A building thermal insulation envelope and method of implementation thereof

Abstract

This invention belongs to the field of building exterior wall insulation technology, specifically relating to a building insulation envelope structure and its implementation method. This invention is a sandwich-like double-layer composite insulation envelope structure. Macroscopically, it consists of two layers of insulation mortar attached to the outer surface of the building exterior wall; microscopically, it incorporates micro- and nano-materials. In practical engineering, this invention uses fly ash and construction waste as partial raw materials, combined with other necessary additives, to achieve joint recycling of construction waste and bulk solid waste from thermal power plant fly ash. This invention aims to solve the problems of existing building insulation materials in terms of insulation performance, mechanical properties, and fire resistance. It possesses excellent thermal performance, reducing energy consumption from indoor heating and air conditioning, while simultaneously considering mechanical properties, fire resistance, and stable physicochemical properties, solving practical problems such as detachment, cracking, and hollowing of existing insulation materials.

Description

Technical Field

[0001] This invention belongs to the field of building exterior wall insulation technology, specifically relating to a building insulation enclosure structure and its implementation method. Background Technology

[0002] Building energy consumption has become one of the three major energy consumers in society. Building energy consumption is mainly used to maintain internal environmental stability, and the thermal insulation performance of building envelopes has always been a core research and development direction in the industry. Improving thermal insulation performance can effectively reduce building carbon emissions. Thermal conductivity, compressive strength, water retention rate, and flammability limit are important indicators for judging the performance of insulation materials. Currently, the practical application of fly ash microspheres, molecular sieve materials, and phase change materials (PCM) filled insulation materials in the field of building insulation is still in its early stages.

[0003] Expanded vitrified microsphere insulation mortar is a representative of inorganic insulation mortars and is often used as a substitute for traditional expanded perlite. Due to its microsphere structure, the material has cavities or closed cells, thus exhibiting better thermal insulation performance compared to traditional expanded perlite. This material requires high quality control; the performance of the insulation mortar varies greatly depending on the temperature environment, region, mix ratio, worker, and operating method, making precise quality control difficult. Summary of the Invention

[0004] Existing thermal insulation materials use natural raw materials, leading to increasingly significant environmental impact; existing thermal insulation materials exhibit varying degrees of poor or unstable insulation performance; existing thermal insulation mortar frequently suffers from problems such as detachment, cracking, water seepage, and hollowing, seriously affecting building quality and safety; organic thermal insulation materials have poor fire resistance and are prone to escalating fires, leading to calls for their ban within the industry; inorganic thermal insulation materials have consistently failed to achieve a balance between tensile strength and insulation performance; existing thermal insulation mortars are prone to poor water retention, resulting in bleeding and slurry flow during use, causing weak adhesion between the mortar and the substrate, and water loss hinders normal bonding and hardening, reducing the mortar's strength.

[0005] To address the aforementioned technical problems, this application provides the following technical solution:

[0006] This invention provides a building insulation enclosure structure, comprising an outer layer of insulation material, an intermediate layer of insulation material, and an exterior wall of the building arranged sequentially. By weight, the outer layer of insulation material is prepared from the following raw materials: 35-45 parts cement, 35-45 parts composite fly ash microspheres, 20 parts fine sand, 1 part adhesive powder, 1-2 parts polypropylene short fibers, and 70-90 parts water.

[0007] By weight, the intermediate layer of the thermal insulation material is prepared from the following raw materials: 25-30 parts cement, 25-30 parts composite fly ash microspheres, 10 parts fine sand, 20-30 parts phase change material (PCM), 5 parts zeolite molecular sieve, 1 part adhesive powder, 1-2 parts polypropylene short fiber, and 60-80 parts water.

[0008] This invention is a sandwich-like double-layer composite thermal insulation enclosure structure. Macroscopically, it consists of a double layer of thermal insulation mortar attached to the outer surface of the building's exterior wall; microscopically, it incorporates micro- and nano-materials. In practical engineering applications, this invention uses fly ash and construction waste as some raw materials, combined with other necessary additives, to achieve the joint recycling of construction waste and bulk solid waste from thermal power plant fly ash.

[0009] The structure of the present invention is as follows Figure 1 As shown, the outer, middle and inner layers of the sandwich structure are 1, 2 and 3 in the figure, respectively. The outer and middle layers are the main structure of the invention, and the inner layer is the building's exterior wall.

[0010] Preferably, the outer layer of the insulation material is less than 15mm thick, and the middle layer of the insulation material is 9-11mm thick, depending on the actual insulation performance requirements of the building project.

[0011] The outer layer is a composite insulating cement mortar containing fly ash microspheres. Due to the shape and dispersion of the microspheres, both the surface and interior of the formed outer layer structure can diffusely reflect some external energy. The structure of this invention uses fly ash microspheres with a mesh number greater than 800 (d...). 90 Theoretically, the larger the diameter of the microspheres (<18μm), the higher the porosity of the molded material and the better the thermal insulation performance. Conversely, the smaller the diameter of the microspheres, the better the mechanical properties of the molded material. The selection of microspheres allows the final insulation material to meet actual engineering requirements. Each microsphere has a cavity; the air within these cavities has a low thermal conductivity, thus providing insulation. Due to the spherical structure of the microspheres, the cavities are typically closed pores rather than interconnected pores. Under the same porosity conditions, closed pores have a lower thermal conductivity and superior thermal insulation performance than interconnected pores.

[0012] The intermediate layer is a composite insulating cement mortar containing fly ash microspheres, phase change material (PCM), and zeolite molecular sieves. The PCM is refined paraffin wax with a melting point of approximately 50°C. During hot weather, it absorbs energy escaping from the outer layer during the day and melts, undergoing a phase change. At night, when temperatures are low, it solidifies and releases heat. Through reflection from the outer layer and absorption by the intermediate layer, the thermal insulation effect of this invention is achieved. Zeolite molecular sieves are spheres or particles with a cubic lattice and microporous structure. They have strong water absorption, effectively improving the water retention of the intermediate layer, thereby increasing the adhesion strength between the intermediate layer and the building exterior wall, and between the outer layer and the intermediate layer. This avoids problems such as reduced material strength, hardening, and detachment caused by water absorption from the substrate.

[0013] Preferably, the zeolite molecular sieve is a type 4A molecular sieve.

[0014] Preferably, the cement is grade 325 cement.

[0015] Furthermore, in the raw materials of the outer layer and the middle layer of the insulation material, cement, fine sand and composite fly ash microspheres are prepared from construction waste and thermal power plant waste.

[0016] Of the above raw materials, the rubber powder and polypropylene short fiber are commercially available, the refined paraffin is commercially available from Sinopec, the zeolite molecular sieve is commercially available, and the 325 grade cement is commercially available; the fly ash microspheres, 325 cement and fine sand can be made from fly ash waste from thermal power plants and construction waste in actual engineering projects. The raw material sources are wide-ranging, realizing the recycling of industrial and construction waste in recycled green building materials.

[0017] Preferably, in the raw materials of the outer layer and the middle layer of the insulation material, the fly ash microspheres have a sieve mesh size greater than 800 and a particle size d. 90 Less than 18μm.

[0018] Preferably, in the raw materials of the outer layer and the middle layer of the insulation material, the particle size d of the fine sand is... 50 Less than 1mm.

[0019] Preferably, the composite fly ash microspheres in the raw materials of the outer layer and the middle layer of the insulation material are prepared by the following steps:

[0020] S11: After sieving the fly ash and flotating it in boiling water, add it sequentially to an aqueous solution of polydimethyl diisopropylammonium chloride (PDDA) and an aqueous solution of polystyrene sulfonic acid (PSS) for 25-35 minutes, and repeat the alternating adsorption 4-6 times to obtain chemically treated fly ash microspheres.

[0021] S12: The chemically treated fly ash microspheres are added to a zeolite colloidal solution for adsorption to obtain seed-modified microspheres; the zeolite colloidal solution is obtained by dispersing nano-X-type molecular sieves in water after impurity removal and adding ammonia.

[0022] S13: The seed-modified microspheres are added to a mixed solution for reaction to obtain the composite fly ash microspheres; the mixed solution includes NaOH, NaAlO2 and water.

[0023] The fly ash microspheres in this invention are mainly composed of silicon dioxide (SiO2) and aluminum oxide (Al2O3). Specific experimental methods are described in CN2023101956280. The general chemical formula can be written as (M). 2 / nO·Al2O3·xSiO2·yH2O, where M represents the metal ions in the material, x is the silicon-to-aluminum ratio, and y is the number of moles of water. Since SiO2 and Al2O3 are inert oxides, they have excellent fire resistance, high temperature resistance, and acid and alkali resistance. They are non-conductive and have a small coefficient of thermal expansion. As building exterior wall insulation materials, they can effectively reduce problems such as fire, corrosion, or cracking and hollowing caused by changes in ambient temperature. They are stable and long-lasting thermal insulation materials.

[0024] The present invention also provides a method for implementing the above-mentioned building thermal insulation envelope, comprising the following steps:

[0025] S21: Leveling and cleaning the exterior walls of the building; repairing any errors.

[0026] S22: After roughening the interface of the building exterior wall, apply dots and screeds; the method of roughening the interface is: mix cement, sand and interface agent and apply to the building exterior wall with a roller to form a rough surface; make the wall surface granular to increase the adhesion of the thermal insulation mortar.

[0027] S23: Apply intermediate layer composite insulation slurry to the outer surface of the building's exterior wall and dry for 68-76 hours (to prevent the intermediate layer insulation material from forming hollow areas) to obtain the intermediate layer of insulation material; by weight, the intermediate layer composite insulation slurry is obtained by mixing 25-30 parts cement, 25-30 parts composite fly ash microspheres, 10 parts fine sand, 20-30 parts phase change material (PCM), 5 parts zeolite molecular sieve, 1 part adhesive powder, 1-2 parts polypropylene short fiber, and 60-80 parts water;

[0028] S24: Apply an outer layer composite insulation slurry to the outer surface of the middle layer of the insulation material, and obtain the outer layer of the insulation material after drying; by weight, the outer layer composite insulation slurry is obtained by mixing 35-45 parts of cement, 35-45 parts of composite fly ash microspheres, 20 parts of fine sand, 1 part of adhesive powder, 1-2 parts of polypropylene short fibers and 70-90 parts of water.

[0029] S25: To maintain the building insulation envelope structure formed by the building exterior walls, the intermediate layer of insulation material and the outer layer of insulation material.

[0030] Preferably, in step S25, after curing is completed, an anti-crack layer and a finishing layer are applied.

[0031] Preferably, in step S22, cement, sand and interface agent are mixed in a mass ratio of 1-2:1-2:1.

[0032] Preferably, in step S22, the thickness of the rough surface is 1-2 mm.

[0033] Specifically, in step S23, the mixing method is to first heat and melt the paraffin wax, then grind the zeolite molecular sieve into powder; add cement, microspheres, fine sand, zeolite molecular sieve and hot melt paraffin wax into a mixing tank, add additives in sequence, and then continuously add water to mix and stir until the slurry consistency is suitable. Stir evenly to ensure uniform dispersion of powder to obtain the intermediate layer composite insulation slurry.

[0034] Specifically, in step S24, the mixing method is as follows: first, cement, microspheres and fine sand are added to the mixing tank, then additives are added in sequence, and water is continuously added and mixed until the consistency of the slurry is suitable. The mixture is stirred evenly to ensure that the powder is evenly dispersed, thus obtaining the outer layer composite thermal insulation slurry.

[0035] This invention addresses the problem of poor thermal insulation performance in existing insulation materials, offering superior thermal performance and reducing energy consumption associated with indoor heating and air conditioning. It also addresses the issue of poor mechanical properties in existing insulation materials, achieving excellent thermal performance while maintaining good mechanical properties, thus resolving problems such as detachment, cracking, and delamination. Furthermore, it addresses the issues of high permeability, poor corrosion resistance, and flammability in existing insulation materials, providing waterproofing, acid and alkali corrosion resistance, and fire resistance. Finally, it addresses the problem of poor water retention in existing mortars, improving adhesion strength and preventing mortar bleeding and runoff. The formula of this invention enables the recycling of construction and industrial waste.

[0036] The technical solution of the present invention has the following advantages compared with the prior art:

[0037] 1. my country's annual fly ash production reaches 800 million tons, and construction waste production reaches 2 billion tons. The raw material formula of this invention can realize the recycling of these bulk solid wastes in actual engineering.

[0038] 2. The structure of this invention is a double-layer composite thermal insulation enclosure structure. Compared with the traditional single-layer thermal insulation structure, the overall thermal conductivity is significantly reduced, and the thermal performance of heat insulation and heat storage is significantly improved. It can effectively reduce the fluctuation of the thermal environment inside the building and improve the living environment.

[0039] 3. This invention uses paraffin wax as the intermediate PCM filler material, which is lower in cost compared to other similar materials. At the same time, the addition of zeolite molecular sieve to the intermediate layer significantly improves the water retention rate of the material, enhances the overall adhesion strength of the structure, and greatly extends the service life.

[0040] 4. For PCM-filled insulation materials, due to the low melting point and low adhesion of PCM after melting, it should not be directly exposed to the outer layer. If it is a single-layer PCM insulation material, special surface treatment is required during construction. The sandwich-like structure designed by placing PCM in the middle layer in this invention can effectively avoid this problem.

[0041] 5. Compared to traditional glass microspheres, fly ash microspheres have higher rigidity and superior mechanical properties, making them more suitable for construction applications. They can withstand higher friction and impact, significantly extending their service life. Due to the texture formed by the microspheres, the material of this invention has excellent wave and particle reflection properties, thus achieving heat insulation and sound insulation effects. It is remarkably effective in blocking heat flow and reducing indoor noise.

[0042] This invention can be used not only as an exterior wall insulation layer or material in hot regions, but also as an exterior wall antifreeze material in cold regions. This invention can withstand temperatures as low as -50°C and prevent thawing for a long time, making it a professional exterior wall antifreeze material for houses in extremely cold regions. Attached Figure Description

[0043] Figure 1 This is a structural diagram of a double-layer thermal insulation building material made from recycled solid waste.

[0044] Explanation of reference numerals in the attached diagram: 1-Outer layer of insulation material, 2-Middle layer of insulation material, 3-Exterior wall of building. Detailed Implementation

[0045] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments described are not intended to limit the present invention.

[0046] I. Examples of Outer Composite Insulation Materials

[0047] For the outer composite thermal insulation material of the present invention, the main raw material mixing ratio and fly ash microsphere particle size were used as variables for comparative tests. All embodiments used 200mm×200mm×20mm molds to prepare experimental samples. The inner surface of the mold was brushed with oil beforehand to facilitate demolding after the material was formed.

[0048] Example 1 (Standard Example):

[0049] Take 35 parts of 325 grade cement and 45 parts of composite fly ash microspheres (d 90 <18μm), with other raw materials in the same proportions, prepare the heat-insulating slurry, mix thoroughly and stir, let stand for 5 minutes, pour into the mold and let it dry naturally (about 72 hours) before demolding.

[0050] Example 2 (mixing ratio is a variable)

[0051] Take 45 parts of 325 grade cement and 35 parts of composite fly ash microspheres (d 90 <18μm), with other raw materials in the same proportions, prepare the heat-insulating slurry, mix thoroughly and stir, let stand for 5 minutes, pour into the mold and let it dry naturally (about 72 hours) before demolding.

[0052] Example 3 (microbead size is a variable)

[0053] Take 35 parts of 325 grade cement and 40 parts of composite fly ash microspheres (mesh count 5000, d 90 <3μm), with other raw materials in the same proportions, prepare the heat-insulating slurry, mix thoroughly and stir, let stand for 5 minutes, pour into the mold and let it dry naturally (about 72 hours) before demolding.

[0054] The outer composite thermal insulation materials of Examples 1-3 were obtained and used as control group 1, and their performance was tested.

[0055] II. Examples of Intermediate Layer Composite Insulation Materials

[0056] For the intermediate layer insulation material of the present invention, the main raw material mixing ratio is used as a variable for a control experiment. Experimental samples are prepared using a 200mm×200mm×20mm mold. The inner surface of the mold is brushed with oil beforehand to facilitate demolding after the material is formed.

[0057] Example 4 (Standard Example)

[0058] Take 30 parts of 325 grade cement, 30 parts of composite fly ash microspheres, 20 parts of paraffin wax, and 5 parts of zeolite molecular sieve. Keep the proportions of other raw materials unchanged and prepare the thermal insulation slurry. Mix thoroughly and let stand for 5 minutes. Pour into the mold and let it dry naturally (about 72 hours) before demolding.

[0059] Example 5 (mixing ratio is a variable)

[0060] Take 25 parts of 325 grade cement, 25 parts of composite fly ash microspheres, 30 parts of paraffin wax, and 5 parts of zeolite molecular sieve. Keep the proportions of other raw materials unchanged and prepare the thermal insulation slurry. Mix thoroughly and let stand for 5 minutes. Pour into the mold and let it dry naturally (about 72 hours) before demolding.

[0061] Example 6 (mixing ratio is a variable)

[0062] Take 30 parts of 325 grade cement, 30 parts of composite fly ash microspheres, and 20 parts of paraffin wax. Do not add zeolite molecular sieves. Keep the proportions of other raw materials unchanged and prepare the thermal insulation slurry. Mix thoroughly and let stand for 5 minutes. Pour into the mold and let it dry naturally (about 72 hours) before demolding.

[0063] The single-layer insulation systems of Examples 4-6 were obtained and used as control group 2, and their performance was tested.

[0064] III. Examples of Double-Layer Insulation Materials

[0065] Example 7

[0066] Using the implementation schemes of Examples 1 and 4, the intermediate layer composite thermal insulation mortar is obtained by using the implementation scheme of Example 4. A 10mm thick intermediate layer composite thermal insulation mortar is poured into the mold and dried for 72 hours to form the intermediate layer 2 of the thermal insulation material. The outer layer composite thermal insulation mortar is obtained by using the implementation scheme of Example 1. A 10mm thick outer layer composite thermal insulation mortar is poured onto the solidified and dried intermediate layer composite thermal insulation material base surface. Finally, after 72 hours, the material is demolded to form the outer layer 1 of the thermal insulation material.

[0067] Performance testing was performed on Example 7, and the results were used to form Control Group 3, which consisted of Examples 1 and 4 alone.

[0068] IV. Comparison and Reference Examples

[0069] Comparative Example 1

[0070] Take commercially available expanded vitrified microsphere thermal insulation mortar and prepare experimental samples of the same size according to its mixing ratio and process.

[0071] Comparative Example 2

[0072] The preparation of ordinary cement mortar is quick. Take a mix ratio of 325 grade cement: sand: additive: water = 1:2.7:0.02:0.4, mix and stir, and pour into a mold to prepare experimental samples of the same size.

[0073] Effect evaluation

[0074] Table 1 Performance tests of each embodiment and comparative example

[0075]

[0076]

[0077] (Note: The thermal conductivity of the material was measured using the steady-state plate method experimental apparatus for determining the thermal conductivity of insulating materials. Test conditions: 35℃~45℃)

[0078] As can be seen from the experimental results and Table 1, the double-layer composite thermal insulation enclosure structure of the present invention has significant advantages over commercially available expanded vitrified microsphere thermal insulation mortar in terms of thermal conductivity, compressive strength, water retention rate and fire resistance. At the same time, it performs well in terms of acid and alkali resistance, adhesion and sound insulation of the thermal insulation material.

[0079] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A building insulation enclosure structure, comprising an outer layer of insulation material (1), an intermediate layer of insulation material (2), and a building exterior wall (3) arranged sequentially, characterized in that, By weight, the outer layer of the thermal insulation material is prepared from the following raw materials: 35-45 parts cement, 35-45 parts composite fly ash microspheres, 20 parts fine sand, 1 part adhesive powder, 1-2 parts polypropylene short fibers and 70-90 parts water. By weight, the intermediate layer of the thermal insulation material is prepared from the following raw materials: 25-30 parts cement, 25-30 parts composite fly ash microspheres, 10 parts fine sand, 20-30 parts phase change material, 5 parts zeolite molecular sieve, 1 part adhesive powder, 1-2 parts polypropylene short fiber, and 60-80 parts water; in the raw materials of the outer layer (1) and the intermediate layer (2) of the thermal insulation material, the composite fly ash microspheres are prepared from fly ash waste from thermal power plants; in the raw materials of the outer layer (1) of the thermal insulation material, the zeolite molecular sieve is a type 4A molecular sieve; in the raw materials of the outer layer (1) of the thermal insulation material, the phase change material is refined paraffin wax; in the raw materials of the outer layer (1) and the intermediate layer (2) of the thermal insulation material, the composite fly ash microspheres are prepared by the following steps: S11: After sieving the fly ash and flotating it in boiling water, add it sequentially to an aqueous solution of polydimethyl diisopropylammonium chloride and an aqueous solution of polystyrene sulfonic acid for 25-35 min, and repeat the alternating adsorption 4-6 times to obtain chemically treated fly ash microspheres. S12: The chemically treated fly ash microspheres are added to a zeolite colloidal solution for adsorption to obtain seed-modified microspheres; the zeolite colloidal solution is obtained by dispersing nano-X-type molecular sieves in water after impurity removal and adding ammonia. S13: The seed-modified microspheres are added to a mixed solution to react and obtain the composite fly ash microspheres; the mixed solution includes NaOH, NaAlO2 and water.

2. The building insulation envelope structure as described in claim 1, characterized in that, The outer layer (1) of the insulation material has a thickness of less than 15 mm, and the middle layer (2) of the insulation material has a thickness of 9-11 mm.

3. The building insulation envelope structure as described in claim 1, characterized in that, The mesh number of the fly ash microbeads in the raw material of the outer layer (1) and the intermediate layer (2) of the thermal insulation material is greater than 800, and the particle size d 90 is less than 18 μm.

4. The building insulation envelope structure as described in claim 1, characterized in that, The particle size d of the fine sand in the raw material of the outer layer (1) and the intermediate layer (2) of the thermal insulation material is less than 1 mm. 50 less than 1 mm.

5. A method for implementing the building insulation envelope structure according to any one of claims 1-4, characterized in that, Includes the following steps: S21: Level and clean the exterior wall (3) of the building; S22: After roughening the interface of the building exterior wall (3), apply dots and screed; the method of roughening the interface is: mix cement, sand and interface agent and apply to the building exterior wall (3) with a roller to form a rough surface; S23: Apply intermediate layer composite thermal insulation slurry to the outer surface of the building exterior wall (3) and dry for 68-76 h to obtain the intermediate layer (2) of thermal insulation material; by weight, the intermediate layer composite thermal insulation slurry is obtained by mixing 25-30 parts of cement, 25-30 parts of composite fly ash microspheres, 10 parts of fine sand, 20-30 parts of phase change material, 5 parts of zeolite molecular sieve, 1 part of adhesive powder, 1-2 parts of polypropylene short fiber, and 60-80 parts of water; S24: Apply an outer layer composite insulation slurry to the outer surface of the middle layer (2) of the insulation material, and obtain the outer layer (1) of the insulation material after drying; by weight, the outer layer composite insulation slurry is obtained by mixing 35-45 parts of cement, 35-45 parts of composite fly ash microspheres, 20 parts of fine sand, 1 part of adhesive powder, 1-2 parts of polypropylene short fiber and 70-90 parts of water; S25: To maintain the building insulation enclosure structure formed by the building exterior wall (3), the intermediate layer of insulation material (2) and the outer layer of insulation material (1).

6. The implementation method as described in claim 5, characterized in that, In step S22, cement, sand and interface agent are mixed in a mass ratio of 1-2:1-2:1.

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