rock wool felt according to claim 5, characterized in that: In step 4, the drop solution obtained in step 4 is added over a period of 2-3 hours, at a temperature of 50-70°C, with a stirring speed of 100-130 r / min. Nitrogen gas is introduced for protection during the drop addition process.

9. A rock wool felt according to claim 5, characterized in that: In steps 4 and 5, the UV lamp irradiation time is 1.5-2 hours, the UV lamp irradiation intensity is 1500-2000 μW / cm², the stirring speed during UV lamp irradiation is 80-100 r / min, and nitrogen gas is introduced for protection during UV lamp irradiation.

10. A method for producing rock wool felt, characterized in that: Includes the following steps: Step 1: The rock wool layer is transported by rollers. Before transport, multiple high-pressure nozzles spray an outer protective emulsion onto the rock wool layer. Step 2: After spraying, the coating is directly placed in the heating chamber set in the middle and rear section of the transport, and initially cured at a temperature of 150-170℃ for 2-3 minutes; Step 3: The rock wool felt of the outer protective layer is initially cured and placed in a curing oven to cure at a temperature of 70-90℃ for 1.5-2 hours. After curing, it is cooled to room temperature to obtain the finished product.

Images