Novel perlite insulation board and preparation process thereof

Abstract

The invention provides a novel perlite insulation board and a preparation process thereof, and belongs to the technical field of building materials. 10-20% of composite mineral powder; 20-30% of a special adhesive; 3-5.5% of a functional additive; through the three-stage particle size gradient design, the composite mineral powder replacing the adhesive and the synergistic effect of the diatomite, the fly ash and the silica fume, the compressive strength, the breaking strength, the toughness and the thermal insulation performance of the thermal insulation board are effectively improved, and finally it is determined that when the optimal proportion of the perlite thermal insulation board product is 55% of expanded perlite particles, 5% of the functional additive, 13% of the composite mineral powder and 27% of the adhesive, the thermal insulation performance of the perlite thermal insulation board product is improved. At the moment, the perlite insulation board shows high compressive strength, breaking strength, toughness and thermal insulation performance, and a new technical solution is provided for the field of building insulation materials.

Description

Technical Field

[0001] This invention belongs to the field of building materials technology, specifically a novel perlite insulation board and its preparation process. Background Technology

[0002] Perlite insulation boards are increasingly used in green and energy-efficient buildings due to their Class A fire resistance and excellent thermal insulation properties. However, current production processes rely on high-temperature drying and curing in kilns, resulting in high production costs and hindering further promotion. To improve the product's economic efficiency, it is necessary to reduce costs and increase efficiency through methods such as optimizing material ratios.

[0003] Adding other materials and additives can effectively reduce the molding conditions and curing temperature of perlite insulation boards, significantly reducing the energy consumption required for drying and curing. The accompanying molding process can further reduce production costs. Traditional perlite insulation boards use water glass as a binder, leading to problems such as water absorption, efflorescence, and delamination. Existing binders such as cement and water glass are expensive, have low compressive strength, and high water absorption. In view of these problems, this invention proposes a novel perlite insulation board and its preparation process. Compared to commercially available perlite insulation boards, this process reduces the amount of binder used. The addition of composite mineral powder utilizes its gelling activity to synergistically bond the expanded perlite with the binder, while also further improving the performance indicators of the perlite insulation board. Summary of the Invention

[0004] The purpose of this invention is to address the aforementioned problems in existing technologies by proposing a novel perlite insulation board and its preparation process.

[0005] The objective of this invention can be achieved through the following technical solutions: A novel perlite insulation board, comprising: Expanded perlite granules 50-55%; composite mineral powder 10-20%; special binder 20-30%; functional additives 3-5.5%; The expanded perlite particles have a particle size gradient of 0.5-1mm (25%), 1-2mm (55%), and 2-3mm (20%), and a bulk density of ≤80kg / m³. The composite mineral powder is composed of diatomaceous earth, fly ash, and silica fume in a mass ratio of 4:3:3. The special adhesive is a styrene-acrylic emulsion modified silicate cement-based material, wherein the styrene-acrylic emulsion has a solid content of 40% and a cement / emulsion mass ratio of 2.5:1. The functional additives, by total mass, include 2% nano-titanium dioxide, 1.5% graphene-modified aerogel, and 2% polypropylene fiber.

[0006] A balance between lightweight and high strength is achieved through multi-scale gradation (perlite + composite mineral powder + fiber), and functional additives impart additional properties such as self-cleaning, crack resistance, and weather resistance.

[0007] Preferably, the expanded perlite particles undergo a two-step surface modification treatment: S1. Hydrophobic treatment: Spray coating of silane coupling agent KH-550 at an appropriate temperature, with a coating amount of 0.8-1.2 wt%. S2. Pore structure enhancement: Impregnate with 5% nano-calcium carbonate suspension, vacuum pressurize to 0.3MPa and hold for 10min, then dry to form an internal support skeleton.

[0008] Nano-calcium carbonate forms a micron-scale support framework within the pores, which enhances the compressive strength of individual particles and improves the overall compressive strength.

[0009] Preferably, 0.5-1% self-healing microcapsules are also added to the special adhesive; The microcapsule shell material is melamine resin, the core material is epoxy resin and curing agent, the particle size is 50-100μm, and the rupture threshold pressure is ≥15MPa.

[0010] Preferably, the insulation board has an embedded steel wire mesh reinforcement structure with a wire diameter of 0.5 mm and a mesh size of 25×25 mm. It is hot-dip galvanized with a coating thickness of ≥80 μm and a volume ratio of 8-12% of the total thickness of the insulation board.

[0011] A novel perlite insulation board preparation process includes the following steps: S1. Raw material pretreatment: The expanded perlite particles are placed in a microwave reactor for 3 minutes to remove adsorbed water and activate surface hydroxyl groups. The composite mineral powder is ball-milled to D90≤10μm and then preheated to 60℃ in a storage tank for later use. S2. Gradient mixing: First, mix the special adhesive with 50% water in a twin-shaft mixer. Then, add expanded perlite particles, composite mineral powder and the remaining water. Finally, add functional additives and mix evenly. S3. Oriented fabric laying: The fabric is laid in layers using a vibrating fabric laying machine, with each layer being 15mm thick. After the fabric is laid, a wire mesh is inserted. S4. Press molding, pre-curing in a constant temperature and humidity chamber for 2 hours, filling the mold with filler, applying pressure in stages using a hydraulic press, and demolding after pressing. S5. After demolding, the product is transferred to a curing rack for room temperature curing or steam curing.

[0012] Preferably, in step S2, the adhesive and water are mixed in a mixer at a speed of 60 rpm for 5 minutes; Among them, after adding expanded perlite particles and composite mineral powder, the rotation speed is 40 rpm and the stirring time is 8 min; After adding the functional additives, the rotation speed was 20 rpm and the stirring time was 3 minutes.

[0013] Preferably, in step S3, the interlayer misalignment angle is 45°, and the total number of layers is 3-5.

[0014] Preferably, in step S4, the temperature in the constant temperature and humidity chamber is set to 25±1℃ and the humidity is ≥90%.

[0015] Preferably, in step S4, the initial pressure is 0.5 MPa and held for 30 seconds, then increased to 1.5 MPa and held for 60 seconds, and finally 3 MPa and held for 120 seconds.

[0016] Preferably, in step S5, the enhanced steam curing includes three stages: stage one is saturated steam curing at 50°C for 6 hours, stage two is dry heat curing at 80°C for 12 hours, and stage three is natural curing for 7 days, with daily spraying of a silicate curing agent with pH=9.

[0017] Compared with existing technologies, this novel perlite insulation board and its preparation process have the following advantages: 1. The present invention provides a novel perlite insulation board and its preparation process, which achieves close packing through a three-level particle size gradient, and uses composite mineral powder to partially replace the adhesive for bonding the expanded perlite, effectively reducing the amount of adhesive used. At the same time, the adsorption properties of diatomaceous earth, the active effect of fly ash, and the nanoscale filling effect of silica fume are utilized to synergistically enhance the interfacial bonding force, thereby significantly improving the comprehensive performance of the insulation board, such as compressive strength.

[0018] 2. The present invention provides a novel perlite insulation board and its preparation process. Different proportions of composite mineral powder and binder are added to expanded perlite particles. By testing the flexural strength and compressive strength of the perlite insulation board under different addition proportions, it is found that when the proportion of composite mineral powder is 13% and the proportion of binder is 27%, the perlite insulation board has excellent compressive strength and flexural strength.

[0019] 3. The present invention provides a novel perlite insulation board and its preparation process, which is simpler and more effective than the molding process of perlite insulation boards on the market, and can effectively ensure the yield of perlite insulation boards.

[0020] 4. The present invention provides a novel perlite insulation board and its preparation process. By examining the effects of different amounts of composite mineral powder and adhesive added on the toughness of the perlite insulation board, it is confirmed that when the proportion of composite mineral powder is set to 12%-13% and the proportion of adhesive is adjusted to 27%-28%, the perlite insulation board exhibits strong toughness.

[0021] 5. The present invention provides a novel perlite insulation board and its preparation process. By testing the effect of different amounts of composite mineral powder and binder added on the thermal conductivity of the perlite insulation board, the optimal amount of composite mineral powder added is determined to be 13%, at which point the perlite insulation board has excellent thermal insulation performance.

[0022] In summary, this invention provides a novel perlite insulation board and its preparation process. Through a three-stage particle size gradient design, the use of composite mineral powder to replace the binder, and the synergistic effect of diatomaceous earth, fly ash, and silica fume, the compressive strength, flexural strength, toughness, and thermal insulation performance of the insulation board are effectively improved. Ultimately, the optimal formulation of this perlite insulation board is determined to be 55% expanded perlite particles, 5% functionalized additives, 13% composite mineral powder, and 27% binder. At this ratio, the perlite insulation board exhibits strong compressive strength, flexural strength, toughness, and thermal insulation performance, providing a new technical solution for the field of building insulation materials. Detailed Implementation

[0023] The following are specific embodiments of the present invention, which further describe the technical solution of the present invention, but the present invention is not limited to these embodiments. Specific Implementation Example 1:

[0025] A novel perlite insulation board includes: Expanded perlite granules 50-55%; composite mineral powder 10-20%; special binder 20-30%; functional additives 3-5.5%; The expanded perlite particles have a particle size gradient of 0.5-1mm (25%), 1-2mm (55%), and 2-3mm (20%), with a bulk density ≤80kg / m³. The expanded perlite particles undergo a two-step surface modification treatment: hydrophobic treatment, in which silane coupling agent KH-550 is sprayed and coated at 260℃-320℃ with a coating amount of 0.8-1.2wt%; and pore structure strengthening, in which 5% nano-calcium carbonate suspension is impregnated, vacuum pressurized to 0.3MPa and held for 10min, and dried to form an internal support skeleton.

[0026] The composite mineral powder is composed of diatomaceous earth, fly ash, and silica fume in a mass ratio of 4:3:3. The special adhesive is a styrene-acrylic emulsion modified silicate cement-based material, wherein the styrene-acrylic emulsion has a solid content of 40% and a cement / emulsion mass ratio of 2.5:1. The functional additives, by total mass, include 2% nano-titanium dioxide, 1.5% graphene-modified aerogel, and 2% polypropylene fiber.

[0027] A balance between lightweight and high strength is achieved through multi-scale gradation (perlite + composite mineral powder + fiber), and functional additives impart additional properties such as self-cleaning, crack resistance, and weather resistance.

[0028] Nano-calcium carbonate forms a micron-scale support framework within the pores, which enhances the compressive strength of individual particles and improves the overall compressive strength.

[0029] The special adhesive also contains 0.5-1% self-healing microcapsules. The shell material of the microcapsules is melamine resin, and the core material is epoxy resin and curing agent. The particle size is 50-100μm, and the bursting threshold pressure is ≥15MPa. The insulation board has an embedded steel wire mesh reinforcement structure with a wire diameter of 0.5mm and a mesh size of 25×25mm. It is hot-dip galvanized with a coating thickness of ≥80μm and a volume ratio of 8-12% of the total thickness of the insulation board. Specific Implementation Example 2:

[0031] A novel perlite insulation board preparation process includes the following steps: S1. Raw material pretreatment: The expanded perlite particles are placed in a microwave reactor for 3 minutes to remove adsorbed water and activate surface hydroxyl groups. The composite mineral powder is ball-milled to D90≤10μm and then preheated to 60℃ in a storage tank for later use. S2. Gradient mixing: First, mix the special binder with 50% water in a twin-shaft mixer (60 rpm, 5 min). Then add expanded perlite particles, composite mineral powder and remaining water (40 rpm, 8 min). Finally, add the functional additives (20 rpm, 3 min) and mix evenly. S3. Oriented fabric laying: The vibratory fabric laying machine is used to lay the fabric in layers, with each layer being 15mm thick. After the fabric is laid, a wire mesh is inserted. The interlayer misalignment angle is 45°, and the total number of layers is 3-5. S4. Press molding: Pre-cur in a constant temperature and humidity chamber (25±1℃, humidity ≥90%) for 2 hours, fill the mold with filling material, and use a hydraulic press to apply pressure in stages (initial pressure 0.5MPa, hold for 30s, then increase to 1.5MPa, hold for 60s, final pressure 3MPa, hold for 120s). After pressing, demold. S5. After demolding, the product is transferred to a curing rack for room temperature curing or steam curing.

[0032] The steam curing enhancement includes three stages: stage one is saturated steam curing at 50℃ for 6 hours, stage two is dry heat curing at 80℃ for 12 hours, and stage three is natural curing for 7 days, with daily spraying of a silicate curing agent with pH=9. Specific Implementation Example 3:

[0034] Specific Example 3 is an experiment on the effect of different amounts of composite mineral powder and binder mentioned in Specific Examples 1 and 2 on the flexural strength of perlite insulation board. The specific content of Specific Example 3 is as follows: 1. Determine the added amount of expanded perlite particles to be 55%, the added amount of functional additives to be 5%, and the total proportion of composite mineral powder and binder to be 40%. Prepare five experimental groups as follows: A: 10% composite mineral powder, 30% binder, 55% expanded perlite granules, and 5% functional additives; B: 11% composite mineral powder, 29% binder, 55% expanded perlite granules, and 5% functional additives; C: 12% composite mineral powder, 28% binder, 55% expanded perlite granules, and 5% functional additives; D: 13% composite mineral powder, 27% binder, 55% expanded perlite granules, and 5% functional additives; E: 14% composite mineral powder, 26% binder, 55% expanded perlite granules, and 5% functional additives. The comparative example uses 55% expanded perlite granules, 40% special binder, and 5% functional additives to prepare the insulation board.

[0035] 2. Pre-treat expanded perlite particles in a microwave reactor for 3 minutes to remove adsorbed water and activate surface hydroxyl groups. After ball milling the composite mineral powder to D90≤10μm, preheat it to 60℃ in a storage tank for later use. First, mix the special binder with 50% water in a twin-shaft mixer (60rpm, 5min). Then add the expanded perlite particles, composite mineral powder, and remaining water (40rpm, 8min). Finally, add the functional additives (20rpm, 3min) and mix evenly. Use a vibrating cloth spreader to spread the material in layers. Press and mold, pre-cur in a constant temperature and humidity chamber (25±1℃, ≥90%) for 2 hours. Fill the mold with filler and apply pressure in stages using a hydraulic press. After pressing, cool and demold.

[0036] 3. Flexural strength was tested according to the specifications in "Test Methods for Inorganic Rigid Thermal Insulation Products" (GB / T5486—2008). The width (b) and thickness (h) of the specimen were measured to an accuracy of 0.1 mm. The specimens were placed symmetrically on the support rollers, with the loading rollers aligned with the center of the specimens. A uniform loading rate of (2±0.5) mm / min was applied until the specimen broke. The breaking load (F, unit: N) was recorded. The flexural strength R = 3FL / 2bh 2 The unit is MPa.

[0037] The table below shows that, compared to the comparative example, the flexural strength of the specimens with added composite mineral powder was improved. When the composite mineral powder content reached 13%, the flexural strength reached a maximum of 0.52 MPa.

[0038] Table 1. Effect of Addition Amount on Flexural Strength of Insulation Board Specific Implementation Example 4: Specific Example 4 is an experiment on the effect of different amounts of composite mineral powder and binder mentioned in Specific Examples 1 and 2 on the compressive strength of perlite insulation board. The content of Specific Example 4 is as follows: 1. Determine the added amount of expanded perlite particles to be 55%, the added amount of functional additives to be 5%, and the total proportion of composite mineral powder and binder to be 40%. Prepare five experimental groups as follows: A: 10% composite mineral powder, 30% binder, 55% expanded perlite granules, and 5% functional additives; B: 11% composite mineral powder, 29% binder, 55% expanded perlite granules, and 5% functional additives; C: 12% composite mineral powder, 28% binder, 55% expanded perlite granules, and 5% functional additives; D: 13% composite mineral powder, 27% binder, 55% expanded perlite granules, and 5% functional additives; E: 14% composite mineral powder, 26% binder, 55% expanded perlite granules, and 5% functional additives. The comparative example uses 55% expanded perlite granules, 40% special binder, and 5% functional additives to prepare the insulation board.

[0040] 2. Pre-treat expanded perlite particles in a microwave reactor for 3 minutes to remove adsorbed water and activate surface hydroxyl groups. After ball milling the composite mineral powder to D90≤10μm, preheat it to 60℃ in a storage tank for later use. First, mix the special binder with 50% water in a twin-shaft mixer (60rpm, 5min). Then add the expanded perlite particles, composite mineral powder, and remaining water (40rpm, 8min). Finally, add the functional additives (20rpm, 3min) and mix evenly. Use a vibrating cloth spreader to spread the material in layers. Press and mold, pre-cur in a constant temperature and humidity chamber (25±1℃, ≥90%) for 2 hours. Fill the mold with filler and apply pressure in stages using a hydraulic press. After pressing, cool and demold.

[0041] 3. The compressive strength shall be tested in accordance with the provisions of "Test Methods for Inorganic Rigid Thermal Insulation Products" (GB / T5486—2008). The actual size of the specimen shall be measured (accurate to 0.1 mm), and the compressive area (A, unit: mm²) shall be calculated. The specimen shall be placed in the center of the press, with the upper and lower pressure plates parallel to the surface of the specimen. The specimen shall be loaded at a uniform speed of (5±1) mm / min until it fails. The maximum load (F, unit: N) shall be recorded. The compressive strength σ = F / A, and the unit is MPa.

[0042] The table below shows that, compared to the comparative example, the compressive strength of the specimens with added composite mineral powder was improved. When the composite mineral powder content reached 13%, the flexural strength reached a maximum of 0.48 MPa.

[0043] Table 2 Effect of Addition Amount on Compressive Strength of Insulation Board Specific Implementation Example 5: Specific Example 5 is an experiment on the effect of different amounts of composite mineral powder and binder mentioned in Specific Examples 1 and 2 on the toughness of perlite insulation board. The content of Specific Example 5 is as follows: 1. Determine the added amount of expanded perlite particles to be 55%, the added amount of functional additives to be 5%, and the total proportion of composite mineral powder and binder to be 40%. Prepare five experimental groups as follows: A: 10% composite mineral powder, 30% binder, 55% expanded perlite granules, and 5% functional additives; B: 11% composite mineral powder, 29% binder, 55% expanded perlite granules, and 5% functional additives; C: 12% composite mineral powder, 28% binder, 55% expanded perlite granules, and 5% functional additives; D: 13% composite mineral powder, 27% binder, 55% expanded perlite granules, and 5% functional additives; E: 14% composite mineral powder, 26% binder, 55% expanded perlite granules, and 5% functional additives. The comparative example uses 55% expanded perlite granules, 40% special binder, and 5% functional additives to prepare the insulation board.

[0045] 2. Pre-treat expanded perlite particles in a microwave reactor for 3 minutes to remove adsorbed water and activate surface hydroxyl groups. After ball milling the composite mineral powder to D90≤10μm, preheat it to 60℃ in a storage tank for later use. First, mix the special binder with 50% water in a twin-shaft mixer (60rpm, 5min). Then add the expanded perlite particles, composite mineral powder, and remaining water (40rpm, 8min). Finally, add the functional additives (20rpm, 3min) and mix evenly. Use a vibrating cloth spreader to spread the material in layers. Press and mold, pre-cur in a constant temperature and humidity chamber (25±1℃, ≥90%) for 2 hours. Fill the mold with filler and apply pressure in stages using a hydraulic press. After pressing, cool and demold.

[0046] 3. Toughness, as a mechanical index characterizing the energy absorption capacity of a material during deformation or fracture, is a composite characteristic of material strength and deformation capacity. It can be achieved by measuring the deflection of the specimen and plotting the load-deflection curve using a universal testing machine. Specifically, the area enclosed by the load-deflection curve when the deflection reaches 2 mm is calculated using the curve integral method as the toughness value. At the same time, the toughness index (defined as the ratio of the area of ​​the curve when the deflection reaches 2 mm to the area of ​​the curve at the initial crack point) is introduced for dual characterization. The correspondence between the two is detailed in the data in the table below.

[0047] The table below shows that the control group had the lowest toughness value and a small toughness index due to the high brittleness of the adhesive and uneven fiber dispersion. In the experimental group, group D (13% composite mineral powder) achieved a toughness index of 3.0 through the synergistic effect of composite mineral powder and adhesive, which was significantly improved compared with the control group.

[0048] Table 3 Effect of Additive Amount on Insulation Board Toughness Specific Implementation Example Six: Specific Example Six is ​​an experiment on the effect of different amounts of composite mineral powder and binder mentioned in Specific Examples One and Two on the thermal conductivity of perlite insulation board. The content of Specific Example Six is ​​as follows: 1. Determine the added amount of expanded perlite particles to be 55%, the added amount of functional additives to be 5%, and the total proportion of composite mineral powder and binder to be 40%. Prepare five experimental groups as follows: A: 10% composite mineral powder, 30% binder, 55% expanded perlite granules, and 5% functional additives; B: 11% composite mineral powder, 29% binder, 55% expanded perlite granules, and 5% functional additives; C: 12% mineral powder, 28% binder, 55% expanded perlite granules, and 5% functional additives; D: 13% composite mineral powder, 27% binder, 55% expanded perlite granules, and 5% functional additives; E: 14% composite mineral powder, 26% binder, 55% expanded perlite granules, and 5% functional additives. The comparative example uses 55% expanded perlite granules, 40% special binder, and 5% functional additives to prepare the insulation board.

[0050] 2. Pre-treat expanded perlite particles in a microwave reactor for 3 minutes to remove adsorbed water and activate surface hydroxyl groups. After ball milling the composite mineral powder to D90≤10μm, preheat it to 60℃ in a storage tank for later use. First, mix the special binder with 50% water in a twin-shaft mixer (60rpm, 5min). Then add the expanded perlite particles, composite mineral powder, and remaining water (40rpm, 8min). Finally, add the functional additives (20rpm, 3min) and mix evenly. Use a vibrating cloth spreader to spread the material in layers. Press and mold, pre-cur in a constant temperature and humidity chamber (25±1℃, ≥90%) for 2 hours. Fill the mold with filler and apply pressure in stages using a hydraulic press. After pressing, cool and demold.

[0051] 3. Thermal conductivity was determined according to the specifications in "Determination of Steady-State Thermal Resistance and Related Properties of Insulation Materials" (GB / T10294—2008). As shown in the table below, the thermal conductivity of the specimen with added composite mineral powder was improved compared to the comparative example. When the composite mineral powder content reached 13%, the insulation effect of the insulation board was better.

[0052] Table 4. Effect of Addition Amount on Thermal Conductivity of Insulation Board

[0053] In summary, with the proportion of composite mineral powder controlled at 12-13% and the proportion of binder controlled at 27-28%, perlite insulation boards exhibit excellent compressive strength, flexural strength, toughness, and thermal insulation performance.

[0054] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. A novel perlite insulation board, characterized in that, include: Expanded perlite granules 50-55%; composite mineral powder 10-20%; special binder 20-30%; functional additives 3-5.5%; The expanded perlite particles have a particle size gradient of 0.5-1mm (25%), 1-2mm (55%), and 2-3mm (20%), and a bulk density of ≤80kg / m³. The composite mineral powder is composed of diatomaceous earth, fly ash, and silica fume in a mass ratio of 4:3:

3. The special adhesive is a styrene-acrylic emulsion modified silicate cement-based material, wherein the styrene-acrylic emulsion has a solid content of 40% and a cement / emulsion mass ratio of 2.5:

1. The functional additives, by total mass, include 2% nano-titanium dioxide, 1.5% graphene-modified aerogel, and 2% polypropylene fiber.

2. The novel perlite insulation board as described in claim 1, characterized in that, The expanded perlite particles undergo a two-step surface modification treatment: S1. Hydrophobic treatment: Spray coating of silane coupling agent KH-550 at an appropriate temperature, with a coating amount of 0.8-1.2 wt%. S2. Pore structure enhancement: Impregnate with 5% nano-calcium carbonate suspension, vacuum pressurize to 0.3MPa and hold for 10min, then dry to form an internal support skeleton.

3. The novel perlite insulation board as described in claim 1, characterized in that, The special adhesive also contains 0.5-1% self-healing microcapsules; The microcapsule shell material is melamine resin, the core material is epoxy resin and curing agent, the particle size is 50-100μm, and the rupture threshold pressure is ≥15MPa.

4. The novel perlite insulation board as described in claim 1, characterized in that, The insulation board has an embedded steel wire mesh reinforcement structure with a wire diameter of 0.5mm and a mesh size of 25×25mm. It is hot-dip galvanized with a coating thickness of ≥80μm and a volume ratio of 8-12% of the total thickness of the insulation board.

5. A preparation process for a novel perlite insulation board as described in any one of claims 1-4, characterized in that, Includes the following steps: S1. Raw material pretreatment: The expanded perlite particles are placed in a microwave reactor for 3 minutes to remove adsorbed water and activate surface hydroxyl groups. The composite mineral powder is ball-milled to D90≤10μm and then preheated to 60℃ in a storage tank for later use. S2. Gradient mixing: First, mix the special adhesive with 50% water in a twin-shaft mixer. Then, add expanded perlite particles, composite mineral powder and the remaining water. Finally, add functional additives and mix evenly. S3. Oriented fabric laying: The fabric is laid in layers using a vibrating fabric laying machine, with each layer being 15mm thick. After the fabric is laid, a wire mesh is inserted. S4. Press molding, pre-curing in a constant temperature and humidity chamber for 2 hours, filling the mold with filler, applying pressure in stages using a hydraulic press, and demolding after pressing. S5. After demolding, the product is transferred to a curing rack for room temperature curing or steam curing.

6. The preparation process of a novel perlite insulation board as described in claim 5, characterized in that, In step S2, the adhesive and water are mixed in a mixer at 60 rpm for 5 minutes. Among them, after adding expanded perlite particles and composite mineral powder, the rotation speed is 40 rpm and the stirring time is 8 min; After adding the functional additives, the rotation speed was 20 rpm and the stirring time was 3 minutes.

7. The preparation process of a novel perlite insulation board as described in claim 5, characterized in that, In step S3, the interlayer misalignment angle is 45°, and the total number of layers is 3-5.

8. The preparation process of a novel perlite insulation board as described in claim 5, characterized in that, In step S4, the temperature in the constant temperature and humidity chamber is set to 25±1℃ and the humidity is ≥90%.

9. The preparation process of a novel perlite insulation board as described in claim 5, characterized in that, In step S4, the initial pressure is 0.5 MPa and held for 30 seconds, then increased to 1.5 MPa and held for 60 seconds, and finally 3 MPa and held for 120 seconds.

10. The preparation process of a novel perlite insulation board as described in claim 5, characterized in that, In step S5, the enhanced steam curing includes three stages: stage one is saturated steam curing at 50°C for 6 hours, stage two is dry heat curing at 80°C for 12 hours, and stage three is natural curing for 7 days, with daily spraying of a silicate curing agent with pH=9.

Images