RU2648096C1 - Thermal and sound insulation material and method of its production - Google Patents

Abstract

FIELD: chemistry.

SUBSTANCE: thermal and sound insulation material is based on mineral fibres and a two-component polymer bond to bind mineral fibres, one component of which includes an aqueous solution of polyvinyl alcohol, and the second component is an aqueous solution of boric acid or its inorganic salts with the addition of an aqueous sodium silicate solution, the polymerisation of which occurs when the components are mixed at room temperature of 5°C to 50°C. The method of producing the material is carried out by simultaneous spraying onto the insulated surface of a mineral fibre and a two-component polymer binder followed by drying.

EFFECT: producing a much thinner, in comparison with analogues, layer of heat and sound insulation formed on the insulated surface without loss of quality of the insulating properties of such material and without sliding or detachment from the surface, to which it is applied.

3 cl

Description

Technical field

The invention relates to the field of inorganic chemistry and can find application for the manufacture of heat and sound insulating material, which is applied to the prepared surface, requiring insulating.

State of the art

From published application RU 2014117555 A, 10.11.2015, C08L 29/04, heat and sound insulating material containing mineral fibers with a diameter of from 0.5 to 10.0 μm, a binder obtained by curing an aqueous composition containing polyvinyl alcohol, modified starch is known a crosslinking agent, a catalyst, a silane, an oil deduster, a water repellent, and nano- or microparticles, the heat and sound insulating material containing these components in the following ratio, wt. %:

mineral fibers 92.0 to 98.0 binder from 0.61 to 7.00, including polyvinyl alcohol from 0.72 to 4.00 modified starch from 0.01 to 3.00 silane from 0.01 to 0.20 water-repellent emulsion from 0.10 to 1.40 dust collector from 0.10 to 1.00 nano or microparticles from 0.01 to 1.00

as well as a method for producing this material, which consists in applying a composition to a mineral fiber, including polyvinyl alcohol, modified starch, a crosslinking agent, a catalyst, a silane, an oil dedusting agent, a water repellent, and nano- or microparticles selected from the group consisting of graphite, fullerenes, carbon nanotubes , clays, particles of metals and their alloys, carbides and oxides, microparticles (microspheres) of silicon dioxide or any combination of the above objects, or any combination thereof, on a mineral fiber with the last by curing at a temperature of 210-240 ° C and obtaining a hard thermosetting polymer.

From the patent RU 2509064 C1, 03/10/2014, C08L 33/26, C08K 3/38, a heat and sound insulating polymer composite material is known, including a fibrous filler — cardboard and / or paper waste and a binder — a cationic anionic polyacrylamide resin of the brand Ultrares DS -150 ", and it additionally contains 15 wt. % aqueous solution of polyvinyl alcohol and sodium tetraborate in the following ratio of components, wt. %:

Fibrous filler - cardboard and / or paper waste 11.0-12.0 Cationic Anionic Polyacrylamide resin of the brand "Ultrez DS-150" 56.0-57.0 Polyvinyl alcohol, 15 wt. % water solution 27.0-28.0 Sodium tetraborate 6.0-3.0

as well as a method of producing this material, including fiberizing the filler, mixing the components, forming a plate and drying, characterized in that the stage of fiberizing is carried out on a rotary disperser with a rotor speed of 2500-3000 rpm ^-1 , while polyvinyl alcohol is introduced at the stage mixing in the form of 15 wt. % aqueous solution together with cationic anionic polyacrylamide resin brand "Ultrares DS-150" and sodium tetraborate.

The technical problem to which the present invention is directed is to improve the quality of heat and sound insulation while simplifying the technology for its production.

Disclosure of invention

The problem, according to the first object of the present invention, is solved due to the fact that the heat and sound insulating material is made on the basis of mineral fibers and a two-component polymer binder for bonding mineral fibers, one component of which includes an aqueous solution of polyvinyl alcohol, and the second component is an aqueous solution of boric acid or its inorganic salts with the addition of an aqueous solution of sodium silicate, the polymerization of which occurs when the components are mixed at room temperature I am from 5 ° C to 50 ° C.

The posed problem, according to the second object of the present invention, is solved due to the fact that in the method for producing heat and sound insulating material according to claim 1, a mineral fiber and a two-component polymer binder are simultaneously sprayed onto the insulated surface, followed by drying at a temperature from 5 ° C to 50 ° C.

In a particular embodiment, drying devices are additionally used using heated air or infrared heating.

The technical result achieved by the claimed group of the invention is to obtain a much thinner, in comparison with analogues, layer of heat and sound insulation formed on the insulated surface without loss of quality of the insulating properties of such material and without sliding or tearing off the surface on which it is applied.

The implementation of the invention

Various particular embodiments of the claimed invention will be described below that do not limit or exhaust other possible embodiments arising from the present invention.

In the current practice of manufacturing and using heat and sound insulating materials, the technology is most often used in which the material itself is made separately in the form of mats, which are then fixed in various ways (by gluing with fasteners) to the surface (walls, floor, ceiling, etc.) .), which is required to be isolated, which, in turn, can lead to the formation of various defects with such fixing. Moreover, often the thickness of such insulation is relatively large, which is a critical point.

The claimed solution allows to eliminate these shortcomings, the essence of which is that the heat and sound insulation material itself can be made directly on the spot and applied to the insulated surface by spraying, which ensures good continuity and uniformity of the coating, and you can also vary the thickness of the applied coating in depending on the purpose and conditions of use of this surface.

In fact, this is a type of shotcrete, but with the mixing of three components: an aqueous solution of polyvinyl alcohol, an aqueous solution of boric acid or its inorganic salts with the addition of an aqueous solution of sodium silicate.

The chemistry of the formation of heat and sound insulating material consists in bonding the fibers of a two-component adhesive composition of their water-soluble, cured inorganic component. To increase the adhesive ability, the adhesive composition consists of two water-based components, which, when mixed, thicken (gel), increasing the viscosity of the adhesive composition by a factor of ten.

Due to this, a much thinner layer of thermal insulation can be applied without sliding or tearing off the material substrate.

The adhesive consists of two components - an aqueous solution of polyvinyl alcohol (PVA), a well-known and widely used polymer, and a solution of boric acid (H ₃ BO ₃ ) or its inorganic salts, in particular sodium tetraborate (Na ₂ B ₄ O ₇ ) (borax ) When mixed, sodium tetraborate interacts with PVA molecules, stitching them together, which leads to the formation of a continuous polymer network and the formation of a viscous solution.

In other particular embodiments, inorganic salts selected from the series are used: sodium metaborate (NaBO ₂ ), sodium pentaborate (NaB ₅ O ₈ ).

Due to the presence of tetraborate in the adhesive, which acts as a binder between the fibers, it has bactericidal and fungicidal properties, and when heated to high temperatures, PVA burns out and sodium tetraborate fuses the fibers together.

As an additive, a 64% aqueous solution of sodium silicate (water glass) and mineral fibers, such as basalt, are used. In other particular cases, either fiberglass, or asbestos, or carbon fiber is used as mineral fibers.

The method is implemented due to the simultaneous application of the specified composition by spraying on an insulated wall at room temperature (20 ° C). In special cases, the temperature range can be from at least 5 ° C to 50 ° C.

This range is due to tests that showed that at temperatures below 5 ° C the polymerization conditions worsen and the quality of the material obtained sharply decreases, and at temperatures above 50 ° C the applied composition starts to “leak” when applied to an insulated surface.

To accelerate the drying process of the applied mixture, various directional devices using heated air (heat guns, fan heaters) or infrared convectors are used that uniformly ensure drying of the entire insulated surface coated with it.

The total content of the components (calculated on dry matter), wt. %:

Mineral fiber (glass, quartz, basalt, kaolin, aluminosilicate) 86.0-98.8 Polyvinyl alcohol 1.0-5.0 Sodium tetraborate 0.1-1.0 Sodium silicate soluble (silicate module 1 ... 4) 0.1-8.0

Polyvinyl alcohol is introduced in the form of a 1.0-15% aqueous solution.

Sodium tetraborate and sodium silicate are introduced in the form of a mixed aqueous solution with a concentration of 0.5-10% and 0.5-25%, respectively.

If you do not limit the concentration of solutions, indicate that "solutions with a concentration that provides the optimal application mode for a given composition of the main components."

Example 1

The material was prepared by co-spraying basalt fiber flakes, an aqueous polymer solution (polyvinyl alcohol) and a mixed aqueous solution of sodium tetraborate and sodium silicate on a substrate, followed by drying of the coating to a moisture content of 2-3%:

Basalt fiber 98.8% Polyvinyl alcohol 1,0% Sodium tetraborate 0.1% Sodium Silicate M 3.0 0.1%

The coating density after drying is 120 kg / m ³ , adhesion and coating strength are insufficient. A decrease in the proportion of polyvinyl alcohol below 1.0% is impractical, since it leads to a further decrease in the adhesion of the material to the substrate.

Example 2

The material was prepared by co-spraying basalt fiber flakes, an aqueous polymer solution (polyvinyl alcohol) and a mixed aqueous solution of sodium tetraborate and sodium silicate on a substrate, followed by drying of the coating to a moisture content of 2-3%:

Basalt fiber 90.9% Polyvinyl alcohol 1,0% Sodium tetraborate 0.1% Sodium Silicate M 3.0 8.0%

The density of the coating after drying is 140 kg / m ³ , the adhesion and strength of the coating are high, the slowed down drying rate of the coating due to the increased content of sodium silicate, which makes the increase in the proportion of sodium silicate over 8.0% impractical.

Example 3

The material was prepared by co-spraying basalt fiber flakes, an aqueous polymer solution (polyvinyl alcohol) and a mixed aqueous solution of sodium tetraborate and sodium silicate on a substrate, followed by drying of the coating to a moisture content of 2-3%:

Basalt fiber 93.9% Polyvinyl alcohol 5.0% Sodium tetraborate 1,0% Sodium Silicate M 3.0 0.1%

The coating density after drying is 120 kg / m ³ , the adhesion and coating strength are high, the drying speed is reduced, due to the high content of water-soluble polymer binder, which makes a further increase in the proportion of polyvinyl alcohol above 5% and sodium tetraborate above 1.0% impractical.

Example 4

The material was prepared by co-spraying basalt fiber flakes, an aqueous polymer solution (polyvinyl alcohol) and a mixed aqueous solution of sodium tetraborate and sodium silicate on a substrate, followed by drying of the coating to a moisture content of 2-3%:

Basalt fiber 86.0% Polyvinyl alcohol 5.0% Sodium tetraborate 1,0% Sodium Silicate M 3.0 8.0%

The coating density after drying is 150 kg / m ³ , the adhesion and coating strength are high, a further increase in the content of the main components of the binder significantly increases the drying time of the material and requires the use of artificial drying, which reduces productivity and complicates the technology.

Example 5

The material was prepared by co-spraying basalt fiber flakes, an aqueous polymer solution (polyvinyl alcohol) and a mixed aqueous solution of sodium tetraborate and sodium silicate on a substrate, followed by drying of the coating to a moisture content of 2-3%:

Basalt fiber 96.5% Polyvinyl alcohol 2.0% Sodium tetraborate 0.5% Sodium Silicate M 3.0 1,0%

The coating density after drying is 120 kg / m ³ , the adhesion and coating strength are high, the drying speed is high, the composition optimally meets the technological and operational requirements.

Example 6

The material was prepared by co-spraying on a substrate flakes of glass superthin (1-2 microns) fiber, an aqueous solution of polymer (polyvinyl alcohol) and a mixed aqueous solution of sodium tetraborate and sodium silicate, followed by drying of the coating to a moisture content of 2-3%:

Glass superthin fiber 96.5% Polyvinyl alcohol 2.0% Sodium tetraborate 0.5% Sodium Silicate M 3.0 1,0%

The coating density after drying is 60 kg / m ³ , the adhesion and strength of the coating are high, the drying speed is high, the composition optimally meets the technological and operational requirements, surpassing compositions based on basalt fiber in heat-shielding properties, but inferior in maximum application temperatures.

Example 7

The material was prepared by co-spraying quartz fiber flakes on a substrate (fiber diameter of 1-3 microns), an aqueous polymer solution (polyvinyl alcohol) and a mixed aqueous solution of sodium tetraborate and sodium silicate, followed by drying of the coating to a moisture content of 2-3%:

Quartz fiber 96.5% Polyvinyl alcohol 2.0% Sodium tetraborate 0.5% Sodium Silicate M 3.0 1,0%

The density of the coating after drying is 70 kg / m ³ , the adhesion and strength of the coating are high, the drying speed is high, the composition optimally meets the technological and operational requirements, surpassing compositions based on basalt fiber in heat-shielding properties and maximum application temperatures, but significantly exceeding in cost due to the high cost silica fiber.

Example 8

The material was prepared by co-spraying flakes of aluminosilicate (kaolin) fiber, an aqueous polymer solution (polyvinyl alcohol) and a mixed aqueous solution of sodium tetraborate and sodium silicate on a substrate, followed by drying of the coating to a moisture content of 2-3%:

Aluminosilicate (kaolin) fiber 96.5% Polyvinyl alcohol 2.0% Sodium tetraborate 0.5% Sodium Silicate M 3.0 1,0%

The coating density after drying is 180 kg / m ³ , the adhesion and strength of the coating are high, the drying speed is high, the composition optimally meets the technological and operational requirements, inferior to the compositions based on basalt, glass and quartz fiber in terms of heat-shielding properties, but significantly exceeds the maximum application temperatures (up to 1250 ° C).

Claims (3)

1. Heat and sound insulating material, characterized in that it is made on the basis of mineral fibers and a two-component polymer bond to bind mineral fibers, one component of which includes an aqueous solution of polyvinyl alcohol, and the second component is an aqueous solution of boric acid or its inorganic salts with the addition of aqueous sodium silicate solution, the polymerization of which occurs when the components are mixed at room temperature from 5 ° C to 50 ° C. 2. The method of producing heat and sound insulating material according to claim 1, characterized in that they simultaneously spray mineral fiber and a two-component polymer binder onto the insulated surface, followed by drying at a room temperature of 5 ° C to 50 ° C. 3. The method according to p. 1, characterized in that it additionally use drying devices using heated air or infrared heating.