Preparation process of aerogel composite board

Abstract

The present invention discloses a process for preparing an aerogel composite board, comprising the following steps: providing several groups of thin inorganic fiber continuous felts as substrates; treating the surfaces of the fiber filaments of the thin inorganic fiber continuous felts with a hydrophilic base solution via a shower coating or roller coating process; and continuously subjecting each group of the substrates to a pressure injection process for injection of aerogel slurry; stacking the several groups of extruded substrates on a production line to form a composite continuous substrate having a length, and subjecting the composite continuous substrate to a layered and pleated process. The layered and pleated process includes sequentially dividing the composite continuous substrate into multiple, yet continuously connected, sections along the length direction, and stacking the sections in layers and pleating them; pressing the laminated and pleated laminates, and then embedding tensile and compressive support members in the laminated and shaped sections. The aerogel composite board produced by this process exhibits excellent thermal insulation performance and tensile and compressive strength.

Description

Technical Field

[0001] The invention relates to the technical field of housing construction engineering, and in particular to a preparation process of an aerogel composite board. Background Art

[0002] Existing technologies use aerogel materials as panels for thermally insulated buildings. However, some existing aerogel products have poor internal distribution uniformity, resulting in uneven overall thermal conductivity and difficulty maintaining uniform thermal insulation performance. Furthermore, these aerogel products have low tensile and compressive strengths, posing numerous safety risks.

[0003] Therefore, how to provide a preparation process for composite panels that can solve the above-mentioned drawbacks has become a technical problem that those skilled in the art urgently need to solve. Summary of the Invention

[0004] In order to solve the above technical problems, the present invention provides a preparation process of an aerogel composite plate, and the specific technical solution is as follows:

[0005] A process for preparing an aerogel composite plate comprises the following steps:

[0006] Providing several groups of thin inorganic fiber continuous felt materials as substrates, each group of the substrates being a continuous felt material with a thickness of 3-10 mm;

[0007] The surfaces of the fiber filaments of the thin inorganic fiber continuous felt are treated by a hydrophilic base solution through a shower coating or roller coating process, so that the surfaces thereof have hydrophilicity;

[0008] The plurality of groups of substrates after the above treatment are pre-dried by filter pressing to make them wet, and each group of substrates continuously enters the pressure extrusion process to extrude the aerogel slurry into the plurality of groups of pre-dried substrates;

[0009] The plurality of groups of extruded substrates are sequentially stacked on a production line to form a composite continuous substrate having a length, and the composite continuous substrate is subjected to a layered pleating process, the layered pleating process comprising: sequentially dividing the composite continuous substrate into a plurality of continuously connected segments along the length direction, and pleating the plurality of segments to form a pleated stacked structure that is sequentially stacked and partially staggered in the front and rear directions, wherein the front and rear direction is a conveying direction of the pleated stacked structure;

[0010] The felt material after the layered wrinkle stacking process is pressed and shaped, and then dried for a second time, and tensile and compressive support members are built into the plate after the pressing and shaped process.

[0011] Preferably, the hydrophilic base solution is a saturated aerogel solution.

[0012] Preferably, the secondary drying is carried out by filter pressing or microwave drying.

[0013] Preferably, the plate with built-in tensile and compressive support members further includes the following steps:

[0014] Double-sided inorganic veneer is carried out, and the inorganic veneer layer is built with fiber mesh cloth;

[0015] Cut and seal the edges according to the preset size.

[0016] The preparation process has the following technical effects:

[0017] Provided is a preparation process for an aerogel composite board that can evenly distribute aerogel to improve the uniformity of overall thermal insulation and enhance tensile and compressive strength. Specifically, the substrate is first treated with a hydrophilic base solution to make it hydrophilic, which can better combine with the subsequently extruded aerogel slurry and enhance the bonding performance between the aerogel slurry and the substrate; multiple groups of thin inorganic fiber continuous felts (3-10 mm) are respectively subjected to hydrophilic and aerogel slurry extrusion, which can make the aerogel more easily bonded to the substrate; and the multiple groups of stacked layers are injected with aerogel at any time. The base material of the slurry is subjected to a layered wrinkling treatment, which enables the aerogel to be evenly distributed between the base materials, forming an overall felt board with uniform texture. The thickness is relatively thick and relatively loose, which greatly improves the uniform thermal insulation performance of the composite board in the later stage. The overall thermal conductivity coefficient is below 0.025, which is suitable for use in the construction industry. It has good thermal insulation performance and is fireproof, filling the gap in the material market. It also has built-in tensile and compressive support parts, which gives the board a higher tensile and compressive strength on the vertical surface, greatly improving its tensile and compressive strengths. The tensile strength and compressive strength are greater than 120 and 300KPa respectively.

[0018] Preferably, an inorganic veneer is provided to make the composite board waterproof, moisture-proof and anti-humidity. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 A schematic flow chart of the preparation process provided by the present invention;

[0020] Figure 2 Schematic diagram of the structure of the prepared aerogel composite plate;

[0021] Figure 3 A schematic structural diagram of a specific embodiment of the upper and lower structural reinforcement layers of the tensile and compressive support member;

[0022] Figure 4 A schematic structural diagram of another specific implementation of the upper and lower structural reinforcement layers;

[0023] Figure 5 Schematic diagram of the connecting rod structure.

[0024] Figure 1-5 The accompanying drawings are numerals as follows:

[0025] 1. Plate after pressing and shaping, 2. Upper structural reinforcement layer, 3. Lower structural reinforcement layer, 4. Adhesive layer, 5. Connecting area, 6. Connecting rod, 7. External frame, 8. Conical clamping protrusion, 9. Sheet, 10. Inorganic veneer layer, 11. Mesh cloth. DETAILED DESCRIPTION

[0026] like Figure 1-5 As shown, Figure 1 A schematic flow chart of the preparation process provided by the present invention; Figure 2 Schematic diagram of the structure of the prepared aerogel composite plate; Figure 3 A schematic structural diagram of a specific embodiment of the upper and lower structural reinforcement layers of the tensile and compressive support member; Figure 4 A schematic structural diagram of another specific implementation of the upper and lower structural reinforcement layers; Figure 5 is a schematic diagram of the structure of the connecting rod. Figure 2-5 Shown are structural schematic diagrams of a combination of tensile and compressive support members and structural schematic diagrams of multiple specific implementations of tensile and compressive members.

[0027] Combine Figure 1 The present invention provides a process for preparing an aerogel composite plate, comprising the following steps:

[0028] Providing several groups of thin inorganic fiber continuous felt materials as substrates, each group of the substrates being a continuous felt material with a thickness of 3-10 mm;

[0029] The surfaces of the fiber filaments of the thin inorganic fiber continuous felt are treated by a hydrophilic base solution through a shower coating or roller coating process, so that the surfaces thereof have hydrophilicity;

[0030] The plurality of groups of substrates after the above treatment are pre-dried by filter pressing to make them wet, and each group of substrates continuously enters the pressure extrusion process to extrude the aerogel slurry into the plurality of groups of pre-dried substrates;

[0031] The plurality of groups of extruded substrates are sequentially stacked on a production line to form a composite continuous substrate having a length, and the composite continuous substrate is subjected to a layered pleating process, the layered pleating process comprising: sequentially dividing the composite continuous substrate into a plurality of continuously connected segments along the length direction, and pleating the plurality of segments to form a pleated stacked structure that is sequentially stacked and partially staggered in the front and rear directions, wherein the front and rear direction is a conveying direction of the pleated stacked structure;

[0032] The felt material after the layered wrinkle stacking process is pressed and shaped, and then dried for a second time, and tensile and compressive support members are built into the plate after the pressing and shaped process.

[0033] Provided is a preparation process for an aerogel composite board that can evenly distribute aerogel to improve the uniformity of overall thermal insulation and enhance tensile and compressive strength. Specifically, the substrate is first treated with a hydrophilic base solution to make it hydrophilic, which can better combine with the subsequently extruded aerogel slurry and enhance the bonding performance between the aerogel slurry and the substrate; multiple groups of thin inorganic fiber continuous felts (3-10 mm) are respectively subjected to hydrophilic and aerogel slurry extrusion, which can make the aerogel more easily bonded to the substrate; and the multiple groups of stacked layers are injected with aerogel at any time. The base material of the slurry is subjected to a layered wrinkling treatment, which enables the aerogel to be evenly distributed between the base materials, forming an overall felt board with uniform texture. The thickness is relatively thick and relatively loose, which greatly improves the uniform thermal insulation performance of the composite board in the later stage. The overall thermal conductivity coefficient is below 0.025, which is suitable for use in the construction industry. It has good thermal insulation performance and is fireproof, filling the gap in the material market. It also has built-in tensile and compressive support parts, which gives the board a higher tensile and compressive strength on the vertical surface, greatly improving its tensile and compressive strengths. The tensile strength and compressive strength are greater than 120 and 300KPa respectively.

[0034] In a specific embodiment, the hydrophilic base solution is a saturated aerogel solution.

[0035] Furthermore, the secondary drying method is filter pressing or microwave drying.

[0036] In a specific embodiment, the plate with built-in tensile and compressive support members further includes the following steps:

[0037] Double-sided inorganic veneer is carried out, and the inorganic veneer layer is built with fiber mesh cloth;

[0038] Cut and seal the edges according to the preset size.

[0039] The inorganic veneer is provided to make the composite board waterproof, moisture-proof and anti-humidity.

[0040] In one embodiment, the extrusion process is as follows: the extrusion aperture is 100 microns, the density is 4 to 8 per M 2 The aerogel slurry is extruded on the production line through pulse extrusion, so that it is evenly and quickly injected into the fiber substrate.

[0041] In a specific embodiment, when performing layered pleating processing, a horizontal conveyor belt is set below, and the horizontal conveyor belt is used for the pleat superposition structure. A swinging conveying mechanism is set above the horizontal conveyor belt. The swinging conveying mechanism swings above the horizontal conveyor belt and simultaneously conveys the composite continuous substrate with a length. The horizontal conveyor belt and the swinging conveying mechanism operate simultaneously, and a pleat superposition structure that is stacked in sequence and partially staggered in the front and back can be formed on the horizontal conveyor belt.

[0042] Regarding the tensile and compressive support members, the specific settings are as follows:

[0043] The plate 1 after plate pressing and shaping has a relative upper surface and lower surface, and the outer sides of the upper surface and the lower surface are respectively provided with an upper structural reinforcement layer 2 and a lower structural reinforcement layer 3 with a hollow shape, and the hollow shape has a number of perforations penetrating the upper and lower sides of the upper structural reinforcement layer 2 or the lower structural reinforcement layer 3 where it is located. The upper and lower structural reinforcement layers are connected by inserting a number of supporting connecting parts of the plate 1 after plate pressing and shaping, and also include adhesive layers 4 arranged corresponding to the upper and lower structural reinforcement layers, and each of the adhesive layers 4 penetrates the several perforations in the hollow shape and covers the corresponding upper and lower structural reinforcement layers.

[0044] An upper structural reinforcement layer 2 and a lower structural reinforcement layer 3 with a hollow shape are provided on the outer sides of the upper and lower surfaces of the plate 1 after plate pressing and forming, and the two are connected and supported by supporting connectors inserted through the plate 1 after plate pressing and forming. As a result, the plate has higher tensile and compressive properties and greatly improves its structural strength; and the adhesive layer 4 penetrates the hollow perforations to cover the upper and lower structural reinforcement layers to form an overall structure with high strength.

[0045] The upper and lower structural reinforcement layers respectively have a connection area 5, and both ends of the plurality of support connectors are respectively clamped in the corresponding connection areas 5 of the upper and lower structural reinforcement layers, and at least three of the plurality of support connectors are distributed non-linearly.

[0046] At least three of the plurality of support connectors are distributed in a non-linear manner, thereby forming a triangular point support. The three-dimensional support structure has better support performance, further improving the tensile and compressive properties of the plate.

[0047] In a specific embodiment, Figure 2 and 4As shown, the supporting connection member is provided with a connecting rod 6, and the structural reinforcement layer includes an outer frame body 7 in a rectangular shape, and the outer frame body 7 is filled with a number of hexagonal unit bodies spliced ​​in sequence, and the four hexagonal unit bodies at the four corners of the outer frame body 7 and the one hexagonal unit body at the center position of the outer frame body 7 form the connecting area 5, and the remaining hexagonal unit bodies are hollow to form the several perforations. The center position of the connecting area 5 includes a protrusion formed by the outer side of the connecting area 5 being recessed inward, and the inner side is a side facing the upper surface or lower surface of the plate 1 after the plate is pressed and formed. A plug-in channel arranged in the vertical direction is formed at the center position of the protrusion, and the several protrusions in the two outer frames 7 correspond one to one in the vertical direction and a protrusion is provided between the corresponding two protrusions. The connecting rod 6, both ends of the connecting rod 6 are provided with a pair of conical clamping protrusions 8 whose axes coincide with the axis of the connecting rod, the bottom surfaces of each pair of the conical clamping protrusions 8 are arranged face to face and the distance between the two bottom surfaces is equal to the thickness of the protrusion and the two bottom surfaces are both in contact with the inner and outer sides of the protrusion, the diameter of the bottom surface of the conical clamping protrusion 8 is larger than the inner diameter of the plug-in channel, and the space formed by the concave side of each protrusion is larger than the volume of the conical clamping protrusion 8. When the outer frame 7 is arranged on the outside of the upper and lower surfaces of the plate 1 after the plate is pressed and formed, several of the protrusions are pressed into the plate 1 after the plate is pressed and the side of the outer frame 7 facing the plate 1 after the plate is pressed and formed is attached to the corresponding upper and lower surfaces of the plate 1 after the plate is pressed.

[0048] The hollow shape formed by multiple spliced ​​hexagonal units can play a role similar to crisscrossing steel bars when combined with the adhesive layer 4, so that the overall strength can be further improved. In this way, the mesh cloth 11 can be omitted, which greatly saves materials and corresponding processing procedures.

[0049] Of course, the number and position settings of the connection areas 5 and the connection rods 6 are not limited to this. These settings can be determined according to the specific area of ​​the plate 1 after plate pressing. For example, it can be arranged in the above manner in the case of a plate 1 after plate pressing of 30 times 30. It can be understood that if the area of ​​the plate 1 after plate pressing increases, the number of connection areas 5 and connection rods 6 will be increased accordingly. For example, in the direction of the long side and short side of the rectangle, multiple connection areas 5 are evenly arranged at intervals of 30. Of course, multiple connection areas 5 can also be evenly arranged at the same intervals on the middle line of the longitudinal direction of the rectangle.

[0050] In another specific embodiment, Figure 1 、 3As shown in FIG4 , the supporting connection member is provided with a connecting rod 6, and each of the structural reinforcement layers includes at least four sheet bodies 9, and the four sheet bodies 9 are respectively arranged at the four corners of the upper surface and the lower surface of the plate 1 after the plate is pressed and formed. Each sheet body 9 is provided with three protrusions formed by the outer side of the sheet body 9 being recessed inward, and the inner side is the side facing the upper surface or the lower surface of the plate 1 after the plate is pressed and formed. The center positions of the three protrusions are connected to form a triangular arrangement, and each of the sheet bodies 9 is also provided with a plurality of circular holes passing through the upper and lower sides thereof to form the plurality of through-holes. A plug-in channel arranged in the vertical direction is formed at the center position of each of the protrusions, and the plurality of protrusions on the two sheet bodies 9 on the upper and lower surfaces of the plate 1 after the plate is pressed and formed correspond one to one in the vertical direction and correspond to each other. A connecting rod 6 is provided between the two protrusions, and a pair of conical clamping protrusions 8 whose axes coincide with the axis of the connecting rod 6 are provided at both ends of the connecting rod 6. The bottom surfaces of each pair of conical clamping protrusions 8 are arranged face to face and the distance between the two bottom surfaces is equal to the thickness of the protrusion and the two bottom surfaces are in contact with the inner and outer sides of the protrusion. The diameter of each bottom surface is larger than the inner diameter of the insertion channel, and the space formed by the concave side of each protrusion is larger than the volume of the conical clamping protrusion 8. When the sheet body 9 is provided on the outside of the upper and lower surfaces of the plate material 1 after the plate is pressed and formed, several of the protrusions are pressed into the plate material 1 after the plate is pressed and formed, and the sheet body 9 is attached to the upper and lower surfaces of the corresponding plate material 1 after the plate is pressed and formed.

[0051] The sheet body 9 is in the shape of a right triangle, and the right angles of the right triangle are arranged corresponding to the right angles at each corner of the upper surface and the lower surface of the plate 1 after the plate is pressed and formed.

[0052] The two corresponding upper and lower sheet bodies 9 are supported and connected by a connecting rod 6 in a three-dimensional triangular shape, so that the tensile and compressive properties are optimized.

[0053] Alternatively, the supporting connecting member is provided with a connecting rod 6, and each of the structural reinforcement layers includes a plurality of parallel strip plates, and the upper and lower surfaces of the plate after the plate is pressed and formed are covered with the plurality of parallel strip plates, and each strip plate is evenly distributed along its length direction with a plurality of protrusions formed by being recessed inward from the outer side of the strip plate, and the inner side is the side facing the upper or lower surface of the plate 1 after the plate is pressed and formed, and each of the strip plates is further provided with a plurality of through holes passing through the upper and lower sides thereof to form the plurality of through holes, and a plug-in channel arranged in the vertical direction is formed at the center position of each of the protrusions, and the plurality of protrusions on the two strip plates on the upper and lower surfaces of the plate 1 after the plate is pressed and formed correspond one to one in the vertical direction and between the two corresponding protrusions. A connecting rod 6 is arranged in the middle, and a pair of conical clamping protrusions 8 with axes coinciding with the axis of the connecting rod 6 are arranged at both ends of the connecting rod 6. The bottom surfaces of each pair of conical clamping protrusions 8 are arranged face to face and the distance between the two bottom surfaces is equal to the thickness of the protrusion and the two bottom surfaces are both in contact with the inner and outer sides of the protrusion. The diameter of each bottom surface is larger than the inner diameter of the plug-in channel, and the space formed by the concave side of each protrusion is larger than the volume of the conical clamping protrusion 8. When the strip plate body is arranged on the outside of the upper and lower surfaces of the plate 1 after the plate is pressed and formed, several of the protrusions are pressed into the plate 1 after the plate is pressed and the side of the strip plate body facing the plate 1 after the plate is pressed and formed is attached to the corresponding upper and lower surfaces of the plate 1 after the plate is pressed.

[0054] In a specific embodiment, Figure 1 As shown, it also includes a mesh cloth 11 arranged corresponding to the structural reinforcement layer. The mesh cloth 11 is arranged on the inner side of the corresponding structural reinforcement layer and is covered by the adhesive layer 4.

[0055] Furthermore, it also includes an inorganic veneer layer 10 arranged corresponding to the structural reinforcement layer and laid on the outside thereof.

[0056] In a specific embodiment, the thickness of each structural reinforcement layer is 1-2 mm.

[0057] The bonding layer 4 is a cement-based waterproof mortar layer or a polyurethane bonding layer.

[0058] The conical engaging projections 8 at both ends of the connecting rod 6 enable quick engagement between the upper and lower structural reinforcement layers and the connecting rod 6. In various embodiments, the projections are pressed into the sheet material 1 after press-forming, and the side of the structural reinforcement layer facing the sheet material 1 after press-forming is attached to the corresponding upper and lower surfaces of the sheet material 1 after press-forming. This arrangement ensures high tensile and compressive strength while maintaining the thickness of the thermal insulation structure as close as possible to the thickness of the sheet material 1 after press-forming.

[0059] The above embodiments are merely exemplary embodiments of the present invention and are not intended to limit the scope of the present invention. The scope of protection of the present invention is defined by the claims. Various modifications or equivalent substitutions made by those skilled in the art within the spirit and scope of protection of the present invention also fall within the scope of protection of the present invention.

Claims

1. A process for preparing an aerogel composite plate, characterized in that: The steps include: Providing several groups of thin inorganic fiber continuous felt materials as substrates, each group of the substrates being a continuous felt material with a thickness of 3-10 mm; The surfaces of the fiber filaments of the thin inorganic fiber continuous felt are treated by a hydrophilic base solution through a shower coating or roller coating process, so that the surfaces thereof have hydrophilicity; The plurality of groups of substrates after the above treatment are pre-dried by filter pressing to make them wet, and each group of substrates continuously enters the pressure extrusion process to extrude the aerogel slurry into the plurality of groups of pre-dried substrates; The plurality of groups of extruded substrates are sequentially stacked on a production line to form a composite continuous substrate having a length, and the composite continuous substrate is subjected to a layered pleating process, the layered pleating process comprising: sequentially dividing the composite continuous substrate into a plurality of continuously connected segments along the length direction, and pleating the plurality of segments to form a pleated stacked structure that is sequentially stacked and partially staggered in the front and rear directions, wherein the front and rear direction is a conveying direction of the pleated stacked structure; The felt material after the layered wrinkle stacking process is pressed and shaped, and then dried for a second time, and tensile and compressive support members are built into the plate after the pressing and shaped process.

2. The process for preparing the aerogel composite plate according to claim 1, wherein: The hydrophilic base solution is a saturated aerogel solution.

3. The process for preparing the aerogel composite plate according to claim 2, wherein: The secondary drying method is filter pressing or microwave drying.

4. The process for preparing the aerogel composite plate according to claim 3, wherein: The following steps are also included for the plate with built-in tensile and compressive support members: Perform double-sided inorganic veneer; Cut and seal the edges according to the preset size.

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