Novel fiber concrete polyurethane fabricated thermal insulation wallboard and manufacturing method thereof

Abstract

A novel fiber concrete polyurethane fabricated thermal insulation wallboard relates to a building wall material and comprises an outer layer A, an inner core and an outer layer B. The inner core is located between the outer layer A and the outer layer B. The outer layer A is provided with an embedded convex block, and the outer layer B is internally provided with an embedded groove. The thermal insulation performance is achieved, polyurethane is adopted as a core thermal insulation material, and the thermal conductivity is low. The heat conductivity coefficient of the aerogel heat insulation felt is extremely low, and the normal-temperature heat conductivity coefficient is about 0.017 W / (Km) and is 3-5 times that of a traditional material; the heat conductivity coefficient of the novel polyurethane insulation board is also very low, and when the density of the hard polyurethane is 35-40 kg / m, the heat conductivity coefficient is only 0.018-0.024 w / (m.k).

Description

Technical Field The invention relates to building wall materials, in particular to a novel fiber concrete polyurethane assembled thermal insulation wallboard and a manufacturing method thereof. Background Art With the increasing global attention to energy efficiency and environmental protection, the construction field pays more and more attention to improving the thermal insulation performance of buildings and reducing energy consumption during the construction process. Although traditional building insulation materials such as polystyrene (EPS) and extruded polystyrene (XPS) have certain thermal insulation effects, they are flammable and have poor durability. The application of these materials limits the performance improvement of building insulation materials, and at the same time cannot meet the high standards of modern buildings for safety and environmental protection. In addition, the installation process of traditional insulation materials is cumbersome, which prolongs the construction period and increases the construction cost. In order to solve these problems, a new thermal insulation wall panel technology has emerged. This technology combines advanced fiber reinforced concrete (FRC) technology with high-efficiency thermal insulation material polyurethane (PU) to design an assembled thermal insulation wall panel with excellent thermal insulation performance and structural stability. Fiber reinforced concrete, as the base material of the wall panel, provides excellent structural strength and durability, while the embedded polyurethane layer gives the wall panel efficient thermal insulation performance. Through this material combination, not only the shortcomings of flammability and poor durability of traditional thermal insulation materials are overcome, but also a perfect balance between thermal insulation performance and structural strength is achieved. In addition, the new type of insulation wall panels with prefabricated design significantly improves construction efficiency. The prefabricated production of wall panels can be completed in the factory, and the on-site installation is quick and easy, which greatly shortens the construction period and reduces construction costs. This prefabricated design also helps to reduce the generation of waste at the construction site, which is in line with the concept of green building and sustainable development. In view of this, the present invention designs a new type of prefabricated insulation wall panel technology that combines fiber concrete and polyurethane insulation materials, aiming to achieve the best balance between the insulation performance and stability of the wall panels, while improving the construction progress and reducing manufacturing costs. Through in-depth research on material properties and innovative design, the present invention provides a building exterior wall insulation solution with high cost performance, high efficiency, easy installation and environmental protection, promoting the development of the construction field.

[0003] Traditional insulation layers have the following disadvantages: 1. Organic insulation materials such as expanded polystyrene (EPS) and extruded polystyrene (XPS) have good insulation effects, with EPS thermal conductivity of 0.037-0.041 and XPS thermal conductivity of 0.028-0.03. However, inorganic insulation materials such as rock wool and vitrified microspheres have relatively poor insulation effects, such as rock wool boards with thermal conductivity of 0.041-0.045 and vitrified microspheres with thermal conductivity of 0.07-0.09. 2. Except for a few inorganic insulation materials such as rock wool, most traditional insulation materials have poor fire resistance. For example, organic insulation materials such as EPS and XPS generally have a fire resistance rating of B2. Level, easy to burn, spread, and may produce toxic gases when a fire occurs; 3. Some traditional insulation materials have poor durability, such as rubber and plastic cotton, which has poor aging resistance and a relatively short service life; rock wool is easily affected by external environment such as humidity and temperature, and is easy to absorb water and deform in a humid environment, and may melt and produce toxic gases in a high temperature environment; 4. The construction of some traditional insulation materials is relatively cumbersome, such as the rock wool board is easy to produce fiber dust during the construction process, which affects the health of construction workers and has poor integrity; rubber powder EPS particle insulation slurry has high construction requirements; 5. Some traditional insulation materials have a certain impact on the environment during production and use, such as EPS, XPS, etc., which may produce greenhouse gases during the production process, and are not easy to degrade after being discarded, and the recycling cost is high; 6. Some traditional insulation materials such as EPS are relatively cheap and have low initial investment costs, but due to their limitations in insulation performance and durability, they may lead to high maintenance costs in the later stage, and the comprehensive cost is not necessarily low. In order to solve the above technical problems, a new technical solution is proposed. Summary of the invention The purpose of the present invention is to overcome the shortcomings of the above-mentioned prior art and to provide a new fiber concrete polyurethane assembled insulation wall panel and a method for making the same, which has significant improvements in insulation performance, fire resistance, durability, construction portability, environmental protection and economy.

[0005] The technical solution adopted by the present invention is: a new type of fiber concrete polyurethane assembled insulation wall panel, which includes an outer layer A, an inner core and an outer layer B. The inner core is located between the outer layer A and the outer layer B. The outer layer A is provided with an embedded protrusion, and the outer layer B is provided with an embedded groove.

[0006] As a preferred technical solution, both the outer layer A and the outer layer B are pre-prepared fiber concrete panels, and the thickness of the outer layer A and the outer layer B is 30 mm.

[0007] As a preferred technical solution, the inner core is a polyurethane insulation layer, and the inner core is between the outer layer A and the outer layer B, with an injection thickness of 100 mm.

[0008] As a preferred technical solution, the main components of the inner core are isocyanate, polyol, catalyst and foaming agent, and the proportion of each component is 30%-50% of isocyanate, 30%-60% of polyol, 0.5%-3% of catalyst and 5%-15% of foaming agent.

[0009] A method for preparing a novel fiber concrete polyurethane assembled thermal insulation wall panel, the method comprising the following steps: Step 1, prefabricating a fiber concrete layer; Step 2: Connection node reservation; Step 3: injecting polyurethane protective layer; Step 4: Maintenance and molding.

[0010] As a preferred technical solution, the prefabricated fiber concrete layer is pre-prepared with two layers of fiber concrete panels in a factory environment, which respectively constitute the inner and outer layers of the insulation wall panels. The thickness of the outer fiber concrete layer is 30 mm to provide sufficient strength and durability to protect the internal insulation material from the external environment; the thickness of the inner fiber concrete layer is 10 mm to further enhance the stability of the overall structure.

[0011] As a preferred technical solution, the connection nodes are reserved, and in the prefabrication process of the fiber concrete, nodes connected to the polyurethane material are especially reserved, and the design of these nodes is intended to enhance the interface bonding performance between the fiber concrete layer and the polyurethane insulation layer.

[0012] As a preferred technical solution, the polyurethane protective layer is injected between the inner and outer layers of the fiber concrete through a specific process to inject a 100mm thick polyurethane insulation material. The polyurethane material, with its excellent thermal insulation performance and low thermal conductivity, provides an effective energy protection layer for the building, greatly improving the energy efficiency of the building.

[0013] As a preferred technical solution, the curing and molding, after the polyurethane is injected, the entire structure enters the curing stage to ensure the perfect combination and solidification between the materials. After the curing is completed, a new type of fiber concrete-polyurethane assembled insulation wall panel is formed, which integrates high-efficiency insulation, good structural strength and quick installation.

[0014] The beneficial effects of the present invention are as follows: 1. Thermal insulation performance: polyurethane is used as the core thermal insulation material, which has a low thermal conductivity and significantly improves the thermal insulation performance of the wall. The thermal conductivity of aerogel insulation felt is extremely low, and the thermal conductivity at room temperature is about 0.017W / (K·m), which is 3-5 times that of traditional materials; the thermal conductivity of the new polyurethane insulation board is also very low. When the density of rigid polyurethane is 35-40kg / m³, the thermal conductivity is only 0.018-0.024w / (m·k); 2. Fireproof performance: inorganic thermal insulation materials such as silicate insulation board and aerogel insulation felt have good fire resistance and belong to Class A Grade non-combustible material; after adding flame retardant, the new polyurethane insulation board is a flame-retardant self-extinguishing material. When burning, carbon deposits will form on its foam surface, which can effectively prevent the spread of flames and does not produce harmful gases; 3. Durability: silicate insulation boards, aerogel insulation felts, etc. have a long service life and good anti-aging and anti-corrosion properties; the average life of the rigid foam polyurethane insulation structure of the new polyurethane insulation board can reach more than 30 years under normal use and maintenance conditions. The introduction of the concrete layer not only improves the physical strength of the wall panel, but also enhances the adhesion with the polyurethane layer by reserving connection nodes, ensuring the long-term stability of the product; 4. Portable construction performance: the assembled design makes the installation of wall panels on site faster and more convenient, effectively shortening the construction period and reducing construction costs. XPS Extruded board has good plasticity and can be cut and installed according to actual needs; materials such as aerogel insulation felt are light in weight, easy to carry and install, and have a smooth surface and high aesthetics; 5. Environmental protection. The production and application of the wallboard is conducive to reducing energy consumption, which meets the current high standards of environmental protection and energy conservation in the construction industry. Graphene insulation materials, aerogel insulation materials, etc. do not contain harmful substances and do not pollute the environment; there is no exhaust gas or wastewater discharge during the production process of silicate insulation board, which is in line with the concept of green building; 6. Economical. The wallboard uses fiber concrete as the inner and outer layers, giving full play to the high ductility of fiber concrete materials, reducing the cross-sectional size, and reducing the deadweight of the wall. However, due to its excellent performance, it can reduce the heating and cooling costs of buildings during use. In the long run, the comprehensive cost performance is high, and some new insulation materials such as aerogel insulation felt are more expensive, but due to their efficient thermal insulation performance, the thickness of the insulation layer can be reduced, thereby saving building space and cost to a certain extent. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic diagram of the structure of the present invention; DETAILED DESCRIPTION The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention; A novel fiber concrete polyurethane assembled thermal insulation wall panel comprises an outer layer A1, an inner core 3 and an outer layer B4. The inner core 3 is located between the outer layer A1 and the outer layer B4. An embedded protrusion 2 is provided on the outer layer A1, and an embedded groove 5 is provided inside the outer layer B4.

[0016] As a preferred technical solution, the outer layer A1 and the outer layer B4 are both pre-prepared fiber concrete panels, and the thickness of the outer layer A1 and the outer layer B4 is 30 mm.

[0017] As a preferred technical solution, the inner core 3 is a polyurethane insulation layer, and the inner core 3 is between the outer layer A1 and the outer layer B4, with an injection thickness of 100 mm.

[0018] As a preferred technical solution, the main components of the inner core 3 are isocyanate, polyol, catalyst and foaming agent, and the proportion of each component is 30%-50% of isocyanate, 30%-60% of polyol, 0.5%-3% of catalyst and 5%-15% of foaming agent.

[0019] A method for preparing a novel fiber concrete polyurethane assembled thermal insulation wall panel, the method comprising the following steps: Step 1, prefabricating a fiber concrete layer; Step 2: Connection node reservation; Step 3: injecting polyurethane protective layer; Step 4: Maintenance and molding.

[0020] As a preferred technical solution, the prefabricated fiber concrete layer is pre-prepared with two layers of fiber concrete panels in a factory environment, which respectively constitute the inner and outer layers of the insulation wall panels. The thickness of the outer fiber concrete layer is 30 mm to provide sufficient strength and durability to protect the internal insulation material from the external environment; the thickness of the inner fiber concrete layer is 10 mm to further enhance the stability of the overall structure.

[0021] As a preferred technical solution, the connection nodes are reserved, and in the prefabrication process of the fiber concrete, nodes connected to the polyurethane material are especially reserved, and the design of these nodes is intended to enhance the interface bonding performance between the fiber concrete layer and the polyurethane insulation layer.

[0022] As a preferred technical solution, the polyurethane protective layer is injected between the inner and outer layers of the fiber concrete through a specific process to inject a 100mm thick polyurethane insulation material. The polyurethane material, with its excellent thermal insulation performance and low thermal conductivity, provides an effective energy protection layer for the building, greatly improving the energy efficiency of the building.

[0023] As a preferred technical solution, the curing and molding, after the polyurethane is injected, the entire structure enters the curing stage to ensure the perfect combination and curing between the materials. After the curing is completed, a new type of fiber concrete-polyurethane assembled insulation wall panel is formed, which integrates high-efficiency insulation, good structural strength and fast installation; All pre-prepared fiber concrete panels are 30mm thick. Fiber concrete has excellent structural strength and durability, and can effectively resist the erosion of internal insulation materials by external environmental factors (such as wind, sun, rain, etc.), play a protective role, and also provide reliable mechanical support for the entire wall panel to ensure its stability during installation and use; it is composed of a polyurethane insulation layer, located between the outer layer A1 and the outer layer B4, with an injection thickness of 100mm. The main components of the polyurethane insulation layer include isocyanate (30% - 50%), polyol (30% - 60%), catalyst (0.5% - 3%) and foaming agent (5% - 15%). These components, through reasonable proportions and chemical reactions, form a polyurethane material with excellent thermal insulation performance, which can effectively prevent heat transfer and improve the energy efficiency of the building; the outer layer A1 is provided with an embedded protrusion 2, and the outer layer B4 is provided with an embedded groove 5 inside. This design helps to achieve better splicing and positioning during the installation of the wall panels, improves the accuracy and convenience of assembly, and also enhances the tightness of the connection between the wall panels to a certain extent; In actual use, when there is a temperature difference between the inside and outside of a building, heat will naturally transfer from the high-temperature side to the low-temperature side. For this thermal insulation wall panel, the outer fiber concrete layer first serves as the first line of defense. With its own structural strength and low permeability, it resists the physical damage of the wall panel to the external environment and the conduction of some heat. The polyurethane insulation layer in the middle is the core insulation barrier. Due to its special chemical structure and low thermal conductivity, it can greatly slow down the speed of heat transfer through the wall panel, making it difficult for the heat inside the building to dissipate in winter and difficult for the external heat to enter in summer, thereby maintaining a relatively stable and comfortable temperature environment inside the building. At the same time, the connection design between the wall panels, such as embedded bumps and embedded grooves, and the good bonding performance between the layers, ensure the integrity and sealing of the entire insulation system, further improve the insulation effect, achieve the synergy of efficient insulation and structural stability, and provide strong guarantees for building energy conservation.

[0024] The specific experimental data are as follows: Thermal insulation performance test data: Under standard test conditions (indoor temperature 25℃, outdoor temperature -10℃), after 8 hours of testing, the heat loss of ordinary brick walls reached 1500kJ / m², while the heat loss of the new wall panels was only 300kJ / m², and the thermal insulation effect was improved by 80%; measured by the heat flow meter method, the average heat transfer coefficient of the new wall panels was 0.2W / (m²・K), which was 55.6% lower than the 0.45W / (m²・K) of traditional EPS insulation wall panels, showing excellent thermal insulation performance; Mechanical performance test data: The new wall panels were tested for compressive strength. When the applied pressure reached 1000kN / m², the wall panels showed no obvious cracks or deformation. Under the same conditions, ordinary aerated concrete wall panels cracked at 600kN / m², indicating that the compressive strength of the new wall panels increased by about 67%. In the bending strength test, the bending load of the new wall panels reached 3500N・m, while the bending load of ordinary fiber cement boards was 2000N・m. The bending performance of the new wall panels increased by 75%, and they can better withstand external loads. Fire performance data: Fire tests were conducted in accordance with national standards. After 120 minutes of open flame burning, the average temperature of the back-fire surface of the new wallboard did not rise more than 140°C, no through cracks occurred, and no flames penetrated, meeting the Class A fire protection standard. In contrast, the traditional XPS insulation board showed obvious flame penetration and dripping after 30 minutes of burning, and the temperature of the back-fire surface rose sharply; Durability test data: After 50 freeze-thaw cycle tests, the mass loss rate of the new wallboard was only 0.5%, and the strength retention rate reached more than 95%. Under the same conditions, the mass loss rate of the traditional rock wool insulation board reached 3%, and the strength retention rate dropped to 80%, showing that the new wallboard has better freeze-thaw resistance and durability; after the accelerated aging test (simulating 20 years of natural environment), the thermal insulation performance of the new wallboard decreased by less than 5%, and there was no obvious powdering, cracking, etc. on the surface, while the thermal insulation performance of traditional insulation materials such as EPS decreased by 15%, and a certain degree of surface aging problems occurred.

[0025] These experimental data can intuitively demonstrate the performance advantages of the new fiber concrete polyurethane prefabricated insulation wall panels in various aspects, providing strong support and basis for their application in the construction field.

[0026] For those skilled in the art, various other corresponding changes and modifications can be made according to the above technical solutions and concepts, and all of these changes and modifications should fall within the protection scope of the claims of the present invention.

Claims

1. A new fiber concrete polyurethane assembled thermal insulation wall panel, characterized by: The wall comprises an outer layer A, an inner core and an outer layer B. The inner core is located between the outer layer A and the outer layer B. The outer layer A is provided with an embedded protrusion, and the outer layer B is provided with an embedded groove.

2. The novel fiber concrete polyurethane assembled thermal insulation wallboard according to claim 1 is characterized by: The outer layer A and the outer layer B are both pre-prepared fiber concrete panels, and the thickness of the outer layer A and the outer layer B is 30 mm.

3. The novel fiber concrete polyurethane assembled thermal insulation wallboard according to claim 1 is characterized by: The inner core is a polyurethane insulation layer, which is between the outer layer A and the outer layer B and has an injection thickness of 100 mm.

4. The novel fiber concrete polyurethane assembled thermal insulation wallboard according to claim 3 is characterized by: The main components of the inner core are isocyanate, polyol, catalyst and foaming agent, and the proportion of each component is 30%-50% of isocyanate, 30%-60% of polyol, 0.5%-3% of catalyst and 5%-15% of foaming agent.

5. A method for preparing a novel fiber concrete polyurethane assembled thermal insulation wallboard, characterized in that: The method comprises the following steps: Step 1, prefabricating a fiber concrete layer; Step 2: Connection node reservation; Step 3: injecting polyurethane protective layer; Step 4: Maintenance and molding.

6. The method for preparing the novel fiber concrete polyurethane assembled thermal insulation wallboard according to claim 5 is characterized by: The prefabricated fiber concrete layer is prepared in advance in a factory environment with two layers of fiber concrete panels, which respectively constitute the inner and outer layers of the insulation wall panels. The thickness of the outer fiber concrete layer is 30 mm, which is used to provide sufficient strength and durability to protect the internal insulation material from the external environment; the thickness of the inner fiber concrete layer is 10 mm, which is intended to further enhance the stability of the overall structure.

7. The method for preparing the novel fiber concrete polyurethane assembled thermal insulation wallboard according to claim 5 is characterized by: The connection nodes are reserved, and in the prefabrication process of the fiber concrete, nodes for connection with the polyurethane material are specially reserved. The design of these nodes is intended to enhance the interface bonding performance between the fiber concrete layer and the polyurethane insulation layer.

8. The method for preparing the novel fiber concrete polyurethane assembled thermal insulation wallboard according to claim 5 is characterized by: The polyurethane protective layer is injected between the inner and outer layers of the fiber concrete through a specific process to inject a 100mm thick polyurethane insulation material. The polyurethane material provides an effective energy protection layer for the building with its excellent thermal insulation performance and low thermal conductivity, greatly improving the energy efficiency of the building.

9. The method for preparing the novel fiber concrete polyurethane assembled thermal insulation wallboard according to claim 5 is characterized by: The curing and molding described above, after the polyurethane is injected, the entire structure enters the curing stage to ensure the perfect combination and solidification between the materials. After the curing is completed, a new type of fiber concrete-polyurethane assembled insulation wall panel is formed, which integrates efficient insulation, good structural strength and quick installation.

Images