External wall insulation board and production method thereof

Abstract

The present invention relates to the technical field of building insulation materials, and in particular to an exterior wall insulation board and a production method thereof. Slag powder, active microsilica, cement, fly ash, a water reducer, a waterproofing agent, a redispersible latex powder, a cellulose ether, silicon dioxide, a reinforcing fiber and water are mixed to obtain a premixed cementitious material; EPS aggregate is added to the premixed cementitious material and mixed at a low speed to obtain a premix; the premix is ​​loaded into an exterior wall insulation board mold, baked at 80-85°C for at least 8 hours after compaction, demoulded after natural cooling, and cured for at least 7 days to obtain an exterior wall insulation board. The exterior wall insulation board provided by the present invention has a compressive strength of ≥0.2MPa and a thermal conductivity of less than 0.050W / (m·K). At the same time, it is tested according to the GB / T 5464 standard and meets the requirements of non-combustible materials of grade A2 and above, has the advantages of low thermal conductivity, high fire resistance, etc., and the high compressive strength can meet the requirements of JG / T 253‑2019.

Description

Technical Field

[0001] The present invention relates to the technical field of building thermal insulation materials, in particular to an exterior wall thermal insulation board and a production method thereof. Background Art

[0002] Frequent exterior wall insulation failures and fires in recent years have not only resulted in significant casualties and property damage, but have also created a structural conflict with rapidly evolving building energy efficiency standards. National building energy efficiency standards have leapt from a 30% energy efficiency ratio to a benchmark of 75%, with some leading regions even raising the standard to an ultra-high efficiency threshold of 83%. Faced with this dual challenge, exterior wall insulation technology has long been constrained by two mutually exclusive technical challenges: the need to overcome the theoretical limits of material thermal conductivity to achieve efficient insulation, while also addressing the ongoing safety issue of fire resistance.

[0003] The current building insulation market exhibits a distinct technological divide: organic insulation systems, represented by polyurethane foam, extruded board, and polystyrene board, have long dominated the market with ultra-low thermal conductivity coefficients on the order of 0.022 W / (m·K). While these materials offer advantages in engineering applications, such as ease of construction and economic efficiency, they are plagued by the dual constraints of flammability and structural instability. Inorganic insulation systems, exemplified by materials like insulation mortar and rock wool, offer a reliable safety barrier thanks to Class A fire resistance. However, their thermal conductivity coefficients, generally exceeding 0.045 W / (m·K), present a difficult-to-break technical bottleneck. Notably, while rock wool has demonstrated breakthrough progress, reaching a thermal conductivity index of 0.036 W / (m·K), the risk of hollowing and shedding caused by its hygroscopic expansion suggests that this surface-balanced performance system still suffers from key technical flaws.

[0004] According to the technical specification of JG / T536-2017 "Thermosetting Composite Polystyrene Foam Insulation Board", the polystyrene modified insulation boards currently circulating on the market are mainly divided into two technical categories: low-density type (D type) and high-density type (G type). Among them, the standard density range of type D material is 35kg / m 3 Up to 50kg / m 3 Its thermal conductivity is ≤0.040W / (m·K), and its combustion performance reaches B1 level (GB8624-2012); the density index of G type material is 140kg / m 3 Up to 200kg / m 3, with a thermal conductivity range of ≤0.050-0.060 W / (m·K), and a flammability rating of A2 (GB8624-2012). Notably, the compressive strength of both products is limited to 0.1-0.2 MPa. However, under current technology, these two product types still exhibit a significant negative correlation between thermal performance and flame retardancy. Low-thermal-conductivity profiles lack a sufficient fire rating, while high-fire-rating profiles suffer from a technical drawback of excessive thermal resistance. The synergistic optimization of the advantages of both has yet to be achieved. Summary of the Invention

[0005] The present invention provides an exterior wall insulation board, a method for manufacturing the exterior wall insulation board, a composition and a premix for manufacturing the exterior wall insulation board. The composition for manufacturing the exterior wall insulation board of the present invention is a compound of a flame-retardant inorganic adhesive material and a polystyrene (EPS) aggregate with a low thermal conductivity coefficient, thereby achieving an optimal balance among the mechanical properties, flame-retardant properties and thermal insulation properties of the exterior wall insulation board, so that the exterior wall insulation board has a higher fire resistance rating, a lower thermal conductivity coefficient and higher mechanical properties.

[0006] Specifically, a first aspect of the present invention provides a composition for making an exterior wall insulation board, the composition comprising a bonding material and EPS aggregate, wherein the EPS aggregate accounts for 6% to 9% of the total weight of the composition, and the two are packaged separately or compounded and packaged together; wherein:

[0007] The bonding material includes:

[0008] Active microsilica fume with a weight ratio of 4.6% to 5.9%;

[0009] SiO2 with a weight ratio of 2.9% to 3.3%;

[0010] 45% to 65% by weight of slag powder;

[0011] 15% to 35% cement by weight;

[0012] Fly ash with a weight ratio of 1.7% to 3.8%;

[0013] Water reducing agent with a weight ratio of 0.8% to 1.3%;

[0014] Waterproofing agent with a weight ratio of 1.5% to 2.0%;

[0015] Redispersible latex powder with a weight ratio of 1.5% to 2.0%;

[0016] 0.5% to 1.0% by weight of cellulose ether;

[0017] 1.5% to 2.0% by weight of a foaming agent;

[0018] 1.0% to 1.5% by weight of chopped glass fiber;

[0019] The EPS aggregates are composed of a density of 10 kg / m 3 , 8kg / m 3 , 5kg / m 3 The three types of EPS particles are compounded in a volume ratio of 4:3:3, with a density of 10kg / m 3 The particle size of EPS particles is 1mm and the density is 8kg / m 3 The particle size of EPS particles is 2mm and the density is 5kg / m 3 The particle size of EPS particles is 3 mm.

[0020] The weight ratio of the EPS aggregate is calculated based on the total weight of the composition, and the weight ratio of the remaining components is calculated based on the total weight of the binder material.

[0021] In conjunction with the first aspect of the present invention, in some embodiments of the present invention:

[0022] The particle size of the silicon dioxide is 800-1000 mesh; and / or,

[0023] The reinforcing fibers are PP short fibers and / or chopped glass fibers with a length of 6 to 12 mm; and / or,

[0024] The slag powder is S95-S105 grade slag powder; and / or,

[0025] The cement is 525# cement; and / or,

[0026] The water reducer is a HF retarding high efficiency water reducer; and / or,

[0027] The foaming agent is a carbonate foaming agent; and / or,

[0028] The waterproofing agent is an organic silicon waterproofing agent.

[0029] The composition for making exterior wall insulation boards of the present invention needs to be mixed with a certain proportion of water before use. Therefore, a second aspect of the present invention provides a premix for making exterior wall insulation boards. The premix is ​​formed by mixing the composition of the first aspect with water, wherein the weight ratio of the binder material to water is 1:0.25-0.40.

[0030] The premix of the present invention needs to be molded in an exterior wall insulation board mold and then demolded before it can be made into an exterior wall insulation board. Therefore, the third aspect of the present invention provides a method for producing an exterior wall insulation board, comprising:

[0031] Mixing the bonding material described in the first aspect with water in a weight ratio of 1:0.25 to 0.40 to obtain a premixed cementitious material;

[0032] Adding the EPS aggregate described in the first aspect to the premixed cementitious material and mixing at a low speed to obtain the premixed material described in the second aspect;

[0033] Place the premix into the exterior wall insulation board mold, compact it and bake it at 80~85℃ for at least 8 hours, remove it from the mold after natural cooling, and cure it for at least 7 days.

[0034] In conjunction with the third aspect of the present invention, in some embodiments of the present invention, the production method further includes a step of preparing EPS aggregate, and the step of preparing EPS aggregate includes:

[0035] The unfoamed EPS particles are foamed multiple times to obtain a density of 10kg / m 3 , EPS particles with a particle size of 1mm and a density of 8kg / m 3 , EPS particles with a particle size of 2mm and a density of 5kg / m 3 , EPS particles with a particle size of 3 mm;

[0036] The three particles were compounded in a volume ratio of 4:3:3.

[0037] In conjunction with the third aspect of the present invention, in some embodiments of the present invention, foaming the unfoamed EPS particles multiple times includes:

[0038] The primary foaming was carried out under steam conditions at 110-115°C, with the steam pressure controlled at 0.15 MPa and the air pressure at 0.3 MPa. The material discharging time was 50 seconds, the pressure was maintained for 15 seconds, and the material was discharged under reduced pressure for 10 seconds. After being shaped at 60°C, the material was aged in a 40°C silo for 12 hours to obtain pre-foamed particles with a density of 13 kg / m³. Subsequently, the secondary foaming was carried out under the same temperature conditions to prepare particles with a density of 10 kg / m³. 3 , EPS particles with a particle size of 1mm and a density of 8kg / m 3 , EPS particles with a particle size of 2mm and a density of 5kg / m 3 , EPS particles with a particle size of 3mm.

[0039] In combination with the third aspect of the present invention, in some embodiments of the present invention, the rate of the low-speed mixing is no more than 50 rpm; and the time of the low-speed mixing is no more than 5 minutes.

[0040] In combination with the third aspect of the present invention, in some embodiments of the present invention, the compacting step includes: filling the premix into the exterior wall insulation board mold to a filling height of H; turning on the vibration table under the exterior wall insulation board mold, and at the same time using the lower pressure plate to compress the filler to a filling height of 0.6H.

[0041] A fourth aspect of the present invention provides an exterior wall insulation board, which is prepared from the composition described in the first aspect, the premix described in the second aspect, and the production method described in the third aspect.

[0042] In conjunction with the fourth aspect of the present invention, in some embodiments of the present invention:

[0043] The dry density of the exterior wall insulation board is 110~150kg / m 3 and / or,

[0044] The thermal conductivity of the exterior wall insulation board is ≤0.050W / (m·K); and / or,

[0045] The compressive strength of the exterior wall insulation board is ≥0.20MPa.

[0046] Compared with the prior art, the present invention has at least the following beneficial effects:

[0047] The exterior wall insulation board provided by the present invention has a compressive strength of ≥0.20 MPa and a thermal conductivity coefficient of less than 0.050 W / (m·K). At the same time, it passes the GB8624 standard test and meets the requirements of A2 and above non-combustible materials. It has the advantages of low thermal conductivity and high fire resistance, and its high compressive strength can meet the requirements of JG / T 253-2019. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Figure 1 : A cross-sectional view of an exterior wall insulation board manufactured in Example 1 of the present invention;

[0049] Figure 2 : Corresponding relationship between compressive strength and thermal conductivity of each sample. DETAILED DESCRIPTION

[0050] To make the objectives, technical solutions, and advantages of the present invention more clear, the technical solutions of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, but not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts shall fall within the scope of protection of the present invention.

[0051] For simplicity, only some explicit numerical ranges are disclosed herein. However, any lower limit can be combined with any upper limit to form an unspecified range; and any lower limit can be combined with other lower limits to form an unspecified range. Similarly, any upper limit can be combined with any other upper limit to form an unspecified range. In addition, although not explicitly stated, each point or individual value between the endpoints of a range is included in the range. Thus, each point or individual value can serve as its own lower limit or upper limit and be combined with any other point or individual value or with other lower limits or upper limits to form an unspecified range.

[0052] It should be noted that, in the description herein, unless otherwise specified, “above” and “below” include the number itself, and the “multiple” in “one or more” means two or more. Relational terms such as “first” and “second” are merely used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply that there is any such actual relationship or order between these entities or operations. Moreover, the terms “include”, “comprising” or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence “comprising one…” do not exclude the presence of other identical elements in the process, method, article or device comprising the elements.

[0053] In the description of this specification, the description with reference to the terms "any embodiment / method", "one embodiment / method", "some embodiments / methods", "example", "specific example" or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment / method or example are included in at least one embodiment / method or example of the present invention. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment / method or example. Moreover, the specific features, structures, materials or characteristics described may be combined in an appropriate manner in any one or more embodiments / methods or examples. In addition, those skilled in the art may combine and combine different embodiments / methods or examples described in this specification and the features of different embodiments / methods or examples, unless they are contradictory.

[0054] The above summary of the invention is not intended to describe every disclosed embodiment or every implementation of the present invention. The following description more specifically illustrates exemplary embodiments. These embodiments can be used in various combinations. In each example, the examples are listed only as representative groups and should not be construed as exhaustive.

[0055] As described in the background technology, there is still a significant negative correlation between the thermal performance and flame retardant properties of polystyrene-based modified insulation materials - the fire resistance level of low thermal conductivity profiles is insufficient, while high fire resistance profiles present the technical difficulty of increased thermal resistance, and the coordinated optimization of the two has not yet been achieved.

[0056] The present invention uses EPS aggregate as an organic insulation matrix, supplemented by inorganic binders such as cement, silica fume, and slag powder, to construct an organic-inorganic composite flame retardant system. The EPS aggregate not only provides skeletal support but also reduces the thermal conductivity of the exterior wall insulation board, improving its insulation effectiveness. The binder not only bonds the EPS aggregate but also fills the gaps between the EPS aggregates, thereby ensuring the strength of the exterior wall insulation board. Furthermore, the inorganic binder encapsulates the EPS aggregate, blocking its contact with air, reducing the possibility of combustion and ensuring the flame retardant properties of the exterior wall insulation board. Therefore, the exterior wall insulation board produced by the present invention simultaneously possesses high mechanical properties, a fire rating, and thermal insulation performance.

[0057] EPS aggregates are formed by expanding the volume of primary EPS particles using steam at 110°C to 130°C, resulting in closed-cell particles with high thermal insulation properties. Conventional EPS particles are foamed once to reach the target particle size. To achieve even better thermal insulation, the present invention uses multiple foaming cycles, gradually expanding the volume of the primary EPS particles. This results in a more closed-cell effect and higher thermal insulation performance.

[0058] The applicant found that the density of EPS aggregate has a significant impact on the thermal conductivity, flame retardancy and mechanical properties of the exterior wall insulation board. Specifically, when the density of EPS aggregate is 18 kg / m 3 When the thermal conductivity reaches the optimal value of 0.033 W / (m·K), the particle packing density is too high, which will lead to: 1) the water migration is blocked, affecting the final thermal conductivity; 2) the material density is too high, reducing the flame retardant performance. The density of EPS aggregate is reduced to 5 kg / m 3 While this facilitates moisture volatilization and reduces calorific value, the mechanical strength of the exterior wall insulation board significantly deteriorates, and the thermal conductivity increases to 0.042 W / (m·K). Therefore, how to balance thermal conductivity, flame retardancy, and mechanical strength becomes a pressing technical challenge for this organic-inorganic composite flame retardant system.

[0059] The present invention has proved through a large number of experiments that the composition of EPS aggregate is the most critical factor in the exterior wall insulation board. Using EPS particles of a single density as EPS aggregate in the exterior wall insulation board cannot achieve ideal mechanical properties, fire resistance and thermal insulation performance.

[0060] Most of the inorganic powders in traditional thermosetting composite polystyrene foam insulation boards use ordinary Portland cement, silica fume and other inorganic powders as gelling agents, which are stirred with water to form a hydration reaction at room temperature. Due to the later brittleness and large deformation coefficient of materials such as cement, and too much cement will affect the thermal conductivity, and too little cement will make it difficult to achieve strength, the present invention uses the heating reaction of silicon calcium to form a calcium silicate material with higher strength and more stable deformation coefficient, and by adding a foaming agent, the calcium silicate forms tiny pores, thereby reducing the thermal conductivity of the exterior wall insulation board.

[0061] After extensive, complex, and creative experiments, the following composition was finally selected for use in producing exterior wall insulation boards. The composition includes a binder and EPS aggregate, with the EPS aggregate accounting for 6% to 9% of the total weight of the composition. The binder and EPS aggregate are packaged separately or compounded together.

[0062] The bonding material comprises:

[0063] Active microsilica fume with a weight ratio of 4.6% to 5.9%;

[0064] SiO2 with a weight ratio of 2.9% to 3.3%;

[0065] 45% to 65% by weight of slag powder;

[0066] 15% to 35% cement by weight;

[0067] Fly ash with a weight ratio of 1.7% to 3.8%;

[0068] Water reducing agent with a weight ratio of 0.8% to 1.3%;

[0069] Waterproofing agent with a weight ratio of 1.5% to 2.0%;

[0070] Redispersible latex powder with a weight ratio of 1.5% to 2.0%;

[0071] 0.5% to 1.0% by weight of cellulose ether;

[0072] 1.5% to 2.0% by weight of a foaming agent;

[0073] 1.0% to 1.5% by weight of chopped glass fiber;

[0074] The EPS aggregates are composed of a density of 10 kg / m 3 , 8kg / m 3 , 5kg / m 3 The three types of EPS particles are compounded in a volume ratio of 4:3:3, with a density of 10kg / m 3 The particle size of EPS particles is 1mm and the density is 8kg / m 3The particle size of EPS particles is 2mm and the density is 5kg / m 3 The particle size of EPS particles is 3 mm.

[0075] The present invention provides dual- or single-packaged compositions, which can eliminate the impact of on-site weighing errors on material properties through factory pre-produced proportions. Dual packaging means the adhesive and EPS aggregate are packaged separately, while single packaging means the adhesive and EPS aggregate are mixed and packaged together.

[0076] (1) When mixing double-packaged dry powder: the independently packaged adhesive material and the full amount of mixing water (weight ratio, adhesive material: water = 1:0.27~0.38) are subjected to high-speed shear dispersion (speed ≥ 300r / min, time ≥ 2min) to form a homogeneous premixed cementitious material, and then the EPS thermal insulation aggregate is introduced and the aggregate deformation is controlled at a low speed of ≤50r / min;

[0077] (2) When mixing single-package dry powder: directly inject measured water into the premixed composition (weight ratio, dry powder: water = 1:0.27~0.36), and adopt a segmented gradient stirring process (initial 30s low-speed wetting, followed by 90s medium-speed homogenization) to achieve synergistic strengthening of the interface between the inorganic phase and the organic aggregate.

[0078] The dry powder and water packaging system supports "ready-to-use" and the single mixing volume is controllable (5~50kg). It is suitable for small handheld devices or automated production lines, improving the convenience of exterior wall insulation board production.

[0079] In some embodiments of the present invention:

[0080] The particle size of the silicon dioxide is 800-1000 mesh; and / or,

[0081] The reinforcing fibers are PP short fibers and / or chopped glass fibers with a length of 6 to 12 mm; and / or,

[0082] The slag powder is S95-S105 grade slag powder; and / or,

[0083] The cement is 525# cement; and / or,

[0084] The water reducer is a HF retarding high efficiency water reducer; and / or,

[0085] The foaming agent is a carbonate foaming agent; and / or,

[0086] The waterproofing agent is an organic silicon waterproofing agent.

[0087] The premix provided by the present invention for making exterior wall insulation boards is prepared by mixing the above-mentioned dry powder with water, wherein the weight ratio of the adhesive material to water is 1:0.3-0.4.

[0088] The premix requires little water and has low fluidity, enabling vertical mold filling without sagging. It is suitable for sandwich insulation layers in prefabricated buildings, exterior wall insulation systems for energy-saving renovations of existing buildings, and is particularly suitable for the one-piece molding of special-shaped curved exterior wall insulation panels.

[0089] Factory-premixed materials ensure component ratio accuracy (error ≤ ±1.5%), avoiding strength dispersion caused by on-site weighing errors (CV value ≤ 5%); and the water-cement ratio can be accurately controlled in the factory, reducing maintenance energy consumption by 30%~40%, and there is no on-site dust pollution.

[0090] The present invention provides a method for producing an exterior wall insulation board, comprising:

[0091] Mix the binder material and water in a weight ratio of 1:0.3-0.4 to obtain a premixed cementitious material;

[0092] Add EPS aggregate to the ready-mixed cementitious material and mix at a low speed to obtain a ready-mixed material;

[0093] Place the premix into the exterior wall insulation board mold, compact it and bake it at 80~85℃ for at least 8 hours, remove it from the mold after natural cooling, and cure it for at least 7 days.

[0094] After the premix is ​​loaded into the exterior wall insulation board mold, due to its weak fluidity, the interior of the premix is ​​not dense, and the filling will show obvious volume shrinkage when it is cooled after baking. A vibration table can be set at the bottom of the exterior wall insulation board mold, and a pressing plate can be used on the top to compact the premix to avoid uneven stress caused by uneven internal structure of the exterior wall insulation board, resulting in low tensile strength.

[0095] The present invention bakes the exterior wall insulation board mold at 80-85°C because during the heating process, the EPS particles will foam again and their volume will increase (by about 10%), which will further increase the density inside the exterior wall insulation board and thus improve the tensile strength of the exterior wall insulation board.

[0096] In some embodiments of the present invention, the oven is closed after baking for 8 hours, and the product is demoulded after being cooled naturally.

[0097] In some embodiments of the present invention, the molded product can be cut and sold after being naturally cured for 7 days after demoulding, and the production efficiency is very high.

[0098] This production method achieves synergistic optimization of the triple performance of fire protection (A2 grade), thermal insulation (≤0.045W / (m·K)), and mechanical properties (≥0.25MPa) through the three-in-one technical path of "low water-cement ratio cementitious system + gradient graded aggregate + low-temperature activation process".

[0099] In some embodiments of the present invention, the production method further comprises a step of preparing EPS aggregate, and the step of preparing EPS aggregate comprises:

[0100] The unfoamed EPS particles are foamed multiple times to obtain a density of 10kg / m 3 , EPS particles with a particle size of 1mm and a density of 8kg / m 3 , EPS particles with a particle size of 2mm and a density of 5kg / m 3 , EPS particles with a particle size of 3 mm;

[0101] The three particles were compounded in a volume ratio of 4:3:3.

[0102] In some embodiments of the present invention, the unfoamed EPS particles are foamed multiple times, including: performing the initial foaming under steam conditions of 110-115°C, controlling the steam pressure to 0.15 MPa and the air pressure to 0.3 MPa, the material discharging time to 50 seconds, the pressure holding time to 15 seconds, the pressure reduction and discharge time to 10 seconds, and aging in a 40°C silo for 12 hours after shaping at 60°C to obtain pre-foamed particles with a density of 13 kg / m³; then performing the secondary foaming under the same temperature conditions to prepare pre-foamed particles with a density of 10 kg / m³. 3 , EPS particles with a particle size of 1mm and a density of 8kg / m 3 , EPS particles with a particle size of 2mm and a density of 5kg / m 3 , EPS particles with a particle size of 3mm.

[0103] In some embodiments of the present invention, the low-speed mixing rate is no greater than 50 rpm, and the low-speed mixing time is no greater than 5 minutes. After repeated testing, the present invention has determined that the stirring speed should be set at 50 rpm and the stirring time should be set at 5 minutes. Excessively high speeds or prolonged stirring times can cause shrinkage and deformation of the EPS particles.

[0104] In some embodiments of the present invention, the compacting step includes: filling the premix into the exterior wall insulation board mold to a filling height of H; activating a vibration table below the exterior wall insulation board mold and simultaneously compressing the filler with a lower pressing plate to a filling height of 0.6H. In some embodiments of the present invention, the exterior wall insulation board mold has dimensions of 3.04 meters in length, 1.24 meters in width, and 1 meter in height. A 1mm thick release agent is applied to the interior to facilitate later demolding. A vibration table is added to the bottom of the exterior wall insulation board mold, and the vibration time is set to 30 seconds.

[0105] In some embodiments of the present invention, the dry density of the exterior wall insulation board is 110-150 kg / m³; and / or the thermal conductivity of the exterior wall insulation board is ≤0.050 W / (m·K); and / or the compressive strength of the exterior wall insulation board is ≥0.20 MPa.

[0106] The following describes the embodiments of the present invention in detail through specific examples, but the protection scope of the present invention is not limited to the following examples.

[0107] Specifications and sources of experimental raw materials:

[0108] Active microsilica fume: 1250 mesh (Luoyang Hemao Silicon Industry Co., Ltd.);

[0109] Silicon dioxide, 800-1000 mesh (Tianjin Jinbei Fine Chemical Co., Ltd.);

[0110] 525# Portland cement (Gezhouba Zhongxiang Cement Co., Ltd.);

[0111] Class C high-calcium fly ash (Xiangyang Fly Ash Products Co., Ltd.);

[0112] HF retarding high-efficiency water-reducing agent (Beijing Borunjia Technology Co., Ltd.);

[0113] Redispersible latex powder (Wuhan Diaoyudao Building Materials Technology Co., Ltd.);

[0114] Hydroxypropyl methylcellulose ether (Beijing Borunjia Technology Co., Ltd.);

[0115] Chopped glass fiber, length 6-12 mm (Huierjie New Materials Technology Co., Ltd.);

[0116] Initial EPS particles, particle size 0.1mm, density 35kg / m 3 (Shenyang Zhengxing New Materials Co., Ltd.);

[0117] Carbonate foaming agent (Guangzhou Jiangyan Chemical Co., Ltd.);

[0118] Silicone waterproofing agent (Hubei Ourike Waterproof Material Technology Co., Ltd.).

[0119] Example 1

[0120] 1. Use multi-stage foaming process to prepare EPS particles of different densities:

[0121] (1) Preparation of EPS particles with a particle size of 3 mm

[0122] S1: The initial EPS particles were foamed under steam conditions at 110-115°C, with steam pressure at 0.15 MPa and air pressure at 0.3 MPa. The foaming time was 50 seconds, pressure was maintained for 15 seconds, and the pressure was reduced and discharged for 10 seconds. After being shaped at 60°C, the particles were aged in a silo at 40°C for 12 hours to obtain a density of 13 kg / m 3 Pre-expanded particles;

[0123] S2: Secondary foaming is performed under steam conditions of 110~115℃:

[0124] Adjust the air pressure to 0.35MPa and the foaming time to 15s to obtain a particle size of 3mm and a density of 10kg / m 3 EPS particles;

[0125] Adjust the air pressure to 0.35MPa and the foaming time to 20s to obtain a particle size of 3mm and a density of 8kg / m 3 EPS particles;

[0126] Adjust the air pressure to 0.35MPa and the foaming time to 25s to obtain a particle size of 3mm and a density of 5kg / m 3 EPS particles.

[0127] (2) Preparation of EPS particles with a particle size of 2 mm

[0128] S1: The initial EPS particles were foamed under steam conditions at 110-115°C, with steam pressure at 0.15 MPa and air pressure at 0.3 MPa. The foaming time was 50 seconds, pressure was maintained for 15 seconds, and the pressure was reduced and discharged for 10 seconds. After being shaped at 60°C, the particles were aged in a silo at 40°C for 12 hours to obtain a density of 13 kg / m 3 Pre-expanded particles;

[0129] S2: Secondary foaming is performed under steam conditions of 110~115℃:

[0130] Adjust the air pressure to 0.45MPa and the foaming time to 15s to obtain a particle size of 2mm and a density of 10kg / m 3 EPS particles;

[0131] Adjust the air pressure to 0.45MPa and the foaming time to 20s to obtain a particle size of 2mm and a density of 8kg / m 3 EPS particles;

[0132] Adjust the air pressure to 0.45MPa and the foaming time to 25s to obtain a particle size of 2mm and a density of 5kg / m 3 EPS particles.

[0133] (III) Preparation of EPS particles with a particle size of 1 mm

[0134] S1: The initial EPS particles were foamed under steam conditions at 110-115°C, with steam pressure at 0.15 MPa and air pressure at 0.3 MPa. The foaming time was 50 seconds, pressure was maintained for 15 seconds, and the pressure was reduced and discharged for 10 seconds. After being shaped at 60°C, the particles were aged in a silo at 40°C for 12 hours, and the density was 13 kg / m 3 Pre-expanded particles;

[0135] S2: Secondary foaming is performed under steam conditions of 110~115℃:

[0136] Adjust the air pressure to 0.55 MPa and the foaming time to 15 s to obtain a particle size of 1 mm and a density of 10 kg / m 3 EPS particles;

[0137] Adjust the air pressure to 0.55 MPa and the foaming time to 20 s to obtain a particle size of 1 mm and a density of 8 kg / m 3 EPS particles;

[0138] Adjust the air pressure to 0.55 MPa and the foaming time to 25 s to obtain a particle size of 1 mm and a density of 5 kg / m 3 EPS particles.

[0139] 2. Preparation of exterior wall insulation boards:

[0140] 2.1 Preparation of premixed cementitious materials: Dry-mix 7 parts of active microsilica powder, 4 parts of SiO2, 77 parts of slag powder, 20 parts of cement, 2 parts of fly ash, 1 part of water reducer, 2 parts of waterproofing agent, 2 parts of redispersible latex powder, 1 part of cellulose ether, 2 parts of foaming agent, and 1.5 parts of chopped glass fiber in a blender, then add mixing water at 25% to 40% of the total weight of the dry powder and control the stirring rate to 300 r / min to obtain the premixed cementitious materials.

[0141] 2.2 Preparation of premix: Add 8 parts of EPS particles of a single particle size and density to the premixed cementitious material, and switch to a low-speed stirring process (50 r / min, 5 min) to avoid deformation of the EPS particles to obtain a premix.

[0142] 2.3 Molding: Pour the premix into a 3.04m x 1.24m x 1m mold (with a 1mm thick release agent applied to the inner wall). Press down through the mold box cover to a 60cm level (40% shrinkage compensation). Install a vibrating table at the bottom (vibrate for 30 seconds). Curing the mold box at 80-85°C for 8 hours, then naturally cool and demold. Curing for 7 days.

[0143] The corresponding relationship between EPS particle size, density, and thermal conductivity of exterior wall insulation board is shown in Table 1:

[0144] Table 1

[0145]

[0146] As shown in Table 1, the smaller the EPS particle size at each density, the lower the thermal conductivity; the greater the density of EPS particles at each particle size, the lower the thermal conductivity. Theoretically, particles with a particle size of 1 mm and a density of 10 kg / m³ should be selected as aggregate. However, since the volume of EPS aggregate in the exterior wall insulation board is fixed, using EPS particles with a particle size of 1 mm and a density of 10 kg / m³ as aggregate will result in the highest calorific value due to their highest bulk density for the same volume. Therefore, further optimization of the thermal conductivity and calorific value of EPS aggregate is necessary.

[0147] Example 2

[0148] In this example, while maintaining the same adhesive composition and dosage as in Example 1, as well as the manufacturing process for the exterior wall insulation board, the total volume of EPS aggregate in the exterior wall insulation board was fixed. EPS particles of the same density were optimized for particle size composition to select the exterior wall insulation board with the lowest thermal conductivity. This example differed from Example 1 only in the EPS aggregate composition.

[0149] Table 2 shows the thermal conductivity of exterior wall insulation boards made of EPS aggregates with different particle size ratios. The volume ratio in Table 2 represents the volume ratio of EPS particles with the same density and particle size of 1 mm, 2 mm, and 3 mm, respectively, when the total volume is fixed.

[0150] Table 2

[0151]

[0152] As shown in Table 2, when the total volume is fixed, no matter which density of EPS particles is graded, the thermal conductivity of EPS aggregate with a volume ratio of 4:3:3 of EPS particles with particle sizes of 1mm, 2mm, and 3mm is the smallest within the same density group. Therefore, the volume ratio of EPS particles with particle sizes of 1mm, 2mm, and 3mm is 4:3:3 as the optimal particle size composition. In all groups, the density of 1mm particle size, 2mm particle size, and 3mm particle size is 10kg / m 3 The thermal conductivity of EPS aggregate composed of EPS particles in a volume ratio of 4:3:3 is the lowest. However, due to the density of 10kg / m 3 The EPS particles with the highest calorific value still need to be further explored, and the EPS aggregate composition with low thermal conductivity and low calorific value needs to be further explored.

[0153] Example 3

[0154] Since the calorific value of homogeneous A2 grade insulation board is required to be below 3, the fire calorific value must be taken into account while considering the thermal conductivity of the insulation board. Since the composition of EPS aggregate has different effects on the calorific value, it is necessary to find out the effect of EPS aggregate composition on the calorific value of the sample under the condition that the composition and dosage of the bonding material remain unchanged. Table 3 shows the effect of different EPS aggregate compositions on the calorific value of the sample. Among them, the EPS aggregate of a single density is composed of EPS particles of the density with a particle size of 1mm, 2mm, and 3mm in a volume ratio of 4:3:3. For example, in Test 1, 10kg / m 3 The EPS aggregate is made of 10kg / m 3 The EPS particles of different densities are composed of 4:3:3 in volume ratio; the volume ratio of the two density EPS aggregates is 1:1, and the EPS aggregates of different densities are composed of EPS particles of the same density with particle sizes of 1mm, 2mm, and 3mm in volume ratio of 4:3:3. For example, in test 4, 10kg / m 3 The EPS aggregate is made of 10kg / m 3 The EPS particles are composed of 4:3:3 in volume ratio; 8kg / m 3 The EPS aggregate is made of 8kg / m 3 The EPS particles are composed of 4:3:3 in volume ratio; at the same time, 10kg / m 3 EPS aggregate and 8kg / m 3 The volume ratio of EPS aggregate is 1:1. In Test 7, the particle size of EPS particles with a density of 10 kg / m³ is 1 mm, the particle size of EPS particles with a density of 8 kg / m³ is 2 mm, and the particle size of EPS particles with a density of 5 kg / m³ is 3 mm. The EPS aggregate is composed of three types of EPS particles with densities of 10 kg / m³, 8 kg / m³, and 5 kg / m³, respectively, in a volume ratio of 4:3:3.

[0155] The samples of this embodiment and embodiment 1 differ only in the EPS aggregate composition.

[0156] Table 3 Effect of different EPS aggregate compositions on the calorific value of samples

[0157]

[0158] Through experimental comparison, it was found that except for the calorific values ​​of the samples prepared in Tests 1 and 4, which exceeded the standard, the calorific values ​​of the samples prepared in other tests could meet the requirements. In order to take into account both thermal insulation performance and thermal conductivity coefficient, the EPS aggregate composition of Test 7 was selected.

[0159] Example 4

[0160] 7 parts of active microsilica; 4 parts of SiO2; 77 parts of slag powder; 20 parts of cement; 2 parts of fly ash; 1 part of water reducer; 2 parts of water repellent; 2 parts of redispersible latex powder; 1 part of cellulose ether; 2 parts of foaming agent; 1.5 parts of chopped glass fiber; 8 parts of EPS aggregate; 35 parts of water → prepare sample A.

[0161] 6.5 parts of active microsilica; 4 parts of SiO2; 72 parts of slag powder; 25 parts of cement; 2.5 parts of fly ash; 1 part of water reducer; 2 parts of water repellent; 2 parts of redispersible latex powder; 1 part of cellulose ether; 2 parts of foaming agent; 1.5 parts of chopped glass fiber; 8 parts of EPS aggregate; 35 parts of water → prepare sample B.

[0162] 6 parts of active microsilica; 4 parts of SiO2; 67 parts of slag powder; 30 parts of cement; 3 parts of fly ash; 1.5 parts of water reducer; 2 parts of water repellent; 2 parts of redispersible latex powder; 1 part of cellulose ether; 2 parts of foaming agent; 1.5 parts of chopped glass fiber; 8 parts of EPS aggregate; 40 parts of water → prepare sample C.

[0163] 5.5 parts of active microsilica; 3.5 parts of SiO2; 62 parts of slag powder; 34 parts of cement; 4 parts of fly ash; 1.5 parts of water reducer; 2 parts of water repellent; 2 parts of redispersible latex powder; 1 part of cellulose ether; 2 parts of foaming agent; 1.5 parts of chopped glass fiber; 8 parts of EPS aggregate; 40 parts of water → prepare sample D.

[0164] 5.5 parts of active microsilica; 3.5 parts of SiO2; 57 parts of slag powder; 39.5 parts of cement; 4.5 parts of fly ash; 1.5 parts of water reducer; 2 parts of water repellent; 2 parts of redispersible latex powder; 1 part of cellulose ether; 2 parts of foaming agent; 1.5 parts of chopped glass fiber; 8 parts of EPS aggregate; 45 parts of water → prepare sample E.

[0165] The content of EPS aggregate was adjusted to 10 parts, and the remaining components were prepared in the same manner as in Examples 1 to 5 to prepare samples F to J, respectively.

[0166] Example 6: 7 parts of active microsilica; 4 parts of SiO2; 77 parts of slag powder; 20 parts of cement; 2 parts of fly ash; 1 part of water reducer; 2 parts of water repellent; 2 parts of redispersible latex powder; 1 part of cellulose ether; 2 parts of foaming agent; 1.5 parts of chopped glass fiber; 10 parts of EPS aggregate; 35 parts of water → Sample F was prepared.

[0167] 6.5 parts of active microsilica; 4 parts of SiO2; 72 parts of slag powder; 25 parts of cement; 2.5 parts of fly ash; 1 part of water reducer; 2 parts of water repellent; 2 parts of redispersible latex powder; 1 part of cellulose ether; 2 parts of foaming agent; 1.5 parts of chopped glass fiber; 10 parts of EPS aggregate; 35 parts of water → prepare sample G.

[0168] 6 parts of active microsilica; 4 parts of SiO2; 67 parts of slag powder; 30 parts of cement; 3 parts of fly ash; 1.5 parts of water reducer; 2 parts of water repellent; 2 parts of redispersible latex powder; 1 part of cellulose ether; 2 parts of foaming agent; 1.5 parts of chopped glass fiber; 10 parts of EPS aggregate; 40 parts of water → prepare sample H.

[0169] 5.5 parts of active microsilica; 3.5 parts of SiO2; 62 parts of slag powder; 34 parts of cement; 4 parts of fly ash; 1.5 parts of water reducer; 2 parts of water repellent; 2 parts of redispersible latex powder; 1 part of cellulose ether; 2 parts of foaming agent; 1.5 parts of chopped glass fiber; 10 parts of EPS aggregate; 40 parts of water → prepare sample I.

[0170] 5.5 parts of active microsilica; 3.5 parts of SiO2; 57 parts of slag powder; 39.5 parts of cement; 4.5 parts of fly ash; 1.5 parts of water reducer; 2 parts of water repellent; 2 parts of redispersible latex powder; 1 part of cellulose ether; 2 parts of foaming agent; 1.5 parts of chopped glass fiber; 10 parts of EPS aggregate; 45 parts of water → prepare sample J.

[0171] Table 4 Weight ratio of each component in the binder material, proportion of aggregate in the composition, and weight ratio of water to binder material used in each sample

[0172]

[0173] Compressive strength was tested according to GB / T5486-2008, tensile strength was tested according to GB / T29906-2013, thermal conductivity was determined according to GB / T10294-2008, bending deformation was evaluated according to GB / T10801.1, and combustion performance was graded according to GB8624-2012. The performance test data for each sample is shown in Table 5.

[0174] Table 5

[0175]

[0176] Table 5 shows that the average tensile strength of the 10 samples was 0.16 MPa, and the average compressive strength reached 0.24 MPa, significantly exceeding the tensile strength limit of 0.15 MPa for Type D materials and the compressive strength requirement of ≥0.2 MPa for Type G materials specified in the JG / T536-2017 "Thermosetting Composite Polystyrene Foam Insulation Board" standard. The average thermal conductivity of the samples was 0.0452 W / (m·K), a 9.6% decrease from the standard upper limit of 0.050 W / (m·K) for Type G materials. All samples met the fire resistance requirements of Class A (A2) non-combustible materials in accordance with GB / T 5464 testing.

[0177] Table 6 is the test report issued by the National Building Fire Protection Product Safety and Quality Inspection and Testing Center for Sample A, report number: FH2022BWX0247.

[0178] Table 6

[0179]

[0180] The foregoing is merely a detailed description of the present invention, intended to enable those skilled in the art to understand and implement the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A composition for making exterior wall insulation boards, characterized in that: The composition comprises a bonding material and EPS aggregate, wherein the EPS aggregate accounts for 6% to 9% of the total weight of the composition, and the two are packaged separately or compounded and packaged together; wherein: The bonding material comprises: Active microsilica fume with a weight ratio of 4.6% to 5.9%; SiO2 with a weight ratio of 2.9% to 3.3%; 45% to 65% by weight of slag powder; 15% to 35% cement by weight; Fly ash with a weight ratio of 1.7% to 3.8%; Water reducing agent with a weight ratio of 0.8% to 1.3%; Waterproofing agent with a weight ratio of 1.5% to 2.0%; Redispersible latex powder with a weight ratio of 1.5% to 2.0%; 0.5% to 1.0% by weight of cellulose ether; 1.5% to 2.0% by weight of a foaming agent; 1.0% to 1.5% by weight of chopped glass fiber; The EPS aggregates are composed of a density of 10 kg / m 3 , 8kg / m 3 , 5kg / m 3 The three types of EPS particles are compounded in a volume ratio of 4:3:3, with a density of 10kg / m 3 The particle size of EPS particles is 1mm and the density is 8kg / m 3 The particle size of EPS particles is 2mm and the density is 5kg / m 3 The particle size of EPS particles is 3mm; The foaming agent is a carbonate foaming agent.

2. The composition according to claim 1, wherein: The particle size of SiO2 is 800-1000 mesh; and / or, The length of the chopped glass fibers is 6 to 12 mm; and / or The slag powder is S95-S105 grade slag powder; and / or, The cement is 525# cement; and / or, The water reducer is a HF retarding high efficiency water reducer; and / or, The waterproofing agent is an organic silicon waterproofing agent.

3. A premix for making exterior wall insulation boards, characterized in that: The composition according to claim 1 or 2 is mixed with water, wherein the weight ratio of the binder material to water is 1:0.25-0.

40.

4. A method for producing an exterior wall insulation board, characterized in that: include: Mixing the adhesive material according to claim 1 and water in a weight ratio of 1:0.25-0.40 to obtain a premixed cementitious material; Adding the EPS aggregate of claim 1 to a premixed cementitious material and mixing at a low speed to obtain the premix of claim 3; Place the premix into the exterior wall insulation board mold, compact it and bake it at 80~85℃ for at least 8 hours, remove it from the mold after natural cooling, and cure it for at least 7 days.

5. The production method according to claim 4, characterized in that: The method further includes a step of preparing EPS aggregate, wherein the step of preparing EPS aggregate includes: The unfoamed EPS particles are foamed multiple times to obtain a density of 10kg / m 3 , EPS particles with a particle size of 1mm and a density of 8kg / m 3 , EPS particles with a particle size of 2mm and a density of 5kg / m 3 , EPS particles with a particle size of 3 mm; The three particles were compounded in a volume ratio of 4:3:

3.

6. The production method according to claim 4, characterized in that: Multiple foaming of unfoamed EPS particles includes: The initial foaming was carried out under steam conditions at 110-115°C, with the steam pressure controlled at 0.15MPa and the air pressure at 0.3MPa. The material was released for 50s, maintained at pressure for 15s, and discharged at reduced pressure for 10s. After being shaped at 60°C, the material was aged in a 40°C silo for 12h to obtain a density of 13kg / m 3 The pre-foamed particles were then foamed again at the same temperature to prepare a particle density of 10 kg / m 3 , EPS particles with a particle size of 1mm and a density of 8kg / m 3 , EPS particles with a particle size of 2mm and a density of 5kg / m 3 , EPS particles with a particle size of 3mm.

7. The production method according to claim 4, characterized in that: The low-speed mixing rate is no more than 50 rpm; The time of the low-speed mixing is no more than 5 minutes.

8. The production method according to claim 4, characterized in that: The compacting step includes: filling the premix into the exterior wall insulation board mold to a filling height of H; turning on the vibration table below the exterior wall insulation board mold, and compressing the filler with a lower pressing plate to a filling height of 0.6H.

9. An exterior wall insulation board, characterized by: The exterior wall insulation board is prepared from the composition according to claim 1 or 2, the premix according to claim 3, and the production method according to any one of claims 4 to 8.

10. The exterior wall insulation board according to claim 9, characterized in that: The dry density of the exterior wall insulation board is 110~150kg / m 3 and / or, The thermal conductivity of the exterior wall insulation board is ≤0.050W / (m·K); and / or, The compressive strength of the exterior wall insulation board is ≥0.20MPa.

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