Fireproof rock wool board and preparation method thereof

Abstract

The invention belongs to the technical field of rock wool boards, and particularly relates to a fireproof rock wool board which comprises the following raw materials in parts by weight: 55-65 parts of basalt, 15-25 parts of slag, 8-12 parts of high silica sand, 8-12 parts of bauxite, 3-7 parts of dolomite, 3-7 parts of boric sludge, 30-40 parts of a flame retardant, 8-12 parts of a binder, 0.5-1.0 part of a silane coupling agent I and 0.5-1.0 part of a water repellent. The flame retardant comprises the following components in parts by weight: 20-28 parts of surface modified aluminum hydroxide, 4-6 parts of zinc borate and 6-8 parts of first-stage activated boron mud. The preparation method comprises the following steps: S1, preparing surface modified aluminum hydroxide and first-stage activated boric sludge, and preparing a flame retardant and a binder; s2, uniformly mixing basalt, slag, high silica sand, bauxite, dolomite and boric sludge, crushing, melting, throwing threads, and adding a binder, a silane coupling agent and a water repellent to obtain rock wool fibers; s3, uniformly introducing a flame retardant into the fiber layer of the rock wool fiber, and paving to form a plate blank; and S4, the plate blank is subjected to cold press molding and curing.

Description

Technical Field

[0001] This invention belongs to the field of rock wool board technology, and particularly relates to a fireproof rock wool board and its preparation method. Background Technology

[0002] Rock wool board is a Class A non-combustible thermal insulation material made from natural minerals such as basalt as the main raw material. After being melted at high temperature, centrifuged into fibers, and then cured with an appropriate amount of binder, it has become a high-end building safety standard. With the improvement of building safety standards, the market has put forward higher requirements for the fire resistance limit, smoke toxicity and long-term stability of rock wool board.

[0003] To improve fire resistance, existing technologies typically add aluminum hydroxide as a flame retardant to rock wool fibers. On the one hand, a large amount of aluminum hydroxide powder forms stress defect points in the rock wool fiber network, severely damaging the integrity of the three-dimensional fiber skeleton and causing a significant decrease in the tensile strength of the board perpendicular to the surface, which cannot meet the high requirements for anchor pull-out force of high-rise building exterior wall insulation. On the other hand, the flame retardant mechanism is singular and its protection against sustained high-temperature fires is insufficient. Summary of the Invention

[0004] The purpose of this invention is to provide a fireproof rock wool board and its preparation method to solve the technical problems mentioned in the background art.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A fireproof rock wool board comprises the following raw materials in parts by weight: 55-65 parts basalt, 15-25 parts slag, 8-12 parts high silica sand, 8-12 parts bauxite, 3-7 parts dolomite, 3-7 parts boron mud, 30-40 parts flame retardant, 8-12 parts binder, 0.5-1.0 parts silane coupling agent I, and 0.5-1.0 parts water repellent. The flame retardant comprises the following components in parts by weight: 20-28 parts of surface-modified aluminum hydroxide, 4-6 parts of zinc borate, and 6-8 parts of one-stage activated boron mud.

[0006] According to claim 1, the fireproof rock wool board, the adhesive comprises the following components in parts by weight: 5.6-8.4 parts of silica sol and 1.0-1.8 parts of water-based phenolic resin.

[0007] As a further improvement of the present invention, the solid content of the silica sol is 30%, and the solid content of the waterborne phenolic resin is 50%.

[0008] As a further improvement of the present invention, the preparation method of the surface-modified aluminum hydroxide includes the following steps: mixing 0.5%-1.5% by weight of aluminum hydroxide powder with silane coupling agent II and anhydrous ethanol at a mass ratio of 1:10 to aluminum hydroxide powder, stirring until completely dissolved, and preparing a modifier solution. Aluminum hydroxide powder was added to the above-mentioned modifier solution, and stirred and dried under constant temperature of 80℃ and stirring conditions of 400-600r / min.

[0009] As a further improvement of the present invention, the preparation method of the first-stage activated boron mud is as follows: calcining the boron mud at 450-500℃ for 1-2 hours, cooling it and then pulverizing it to 100-200 mesh.

[0010] As a further improvement of the present invention, the hydrophobic agent is emulsified silicone oil or octyltriethoxysilane emulsion.

[0011] The method for preparing a fire-resistant rock wool board as described above includes the following steps: S1 was used to prepare surface-modified aluminum hydroxide and one-stage activated boron mud, and to prepare flame retardants and binders; S2. Mix basalt, slag, high silica sand, bauxite, dolomite, and boron mud evenly, crush, melt, spin into fibers, add binder, silane coupling agent and water-repellent agent to obtain rock wool fiber; S3. Introduce the flame retardant evenly into the fiber layer of the rock wool fiber, lay it up, and form a slab; S4. Cold press the slab into shape and cure it.

[0012] As a further improvement of the present invention, in step S1, the step of preparing the flame retardant includes: dry mixing surface-modified aluminum hydroxide, zinc borate and first-stage activated boron mud for 10-20 minutes.

[0013] The beneficial effects of adopting the above technical solution are as follows: The flame retardant of this invention comprises surface-modified aluminum hydroxide, zinc borate, and a one-stage activated boron mud, constructing a multi-layered synergistic flame retardant mechanism to form a complementary effect rather than a single mechanism. Among them, surface-modified aluminum hydroxide is used for core heat absorption and flame retardancy, providing initial fire protection; zinc borate is used to release borate esters at high temperatures, covering the fiber surface to form a heat-insulating char layer, while inhibiting smoke generation; the one-stage activated boron mud is used to form a glassy molten layer at high temperatures, encapsulating the fiber and blocking oxygen contact, and coping with prolonged high-temperature fires.

[0014] This invention not only uses boron mud as one of the raw materials for fiber formation in high-temperature melting, allowing its B2O3 to be incorporated into the rock wool fiber body, thus optimizing the fiber's thermal stability and fire resistance; but also uses first-stage activated boron mud as a flame retardant component, compounded with aluminum hydroxide and zinc borate, to supplement flame retardant elements and reduce the amount of expensive flame retardants; thus reducing industrial solid waste emissions and lowering raw material costs.

[0015] This invention employs surface-modified aluminum hydroxide: silane coupling agent I is used to form organic long chains on its surface, which enhances the interfacial bonding force between aluminum hydroxide and rock wool fibers and binders, allowing it to be uniformly dispersed in the fiber network, avoiding local agglomeration that forms stress defects, and reducing damage to the fiber skeleton. Detailed Implementation

[0016] To better understand the purpose, structure, and function of this invention, a clear and complete description of the invention is provided.

[0017] Unless otherwise specified, all raw materials used in the following examples and comparative examples are commercially available industrial-grade products. Silane coupling agents I and II are γ-aminopropyltriethoxysilane (KH-550). The silica sol has a solid content of 30%, a nanoparticle size of 8-12 nm, and a Na2O content of ≤0.1%. The waterborne phenolic resin has a solid content of 50%, and the aluminum hydroxide has a particle size D50 ≤2 μm. Example

[0018] A fireproof rock wool board, by weight, comprises 60 parts basalt, 20 parts slag, 10 parts high silica sand, 10 parts bauxite, 5 parts dolomite, 5 parts boron mud, 0.8 parts silane coupling agent I, 0.7 parts water-repellent agent (emulsified silicone oil), 36 parts flame retardant, and 10 parts binder.

[0019] The flame retardant formulation includes 24 parts of surface-modified aluminum hydroxide, 5 parts of zinc borate, and 7 parts of one-stage activated boron mud; the binder formulation includes 7.0 parts of silica sol and 1.4 parts of water-based phenolic resin.

[0020] A method for preparing a fire-resistant rock wool board includes the following steps: S1: Prepare surface-modified aluminum hydroxide and one-stage activated boron mud to prepare flame retardants and binders; Preparation of activated boron mud in the first stage: calcined boron mud at 480℃ for 1.5 hours, cooled and then pulverized to 150 mesh for later use; Preparation of surface-modified aluminum hydroxide: Take aluminum hydroxide powder, add silane coupling agent II at 1.0% of its weight, mix with anhydrous ethanol at a mass ratio of 1:10, stir until completely dissolved to prepare a modifier solution; add aluminum hydroxide powder to the solution, stir for 60 minutes at a constant temperature of 80℃ and stirring at 500r / min, and then dry at 100℃ for 4 hours for later use; Flame retardant preparation: Dry mix the above-mentioned surface-modified aluminum hydroxide, zinc borate and first-stage activated boron mud for 15 minutes, mix evenly and set aside; Adhesive preparation: Mix silica sol and water-based phenolic resin in a certain proportion and stir for 20 minutes to form a uniform viscous liquid for later use.

[0021] S2: Basalt, slag, high silica sand, bauxite, dolomite, and boron mud are mixed evenly, crushed to a particle size ≤5mm, and fed into a furnace to melt at 1400℃. The fibers are then spun by a centrifugal spinning machine (5000r / min). A binder, silane coupling agent I, and a water-repellent agent are sprayed onto the fiber surface to obtain rock wool fibers. S3: Sprinkle the flame retardant evenly into the fiber layer of the coated rock wool fiber and lay it into a 50mm thick board. S4: Place the slab in a cold press and cold press it under a pressure of 1.0 MPa. Then send it into a curing chamber and cure it at 190°C for 6 minutes. Example

[0022] A fireproof rock wool board, by weight, comprises 65 parts basalt, 25 parts slag, 12 parts high silica sand, 12 parts bauxite, 7 parts dolomite, 7 parts boron mud, 1.0 part silane coupling agent I, 1.0 part water repellent (emulsified silicone oil), 40 parts flame retardant, and 12 parts binder. The flame retardant formulation includes 28 parts of surface-modified aluminum hydroxide, 6 parts of zinc borate, and 8 parts of one-stage activated boron mud; the binder formulation includes 8.4 parts of silica sol and 1.8 parts of water-based phenolic resin.

[0023] A method for preparing a fire-resistant rock wool board includes the following steps: S1: Prepare surface-modified aluminum hydroxide and one-stage activated boron mud to prepare flame retardants and binders; Preparation of activated boron mud in the first stage: calcined boron mud at 500℃ for 1 hour, cooled and pulverized to 200 mesh for later use; Preparation of surface-modified aluminum hydroxide: Take aluminum hydroxide powder, add silane coupling agent II at 1.5% of its weight, mix with anhydrous ethanol at a mass ratio of 1:10, stir until completely dissolved to prepare a modifier solution; add aluminum hydroxide powder to the solution, stir for 70 minutes at a constant temperature of 80℃ and stirring at 600r / min, and then dry at 110℃ for 3 hours for later use; Flame retardant preparation: Dry mix the above-mentioned surface-modified aluminum hydroxide, zinc borate and first-stage activated boron mud for 20 minutes, mix evenly and set aside; The adhesive preparation is the same as in Example 1.

[0024] S2: Mix the fiber forming raw materials evenly, crush them to a particle size ≤4mm, send them into a furnace to melt at 1420℃, and then spin them into fibers using a centrifugal spinning machine (speed 5500r / min); the subsequent spraying and laying steps are the same as in Example 1, and the slab thickness is 60mm.

[0025] S4: Place the slab in a cold press and cold press it under a pressure of 2.0 MPa. Then send it into a curing chamber and cure it at 200°C for 5 minutes. Example

[0026] A fireproof rock wool board, by weight, comprises 55 parts basalt, 15 parts slag, 8 parts high silica sand, 8 parts bauxite, 3 parts dolomite, 3 parts boron mud; 0.5 parts silane coupling agent I, 0.5 parts water-repellent agent (emulsified silicone oil); 30 parts flame retardant, and 8 parts binder.

[0027] The flame retardant formulation includes 20 parts of surface-modified aluminum hydroxide, 4 parts of zinc borate, and 6 parts of one-stage activated boron mud; the binder formulation includes 5.6 parts of silica sol and 1.0 part of water-based phenolic resin.

[0028] A method for preparing a fire-resistant rock wool board includes the following steps: S1: Prepare surface-modified aluminum hydroxide and one-stage activated boron mud to prepare flame retardants and binders; Preparation of activated boron mud in the first stage: calcined boron mud at 450℃ for 2 hours, cooled and pulverized to 100 mesh for later use; Preparation of surface-modified aluminum hydroxide: Take aluminum hydroxide powder, add silane coupling agent II at 0.5% by weight, mix with anhydrous ethanol at a mass ratio of 1:10, stir until completely dissolved to prepare a modifier solution; add aluminum hydroxide powder to the solution, stir for 50 minutes at a constant temperature of 80℃ and stirring at 400r / min, and then dry at 90℃ for 5 hours for later use; Flame retardant preparation: Dry mix the above-mentioned surface-modified aluminum hydroxide, zinc borate and first-stage activated boron mud for 10 minutes, mix evenly and set aside; The adhesive preparation is the same as in Example 1.

[0029] S2: Mix the fiber forming raw materials evenly, crush them to a particle size ≤6mm, send them into a furnace to melt at 1380℃, and then spin them into fibers using a centrifugal spinning machine (speed 4500r / min); the subsequent spraying and laying steps are the same as in Example 1, and the slab thickness is 40mm.

[0030] S4: Place the slab in a cold press and cold press it under a pressure of 0.5MPa. Then send it into a curing chamber and cure it at 180℃ for 8 minutes. Example

[0031] A fire-resistant rock wool board has the same raw material formula as in Example 1. The difference is that the boron mud in the fiber forming raw material group needs to be pre-calcined at 550°C for 30 minutes before being mixed with other raw materials.

[0032] The preparation steps are the same as in Example 1.

[0033] A fireproof rock wool board, by weight, comprises 65 parts basalt, 20 parts slag, 10 parts high silica sand, 10 parts bauxite, 5 parts dolomite (without using boron mud); 0.8 parts silane coupling agent I, 0.7 parts water-repellent agent (emulsified silicone oil), 36 parts flame retardant, and 10 parts binder.

[0034] The flame retardant formulation includes 24 parts of surface-modified aluminum hydroxide and 5 parts of zinc borate; the binder formulation includes 7.0 parts of silica sol and 1.4 parts of water-based phenolic resin.

[0035] The preparation steps are the same as in Example 1.

[0036] A fireproof rock wool board has the same raw material formula as in Example 1, except that the binder is only 8.4 parts of water-based phenolic resin and no silica sol is used.

[0037] The preparation steps are the same as in Example 1.

[0038] A fireproof rock wool board has the same raw material formula as in Example 1, except that the surface-modified aluminum hydroxide in the flame retardant is replaced with an equal amount of unmodified aluminum hydroxide.

[0039] The preparation steps are the same as in Example 1, but the preparation process of surface-modified aluminum hydroxide is not required.

[0040] Performance testing Mechanical strength test: The tensile strength of the rock wool board was determined in accordance with GB / T 25975-2018 "Rock wool products for external insulation of building walls".

[0041] Fire resistance test: GB / T 9978.1-2008 "Fire resistance test method for building components - Part 1: General requirements" determines the fire resistance of rock wool boards.

[0042] The results of the above performance tests are shown in Table 1.

[0043] Table 1. Test results of mechanical and fire-resistant properties of rock wool boards Group Fire resistance limit (min) Tensile strength (kPa) Example 1 150 20.5 Example 2 165 23.8 Example 3 125 16.2 Example 4 158 22.3 Comparative Example 1 95 12.8 Comparative Example 2 100 11.5 Comparative Example 3 105 13.5 As shown in Table 1, the fireproof rock wool boards prepared in Examples 1-4 of the present invention have superior mechanical and fire-resistant properties compared with the comparative examples. The tensile strength can reach more than 16.2 kPa, and the preferred embodiment can reach more than 20 kPa. The fire resistance limit is more than 120 minutes, and the preferred embodiment can reach more than 150 minutes.

[0044] Compared to Example 1, Comparative Example 1 did not add boron mud and first-stage activated boron mud to the flame retardant when preparing the rock wool board, Comparative Example 2 did not use silica sol in the binder when preparing the rock wool board, and Comparative Example 3 used unmodified aluminum hydroxide when preparing the flame retardant. The mechanical properties and fire resistance of Comparative Examples 1-3 all decreased significantly.

[0045] This invention adds a flame retardant composed of surface-modified aluminum hydroxide, zinc borate, and one-stage activated boron mud to rock wool boards. By utilizing the synergistic relay flame retardant mechanism of surface-modified aluminum hydroxide core heat absorption, zinc borate high-temperature charring and smoke suppression, and one-stage activated boron mud high-temperature glass formation and oxygen inhibition, the fire resistance limit of rock wool boards is effectively improved, overcoming the shortcomings of single flame retardant components with limited mechanism and insufficient protection against sustained high-temperature fires.

[0046] This invention uses silica sol and water-based phenolic resin as binders, and significantly improves the interfacial bonding force between the flame retardant, rock wool fibers, and binder by surface modification of aluminum hydroxide. The introduction of silica sol enhances the inorganic bonding network and works synergistically with the water-based phenolic resin. While reducing the organic content of the product, it effectively alleviates the cutting effect of high-filler flame retardant on the fiber skeleton, thus ensuring and improving the tensile strength of the rock wool board while achieving high flame retardancy.

[0047] It is understood that the present invention has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of the invention. Furthermore, under the teachings of the present invention, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of the invention. Therefore, the present invention is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of the present invention.

Claims

1. A fire-resistant rock wool board, characterized in that: It comprises the following raw materials in parts by weight: 55-65 parts basalt, 15-25 parts slag, 8-12 parts high silica sand, 8-12 parts bauxite, 3-7 parts dolomite, 3-7 parts boron mud, 30-40 parts flame retardant, 8-12 parts binder, 0.5-1.0 parts silane coupling agent I, and 0.5-1.0 parts water repellent. The flame retardant comprises the following components in parts by weight: 20-28 parts of surface-modified aluminum hydroxide, 4-6 parts of zinc borate, and 6-8 parts of one-stage activated boron mud.

2. The fireproof rock wool board according to claim 1, characterized in that: The adhesive comprises the following components in parts by weight: 5.6-8.4 parts silica sol and 1.0-1.8 parts waterborne phenolic resin.

3. The fireproof rock wool board according to claim 2, characterized in that: The silica sol has a solid content of 30%, and the waterborne phenolic resin has a solid content of 50%.

4. The fireproof rock wool board according to claim 1, characterized in that: The preparation method of the surface-modified aluminum hydroxide includes the following steps: 0.5%-1.5% by weight of aluminum hydroxide powder, silane coupling agent II, and anhydrous ethanol at a mass ratio of 1:10 with aluminum hydroxide powder are mixed evenly and stirred until completely dissolved to prepare a modifier solution. Aluminum hydroxide powder was added to the above-mentioned modifier solution, and stirred and dried under constant temperature of 80℃ and stirring conditions of 400-600r / min.

5. A fireproof rock wool board according to claim 1, characterized in that: The preparation method of the first-stage activated boron mud is as follows: calcining the boron mud at 450-500℃ for 1-2 hours, cooling it, and then pulverizing it to 100-200 mesh.

6. A fireproof rock wool board according to claim 1, characterized in that: The hydrophobic agent is emulsified silicone oil or octyltriethoxysilane emulsion.

7. A method for preparing a fire-resistant rock wool board according to any one of claims 1-6, characterized in that, It includes the following steps: S1 was used to prepare surface-modified aluminum hydroxide and one-stage activated boron mud, and to prepare flame retardants and binders; S2. Mix basalt, slag, high silica sand, bauxite, dolomite, and boron mud evenly, crush, melt, spin into fibers, add binder, silane coupling agent and water-repellent agent to obtain rock wool fiber; S3. Introduce the flame retardant evenly into the fiber layer of the rock wool fiber, lay it up, and form a slab; S4. Cold press the slab into shape and cure it.

8. The method for preparing a fire-resistant rock wool board according to claim 7, characterized in that, In step S1, the flame retardant preparation step includes: dry mixing surface-modified aluminum hydroxide, zinc borate, and first-stage activated boron mud for 10-20 minutes.