Foam concrete insulation board and preparation method thereof

Abstract

The present invention provides a foam concrete insulation board and a preparation method thereof, including: a plurality of vertical fiber bundles are arranged in a concrete base, one end of the vertical fiber bundle is fixed in the concrete base, the other end of the vertical fiber bundle runs through the concrete base and extends vertically upward, a plurality of transverse fiber bundles are arranged between the plurality of vertical fiber bundles to carry out multi-level winding connection of the plurality of vertical fiber bundles along one end of the vertical fiber bundle to the other end, and a plurality of vertical fiber bundles and transverse fiber bundles are combined into a tightly connected network skeleton; a filling layer, a filling layer is cast in a network skeleton on a concrete base, and the filling layer is made of the following components in parts by weight: 20-30 parts of cement mortar, 8-12 parts of palygorskite, 4-8 parts of foaming agent, 3-6 parts of plasticizer, 1-2 parts of waterproofing agent, 20-25 parts of water, 0.5-2 parts of auxiliary materials, and a preparation method of a foam concrete insulation board. The foam concrete insulation board of the present invention has a strong bonding strength.

Description

Technical Field

[0001] The invention relates to a thermal insulation board and a preparation method thereof, in particular to a foam concrete thermal insulation board and a preparation method thereof. Background Art

[0002] Foam concrete (also known as foamed cement, lightweight concrete) is a new type of building energy-saving material that is waste-recycling, environmentally friendly, energy-saving, inexpensive and non-flammable; foam concrete insulation board is a kind of insulation board with the characteristics of lightweight insulation, good durability, combustion performance reaching Class A, low carbon and environmental protection, energy saving and waste recycling. It is suitable for exterior wall insulation and its fire isolation zone, and meets the urgent need for fire safety in the exterior wall insulation market.

[0003] Since the foam concrete insulation board in the prior art is generally prepared by mixing concrete with various materials, the bonding between the various materials is fixed by fibers, and the fibers are generally mixed with concrete at random, so that the foam concrete insulation board formed has poor strength and is very likely to crack during long-term use. Therefore, the present invention studies and designs a foam concrete insulation board. Summary of the invention

[0004] Therefore, the technical problem to be solved by the present invention is to overcome the defects of poor strength of the foam concrete insulation board in the prior art and easy cracking during long-term use, thereby providing a foam concrete insulation board and a preparation method thereof.

[0005] In order to solve the above problems, the present invention provides a foam concrete insulation board, which comprises:

[0006] A concrete base layer, wherein a plurality of vertical fiber bundles are arranged in the concrete base layer, one end of the vertical fiber bundle is fixed in the concrete base layer, the other end of the vertical fiber bundle passes through the concrete base layer and extends vertically upward, a plurality of transverse fiber bundles are arranged between the plurality of vertical fiber bundles so as to connect the plurality of vertical fiber bundles by winding them in multiple layers along one end of the vertical fiber bundle to the other end, and the plurality of vertical fiber bundles and the transverse fiber bundles are combined into a tightly connected network skeleton;

[0007] A filling layer is cast in a network skeleton on the concrete base, and is made of the following components in parts by weight: 20-30 parts of cement mortar, 8-12 parts of palygorskite, 4-8 parts of foaming agent, 3-6 parts of plasticizer, 1-2 parts of waterproofing agent, 20-25 parts of water, and 0.5-2 parts of auxiliary materials.

[0008] Preferably, the plurality of vertical fiber bundles are evenly distributed in the concrete base layer in a rectangular matrix.

[0009] Preferably, the vertical fiber bundles and the transverse fiber bundles are one or at least two of polyvinyl alcohol fibers, basalt fibers, glass fibers or carbon fibers.

[0010] Preferably, the waterproofing agent is a melamine-based waterproofing agent.

[0011] Preferably, the auxiliary material is one or a combination of latex powder, polyvinyl alcohol, and lithium carbonate.

[0012] Preferably, the foaming agent is a two-component physical foaming agent containing a foam stabilizer.

[0013] The present invention also provides a method for preparing a foamed concrete insulation board, which includes the method for preparing a foamed concrete insulation board as described in any of the preceding items, comprising the following steps:

[0014] Step 1: Prefabricate the mold required for the concrete base and waterproof the bottom and corners of the mold:

[0015] Step 2, pouring concrete into the mold, inserting multiple vertical fibers evenly into the poured concrete base in a rectangular matrix, and allowing them to dry naturally, winding and connecting the transverse fiber bundles between the multiple vertical fiber bundles, and performing multi-layer winding from one end to the other end of the vertical fiber bundles to obtain a combined network skeleton;

[0016] Step 3, weigh the raw materials, by weight, 20-30 parts of cement mortar, 8-12 parts of palygorskite, 3-6 parts of plasticizer, 1-2 parts of waterproofing agent, 20-25 parts of water, 0.5-2 parts of auxiliary materials, stir at a rate of 20-45r / min for 3-4min to mix evenly, then add 4-8 parts of foaming agent and stir the mixed plate at a rate of 40-120r / min for 3-4min, pour it in a mold, heat it to a certain extent, and perform moisture curing to form a foam concrete insulation board.

[0017] Preferably, the curing temperature of the foam concrete insulation board is 65° C. to 75° C., the humidity is ≥80%, and the curing is for 12 hours.

[0018] Preferably, when the foam concrete insulation board is poured, the injection amount each time is 1 / 4 of the total injection amount.

[0019] The foam concrete insulation board and the preparation method thereof provided by the present invention have the following beneficial effects:

[0020] The present invention arranges vertical fiber bundles in a prefabricated concrete base layer, and arranges multiple transverse fiber bundles between the multiple vertical fiber bundles to connect the multiple vertical fiber bundles by multi-layer winding along one end of the vertical fiber bundle to the other end. The multiple vertical fiber bundles and the transverse fiber bundles are combined into a tightly connected network skeleton, so that after the filling layer is injected into the network skeleton, they can be tightly connected together, thereby enhancing the strength of the foam concrete insulation board. At the same time, palygorskite is used in the filling layer. Since palygorskite is light in weight, has a large specific surface area and adsorption capacity, good rheological and catalytic properties, and good colloidal properties, it can improve the bonding between the components in the filling layer, thereby enhancing the strength performance of the foam concrete insulation board. DETAILED DESCRIPTION

[0021] The present invention will be further described below with reference to specific embodiments, but they are not intended to be limiting of the present invention.

[0022] The present application discloses a foam concrete insulation board, which comprises:

[0023] A concrete base layer, wherein a plurality of vertical fiber bundles are arranged in the concrete base layer, one end of the vertical fiber bundle is fixed in the concrete base layer, the other end of the vertical fiber bundle passes through the concrete base layer and extends vertically upward, a plurality of transverse fiber bundles are arranged between the plurality of vertical fiber bundles so as to connect the plurality of vertical fiber bundles by winding them in multiple layers along one end of the vertical fiber bundle to the other end, and the plurality of vertical fiber bundles and the transverse fiber bundles are combined into a tightly connected network skeleton to form a concrete insulation board with higher strength;

[0024] A filling layer is cast in a network skeleton on the concrete base, and the filling layer is made of the following components in parts by weight: 20-30 parts of cement mortar, 8-12 parts of palygorskite, 4-8 parts of foaming agent, 3-6 parts of plasticizer, 1-2 parts of waterproofing agent, 20-25 parts of water, and 0.5-2 parts of auxiliary materials, and the components are mixed in different orders, wherein a vertical fiber bundle is arranged in the prefabricated concrete base, and a plurality of transverse fiber bundles are arranged between the plurality of vertical fiber bundles so as to connect the plurality of vertical fiber bundles by multi-layer winding along one end of the vertical fiber bundle to the other end, and the plurality of vertical fiber bundles and the transverse fiber bundles are combined into a tightly connected network skeleton, so that after the filling layer is injected into the network skeleton, the network skeleton can be tightly connected together, thereby enhancing the strength of the foam concrete insulation board, and palygorskite is used in the filling layer. Since palygorskite is light in weight, has a large specific surface area and adsorption capacity, good rheological properties and catalytic properties, and good colloidal properties, the bonding between the components in the filling layer can be improved, thereby enhancing the strength performance of the foam concrete insulation board.

[0025] Preferably, the plurality of vertical fiber bundles are evenly distributed in the concrete base layer in the form of a rectangular matrix, and the evenly distributed rectangular matrix makes the combined network skeleton more compact.

[0026] Preferably, the vertical fiber bundles and the transverse fiber bundles are one or at least two of polyvinyl alcohol fibers, basalt fibers, glass fibers or carbon fibers.

[0027] Preferably, the waterproofing agent is a melamine-based waterproofing agent.

[0028] Preferably, the auxiliary material is one or a combination of latex powder, polyvinyl alcohol, and lithium carbonate.

[0029] Preferably, the foaming agent is a two-component physical foaming agent containing a foam stabilizer.

[0030] Embodiment 1:

[0031] Prefabricate the mold required for the concrete base, and waterproof the bottom and corners of the mold:

[0032] Concrete is poured into the mold, and multiple vertical fibers are uniformly inserted into the poured concrete base layer in a rectangular matrix, and after being naturally air-dried, the transverse fiber bundles are wound and connected between the multiple vertical fiber bundles, and multiple layers of winding are performed along one end of the vertical fiber bundle to the other end to obtain a combined network skeleton;

[0033] Calculated by weight, 20 parts of cement mortar, 8 parts of palygorskite, 3 parts of plasticizer, 1 part of waterproofing agent, 20 parts of water and 1 part of auxiliary materials are stirred at 40r / min for 3 minutes to mix evenly, then 4 parts of foaming agent are added and stirred at 60r / min for 4 minutes to roll the board, and the injection amount each time is 1 / 4 of the total injection amount and poured into the mold, heated to 65℃, and cured at 80% humidity for 12 hours to form a foam concrete insulation board.

[0034] The vertical fiber bundle is polyvinyl alcohol fiber, and the transverse fiber bundle is basalt fiber; the waterproofing agent is a melamine-based waterproofing agent, specifically a sulfonated melamine waterproofing agent; the auxiliary material is latex powder; and the foaming agent is a two-component physical foaming agent containing a foam stabilizer, specifically a two-component polyurethane foaming agent.

[0035] After testing, the foam concrete insulation board prepared in this embodiment has the following properties: density of 400 kg / m3, thermal conductivity of 0.071 w / (m·k), and bonding strength of 0.71 MPa, which meets industrialization requirements and conforms to industry standards.

[0036] Embodiment 2:

[0037] Prefabricate the mold required for the concrete base, and waterproof the bottom and corners of the mold:

[0038] Concrete is poured into the mold, and multiple vertical fibers are uniformly inserted into the poured concrete base layer in a rectangular matrix, and after being naturally air-dried, the transverse fiber bundles are wound and connected between the multiple vertical fiber bundles, and multiple layers of winding are performed along one end of the vertical fiber bundle to the other end to obtain a combined network skeleton;

[0039] Calculated by weight, 23 parts of cement mortar, 11 parts of palygorskite, 4 parts of plasticizer, 1 part of waterproofing agent, 25 parts of water and 1 part of auxiliary materials are stirred at 45r / min for 4 minutes to mix evenly, then 4 parts of foaming agent are added and stirred at 80r / min for 4 minutes to roll the board, and the injection amount each time is 1 / 4 of the total injection amount and poured into the mold, heated to 70℃, and cured at 80% humidity for 12 hours to form a foam concrete insulation board.

[0040] The vertical fiber bundles are polyvinyl alcohol fibers, and the transverse fiber bundles are carbon fibers; the waterproofing agent is a melamine-based waterproofing agent, specifically a sulfonated melamine waterproofing agent; the auxiliary material is polyvinyl alcohol; and the foaming agent is a two-component physical foaming agent containing a foam stabilizer, specifically a two-component polyurethane foaming agent.

[0041] After testing, the foam concrete insulation board prepared in this embodiment has the following properties: density of 412kg / m3, thermal conductivity of 0.068w / (m·k), and bonding strength of 0.73MPa, which meets industrialization requirements and conforms to industry standards.

[0042] Embodiment 3:

[0043] Prefabricate the mold required for the concrete base, and waterproof the bottom and corners of the mold:

[0044] Concrete is poured into the mold, and multiple vertical fibers are uniformly inserted into the poured concrete base layer in a rectangular matrix, and after being naturally air-dried, the transverse fiber bundles are wound and connected between the multiple vertical fiber bundles, and multiple layers of winding are performed along one end of the vertical fiber bundle to the other end to obtain a combined network skeleton;

[0045] Calculated by weight, 30 parts of cement mortar, 12 parts of palygorskite, 5 parts of plasticizer, 2 parts of waterproofing agent, 25 parts of water and 1 part of auxiliary material are stirred at 45r / min for 4 minutes to be evenly mixed, then 8 parts of foaming agent are added and stirred at 80r / min for 4 minutes to roll the board, and the injection amount each time is 1 / 4 of the total injection amount and poured into the mold, heated to 70℃, and cured at 80% humidity for 12 hours to form a foam concrete insulation board.

[0046] The vertical fiber bundles and the transverse fiber bundles are both polyvinyl alcohol fibers; the waterproofing agent is a melamine-based waterproofing agent, specifically a sulfonated melamine waterproofing agent; the auxiliary material is lithium carbonate; the foaming agent is a two-component physical foaming agent containing a foam stabilizer, specifically a two-component polyurethane foaming agent.

[0047] After testing, the foam concrete insulation board prepared in this embodiment has the following properties: density of 416 kg / m3, thermal conductivity of 0.065 w / (m·k), and bonding strength of 0.65 MPa, which meets industrialization requirements and conforms to industry standards.

[0048] Comparative Example 1:

[0049] Prefabricate the mold required for the concrete base, and waterproof the bottom and corners of the mold:

[0050] Concrete is poured into the mold, and multiple vertical fibers are uniformly inserted into the poured concrete base layer in a rectangular matrix, and after being naturally air-dried, the transverse fiber bundles are wound and connected between the multiple vertical fiber bundles, and multiple layers of winding are performed along one end of the vertical fiber bundle to the other end to obtain a combined network skeleton;

[0051] Calculated by weight, 30 parts of cement mortar, 2 parts of palygorskite, 3 parts of plasticizer, 2 parts of waterproofing agent, 20 parts of water and 1 part of auxiliary material are stirred at 45r / min for 4 minutes to mix evenly, then 8 parts of foaming agent are added and stirred at 80r / min for 4 minutes to roll the board, and the injection amount each time is 1 / 4 of the total injection amount and poured into the mold, heated to 70℃, and cured at 80% humidity for 12 hours to form a foam concrete insulation board.

[0052] The vertical fiber bundles and the transverse fiber bundles are both polyvinyl alcohol fibers; the waterproofing agent is a melamine-based waterproofing agent, specifically a sulfonated melamine waterproofing agent; the auxiliary material is lithium carbonate; the foaming agent is a two-component physical foaming agent containing a foam stabilizer, specifically a two-component polyurethane foaming agent.

[0053] After testing, the foam concrete insulation board prepared in this embodiment has the following properties: density of 406 kg / m3, thermal conductivity of 0.060 w / (m·k), and bonding strength of 0.41 MPa, which do not meet industrialization requirements and do not meet industry standards.

[0054] Comparative Example 1 was used to form a frame composed of vertical fibers and transverse fiber bundles, but the bonding strength was not high due to the low weight percentage of the palygorskite.

[0055] Comparative Example 2:

[0056] Prefabricate the mold required for the concrete base, and waterproof the bottom and corners of the mold:

[0057] Pour concrete into the mold, calculated by weight, including 30 parts of cement mortar, 2 parts of palygorskite, 3 parts of plasticizer, 2 parts of waterproofing agent, 20 parts of water and 1 part of auxiliary material, stir at 45r / min for 4 minutes to mix evenly, then add 8 parts of foaming agent and stir at 80r / min for 4 minutes to roll the plate, pour in the mold each time at 1 / 4 of the total injection amount, heat to 70°C, and maintain at 80% humidity for 12 hours to form a foam concrete insulation board.

[0058] The waterproofing agent is a melamine-based waterproofing agent, specifically a sulfonated melamine waterproofing agent; the auxiliary material is lithium carbonate; and the foaming agent is a two-component physical foaming agent containing a foam stabilizer, specifically a two-component polyurethane foaming agent.

[0059] After testing, the foam concrete insulation board prepared in this embodiment has the following properties: density of 380 kg / m3, thermal conductivity of 0.070 w / (m·k), and bonding strength of 0.37 MPa, which do not meet the industrialization requirements and do not meet the industry standards.

[0060] In Comparative Example 2, since there is no frame composed of vertical fibers and transverse fiber bundles, the bonding strength is low.

[0061] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principle of the present invention shall be included in the protection scope of the present invention. The above description is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and variations can be made without departing from the technical principles of the present invention. These improvements and variations should also be regarded as the protection scope of the present invention.

Claims

1. Foam concrete insulation board, characterized by: include: A concrete base layer, wherein a plurality of vertical fiber bundles are arranged in the concrete base layer, one end of the vertical fiber bundle is fixed in the concrete base layer, the other end of the vertical fiber bundle passes through the concrete base layer and extends vertically upward, a plurality of transverse fiber bundles are arranged between the plurality of vertical fiber bundles so as to connect the plurality of vertical fiber bundles by winding them in multiple layers along one end of the vertical fiber bundle to the other end, and the plurality of vertical fiber bundles and the transverse fiber bundles are combined into a tightly connected network skeleton; A filling layer is cast in a network skeleton on the concrete base, and is made of the following components in parts by weight: 20-30 parts of cement mortar, 8-12 parts of palygorskite, 4-8 parts of foaming agent, 3-6 parts of plasticizer, 1-2 parts of waterproofing agent, 20-25 parts of water, and 0.5-2 parts of auxiliary materials.

2. The foam concrete insulation board according to claim 1, characterized in that: The plurality of vertical fiber bundles are evenly distributed in the concrete base layer in a rectangular matrix.

3. The foam concrete insulation board according to claim 1, characterized in that: The vertical fiber bundles and the transverse fiber bundles are one or at least two of polyvinyl alcohol fibers, basalt fibers, glass fibers or carbon fibers.

4. The foam concrete insulation board according to claim 1, characterized in that: The waterproofing agent is a melamine waterproofing agent.

5. The foam concrete insulation board according to claim 1, characterized in that: The auxiliary material is one or a combination of latex powder, polyvinyl alcohol and lithium carbonate.

6. The foam concrete insulation board according to claim 1, characterized in that: The foaming agent is a two-component physical foaming agent containing a foam stabilizer.

7. The method for preparing the foamed concrete insulation board according to any one of claims 1 to 6, characterized in that: The following steps are involved: Step 1: Prefabricate the mold required for the concrete base and waterproof the bottom and corners of the mold: Step 2, pouring concrete into the mold, inserting multiple vertical fibers evenly into the poured concrete base in a rectangular matrix, and allowing them to dry naturally, winding and connecting the transverse fiber bundles between the multiple vertical fiber bundles, and performing multi-layer winding from one end to the other end of the vertical fiber bundles to obtain a combined network skeleton; Step 3, weigh the raw materials, by weight, 20-30 parts of cement mortar, 8-12 parts of palygorskite, 3-6 parts of plasticizer, 1-2 parts of waterproofing agent, 20-25 parts of water, 0.5-2 parts of auxiliary materials, stir at a rate of 20-45r / min for 3-4min to mix evenly, then add 4-8 parts of foaming agent and stir the mixed plate at a rate of 40-120r / min for 3-4min, pour it in a mold, heat it to a certain extent, and perform moisture curing to form a foam concrete insulation board.

8. The method for preparing the foamed concrete insulation board according to claim 7, characterized in that: The curing temperature of the foam concrete insulation board is 65° C. to 75° C., the humidity is ≥80%, and the curing time is 12 hours.

9. The method for preparing the foamed concrete insulation board according to claim 7, characterized in that: When the foam concrete thermal insulation board is poured, the injection amount each time is 1 / 4 of the total injection amount.