High-strength non-combustible thermal insulation formwork and preparation method thereof

Abstract

This invention discloses a high-strength, non-combustible, heat-insulating, non-removable formwork and its preparation method, relating to the field of heat-insulating, non-removable formwork technology. It includes a bottom insulation board, a middle insulation board, an upper insulation board, a reinforcing mesh, and connecting anchors. Reinforcing meshes are provided between the upper insulation board and the middle insulation board, and between the middle insulation board and the bottom insulation board. This high-strength, non-combustible, heat-insulating, non-removable formwork and its preparation method, through the inclusion of the bottom insulation board, middle insulation board, upper insulation board, reinforcing mesh, and connecting anchors, enable the heat-insulating, non-removable formwork to have higher bending load resistance, lower thermal conductivity, higher short-term and long-term flexural and compressive strength, lower short-term and long-term shrinkage rates, and a simpler manufacturing process. The raw materials used in this heat-insulating, non-removable formwork are of moderate cost, the manufacturing process is simple, and the formwork exhibits excellent thermal insulation and non-combustible properties, with well-balanced short-term and long-term structural mechanical properties.

Description

Technical Field

[0001] This invention relates to the field of thermal insulation and non-removable formwork technology, specifically to a high-strength, non-combustible thermal insulation and non-removable formwork and its preparation method. Background Technology

[0002] Statistics show that approximately 95% of existing buildings in my country are high-energy-consuming buildings, making building energy conservation a significant challenge for the country. Building energy conservation generally refers to reducing building energy consumption and loss, and improving the utilization rate of existing energy sources, while ensuring normal building use. Building energy conservation technologies must comply with national and local energy conservation technical requirements.

[0003] To meet the corresponding building energy-saving design standards, thermal insulation design of building envelope has important engineering value. From existing engineering examples, most still use the traditional form of external thermal insulation materials to meet the building energy-saving requirements. This approach makes various building quality problems such as fire, water seepage, and detachment common. Moreover, the thermal insulation materials are generally replaced every 10 to 25 years, resulting in relatively high material and construction costs.

[0004] Currently, the most widely used organic building insulation materials on the market include phenolic boards, molded polystyrene boards (EPS boards), extruded polystyrene boards (XPS boards), rigid polyurethane boards, and rock wool boards. Phenolic boards are made from phenolic resin foam, are lightweight, have good flame retardant properties, do not drip during combustion, and are easy to install. However, they are brittle, prone to powdering and crumbling, and have poor toughness; there is currently no perfect solution for this. Rigid polyurethane boards are insulation boards with rigid polyurethane foam as the core material and a non-decorative surface layer on both sides. They have advantages such as water repellency, resistance to cracking, sound insulation, high closed-cell rate, and low thermal conductivity, making them a high-efficiency insulation material. However, the boards are expensive and pose problems such as flammability and toxic combustion gases. Polystyrene boards have excellent characteristics such as light weight, good elasticity and impact resistance, and outstanding thermal insulation performance. However, their use is limited due to their poor fire resistance. Compared to organic building materials, inorganic building insulation materials are generally high-temperature resistant and flame-retardant. Commonly used materials include expanded vitrified microspheres (closed-cell perlite) insulation mortar and boards, and rock wool. Expanded vitrified microspheres (closed-cell perlite) insulation mortar and boards have good fire resistance, sound absorption, electrical insulation, and corrosion resistance. However, their high water absorption rate may lead to frost heave, and their relatively high thermal conductivity limits their insulation performance. Rock wool is formed by melting natural minerals at high temperatures, drawing them into fibers, and adding a certain amount of binder. It has a high fire resistance rating, a density of 80-200 kg / m³, and low thermal conductivity. However, its high water absorption rate makes it unsuitable for use in extremely cold and humid regions. Furthermore, the boards themselves have relatively low strength, and prolonged use in harsh weather conditions such as strong winds increases the likelihood of insulation system detachment, leading to a shorter service life. Workers exposed to rock wool for extended periods may also experience respiratory damage, skin allergies, and some harm to the mucous membranes of the eyes.

[0005] In summary, organic insulation materials offer excellent insulation performance, low density, low thermal conductivity, and easy construction; however, they are easily combustible, and some organic insulation materials, such as polyurethane, produce large amounts of harmful gases when burned, threatening user safety and severely polluting the environment. Inorganic insulation materials have good flame retardant properties but relatively poor insulation performance, and are also heavy, have poor waterproofing, and are inconvenient to construct. Organic-inorganic composite insulation materials combine the advantages of both and represent the main direction of insulation material development.

[0006] The composite modification of inorganic and organic materials to prepare thermal insulation templates that combine the advantages of both is a widely recognized and feasible technical route in the domestic and international thermal insulation building materials industry. Among these methods, considering the difficulty and cost of production, using the hydration products generated from the hydration reaction of cement-based materials and active mineral admixtures to encapsulate pre-expanded polystyrene or graphite polystyrene particles is a relatively common practice. Specifically, the hardened structure of cement-based materials and active mineral admixtures serves as the matrix framework, while pre-expanded polystyrene or graphite polystyrene particles act as fillers. Organic materials, represented by polystyrene or graphite polystyrene particles, can achieve basic stability of their physical and mechanical properties in a relatively short time, with the performance development period primarily involving simple physical changes. In contrast, the physical and mechanical properties of cement-based materials and active mineral admixtures develop and stabilize over a longer period, during which complex multiphase chemical reactions and physical changes occur simultaneously. Therefore, the (long-term) performance uncertainty that may result from the difference in the maturity of inorganic and organic materials and the inconsistency in the reaction types and complexity corresponding to the performance development period is a key issue that should be focused on and resolved during the use of inorganic composite organic thermal insulation templates. However, this issue has not yet been reasonably resolved.

[0007] Furthermore, in traditional construction processes, cast-in-place formwork often uses wooden or steel formwork. Wooden formwork has low strength and is prone to deformation, while steel formwork is heavy and requires cranes for operation, increasing the difficulty of construction. Traditional formwork dismantling processes are complex, time-consuming, and costly, resulting in various problems and defects. Currently, existing thermal insulation formwork systems on the market have encountered problems such as strength issues, shrinkage cracking, and high water absorption, especially regarding the bonding between the thermal insulation formwork and the matching mortar, which presents significant risks. Recently, the "Work Guidelines for Construction Safety and Quality Supervision of Shanghai Municipal Construction Engineering Safety and Quality Supervision Station" (Shanghai Safety and Quality Supervision Guidelines

[2022] No. 54) pointed out that the silicon graphene non-removable formwork exterior wall insulation system already in construction has problems such as insufficient bonding strength between the plaster layer and the insulation layer. The "2022 Shanghai Municipal Special Inspection Report on the Quality of Graphene-based Non-removable Exterior Wall Insulation Systems" (Shanghai Construction Safety Quality Supervision

[2023] No. 3) reported that the results of the supervision and spot checks showed that the tensile bond strength between the plaster layer and the insulation layer of the graphene-based non-removable exterior wall insulation system at the construction site was generally lower than the design requirements.

[0008] Based on the above market situation and problems, we propose a high-strength, non-combustible, heat-insulating, non-removable template and its preparation method, which has convenient raw material sources, simple preparation conditions, and good structural mechanical properties, volume stability, and long-term weather resistance. Summary of the Invention

[0009] To address the shortcomings of existing technologies, this invention provides a high-strength, non-combustible, heat-insulating, and non-removable template and its preparation method, thus solving the problems mentioned in the background section.

[0010] To achieve the above objectives, the present invention provides the following technical solution: a high-strength, non-combustible, heat-insulating, non-removable template, comprising a bottom insulation board, a middle insulation board, an upper insulation board, a reinforcing mesh, and connecting anchors. Reinforcing meshes are provided between the upper insulation board and the middle insulation board, and between the middle insulation board and the bottom insulation board. The raw material compositions of the upper insulation board, the middle insulation board, and the bottom insulation board all include 350-500 parts of basic mineral materials, 30-80 parts of mineral additives, 12-25 parts of redispersible latex powder, 1.5-3.5 parts of cellulose ether, 6-10 parts of water-reducing agent, 0-1.5 parts of air-entraining agent, 1-4 parts of water-repellent agent, 3-8 parts of fiber materials, 4-10 parts of surfactant, 2-6 parts of anti-caking agent, 50-100 parts of heat-insulating granules, and 160-320 parts of water.

[0011] Optionally, compared to the material ratio of the silicon hydrocarbon insulation board involved in the invention patent application No. 2022116741997, "A Silicon Hydrocarbon Insulation Board and Its Preparation Method", the raw material ratio of the insulation board described in this invention can use 52.5 ordinary Portland cement (white cement or gray cement) with a higher strength grade to obtain better structural mechanical properties.

[0012] Optionally, the raw material ratio of the insulation board can adopt a ternary cementitious material system of ordinary silicate cement / aluminate cement / gypsum (β-hemihydrate gypsum and / or anhydrous gypsum). This synergistically improves the short-term and long-term mechanical properties, the maturity of the hardened structure, and the volume stability of the insulation board, and also benefits its fire-retardant properties.

[0013] Optionally, in the raw material formulation of the insulation board, metakaolin can be used as the anti-caking agent. The smaller metakaolin particles can adsorb onto the larger pre-expanded graphite polystyrene particles or the surface of the pre-expanded polystyrene particles, preventing the surfactant particles adsorbed on the surface of the pre-expanded graphite polystyrene particles from agglomerating due to charge.

[0014] Preferably, the raw material formulation of the insulation board uses low-viscosity (alkyl)-modified hydroxyethyl cellulose ether, and the air-entraining agent, early-strength agent, and expansion and shrinkage-reducing agent are removed. This is because the non-removable insulation template contains a reinforcing mesh design, and the mesh openings create a certain penetration resistance for the slurry to pass through the mesh and be compacted into a uniform matrix during the molding process. By adjusting the raw materials, the viscosity (resistance) of the material when mixed with water can be reduced, and air can be appropriately entrained and the workable time extended.

[0015] Optionally, the reinforcing mesh can be a steel wire mesh, and the steel wire mesh is hot-dip galvanized stainless steel wire mesh with a wire diameter of 0.5-2mm, more specifically 0.6-1.8mm, and a mesh size of 10-20mm, more specifically 11-18mm. Hot-dip galvanizing is a chemical process in which molten zinc reacts with an iron substrate to produce an alloy layer, thereby combining the substrate and the coating. Hot-dip galvanizing has advantages such as uniform coating, thick zinc layer, strong adhesion, and long service life. Compared with cold galvanizing (electro-galvanizing), it is thicker and has stronger corrosion resistance.

[0016] Optionally, the four sides of the wire mesh may be made of thicker steel wires, with a wire diameter of 3mm.

[0017] Optionally, the reinforcing mesh is anchored to the upper insulation board and the lower insulation board by two sets of connecting anchors. Each connecting anchor has a set of expansion wings on top of the reinforcing mesh and a set of fixed wings on the bottom of the reinforcing mesh. There are six expansion wings and six fixed wings. The connecting anchors are anchored between the upper insulation board, the lower insulation board and the two layers of reinforcing mesh. There are two sets of connecting anchors, with five anchors in each set. The ten connecting anchors are located at the center of the two layers of reinforcing mesh and at one-quarter and three-quarter positions of the two diagonals on the reinforcing mesh.

[0018] Optionally, the reinforcing mesh can be a fiberglass mesh, with a wire diameter of 1-5 mm, further 2-3 mm, and even further 3 mm. The mesh size of the fiberglass mesh is 5-30 mm, further 20-30 mm, and even further 25 mm. As a reinforcing mesh, the fiber mesh enhances the cohesion within the matrix, constrains the propagation of matrix cracks, and forms a unified whole. Its main function is to improve the mechanical strength of the surface layer, ensure the consistency of stress on the surface layer, disperse the shrinkage and thermal stress of the surface layer, avoid stress concentration, and resist surface cracking caused by changes in temperature and humidity and external impacts.

[0019] The fiberglass mesh is configured in both directions to improve ductility, effectively alleviate stress concentration, and comprehensively improve the bending strength and impact resistance of the matrix.

[0020] The reinforcing mesh can be an alkali-resistant glass fiber mesh, with a basis weight of 150-300g, more preferably 300g, a weft width of 1-2mm, more preferably 1.5mm, a warp width of 0.5-1.5mm, more preferably 0.5mm, and a mesh spacing of 2-6mm, more preferably 4mm. The alkali-resistant glass fiber mesh is a product made from glass fiber yarn woven into a glass fiber mesh substrate, then coated with organic resin and dried. It features stable structure, high strength, good alkali resistance, corrosion resistance, and crack resistance. When used as a reinforcing mesh in insulation systems, it can effectively increase the tensile strength of the protective layer, effectively disperse stress, and break up potentially wide cracks into many finer cracks, thereby enhancing its crack resistance.

[0021] A high-strength, non-combustible, heat-insulating, and non-removable formwork includes the following steps:

[0022] S1: First, pre-expanded polystyrene granules or graphite polystyrene granules are foamed at a heating temperature of 150℃ and a steam pressure of 0.6MPa for 42-45s. The bulk density of the foamed polystyrene granules is 18-20kg / m3.

[0023] S2: Surface modification of thermal insulation particles; Dissolve surfactant in an appropriate amount of water to form a uniform solution, pour thermal insulation particles into a mixing pot and stir, while uniformly spraying surfactant solution onto the surface of thermal insulation particles that are tumbling during stirring, and uniformly sprinkling anti-caking agent onto the surface of thermal insulation particles, so that the surface of thermal insulation particles is uniformly coated with surfactant and anti-caking agent.

[0024] S3: Mix the raw materials with the surface-modified thermal insulation particles according to the designed weight ratio and add water to stir to obtain the slurry. According to the structural position of the template-free design, calculate the amount of slurry corresponding to the bottom layer, middle layer and top layer respectively. First, put the bottom layer slurry into the mold cavity, flatten and initially compact it. Then, put the bottom layer reinforcing mesh straight in. Put the middle layer slurry in, flatten and initially compact it. Then, put the top layer reinforcing mesh straight in. Put the top layer slurry in, flatten and initially compact it. Pressurize at 0.10-0.15MPa, with a compression ratio of 20%-30%, and maintain the pressure for 4-5 hours. Then demold.

[0025] S4: After demolding, cure at a temperature of 10-35℃. Cure for a certain period of time according to the curing temperature, then cut to the required dimensions.

[0026] Optionally, in step S3, the raw materials and surface-modified thermal insulation particles are mixed according to the designed weight ratio, and water is added and stirred to obtain a slurry. Based on the structural position designed for the template-free installation, the slurry quantities corresponding to the bottom, middle, and top layers are calculated. First, the bottom layer slurry is poured into the mold cavity, leveled, and initially compacted. The lower reinforcing mesh is then placed horizontally. Next, the middle layer slurry is poured in, leveled, and initially compacted. Finally, the upper reinforcing mesh is placed horizontally, and the upper layer slurry is poured in, leveled, and initially compacted. Pressure is applied at 0.10-0.15 MPa, with a compression ratio of 20%-30%, and the pressure is maintained for 4-5 hours. Then, in the demolding step, if steel wire mesh is used as the reinforcing mesh, it needs to be chemically treated. The specific method is as follows: A composite chemical treatment solution is used to chemically treat the steel wires and welding points of the steel wire mesh to enhance the bonding force between the steel wire mesh and the insulation board substrate material. The composition of the composite chemical treatment solution is: 3 parts zinc phosphate, 6 parts sodium nitrate, 0.5 parts sodium fluoride, and 0.5 parts zinc oxide, dissolved in 90 parts water. After stirring evenly, the solution is heated to 70-80°C to obtain the chemical treatment solution. The chemical treatment solution is sprayed onto the surface of the steel wire mesh for 20-25 minutes, washed with water, and then dried.

[0027] Optionally, in step S3, the raw materials and surface-modified thermal insulation particles are mixed according to the designed weight ratio and water is added to stir to obtain a slurry. According to the structural position of the template-free design, the amount of slurry corresponding to the bottom layer, middle layer and top layer is calculated. First, the bottom layer slurry is input into the mold cavity, leveled and initially compacted. The lower reinforcing mesh is then placed straight in. The middle layer slurry is input, leveled and initially compacted. The upper reinforcing mesh is then placed straight in. The upper layer slurry is input, leveled and initially compacted. Pressure is applied at 0.10-0.15MPa, with a compression ratio of 20%-30%, and the pressure is maintained for 4-5 hours. Then, demolding is performed. If steel wire mesh is used for the reinforcing mesh, connecting anchors are required. The connecting anchors are made of glass fiber polyurethane produced by pultrusion process.

[0028] This invention provides a high-strength, non-combustible, heat-insulating, and non-removable template and its preparation method, which has the following beneficial effects:

[0029] This high-strength, non-combustible, heat-insulating, non-removable formwork and its preparation method, through the arrangement of a bottom insulation board, a middle insulation board, an upper insulation board, a reinforcing mesh, and connecting anchors, enables the heat-insulating, non-removable formwork to have higher bending load resistance, lower thermal conductivity, higher short-term and long-term flexural and compressive strength, lower long-term shrinkage rate, and simpler operation process. The raw materials used in this heat-insulating, non-removable formwork have moderate costs, the preparation process is simple, and the heat-insulating, non-removable formwork has good thermal insulation performance and relatively balanced short-term and long-term structural mechanical properties. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the thermal insulation, non-removable template structure of the present invention;

[0031] Figure 2 This is a schematic diagram of the wire mesh structure of the present invention;

[0032] Figure 3 This is a schematic diagram of the structure of the thermal insulation template of the present invention, which uses steel wire mesh as reinforcement.

[0033] Figure 4 This is a schematic diagram of the connecting anchor structure of the present invention;

[0034] Figure 5 This is a perspective view of the connecting anchor of the present invention without being subjected to mold pressure;

[0035] Figure 6 This is a perspective view of the connecting anchor of the present invention subjected to mold pressure.

[0036] In the diagram: 1. Bottom insulation board; 2. Middle insulation board; 3. Top insulation board; 4. Reinforcing mesh; 5. Connecting anchors; 6. Expanding wing; 7. Fixed wing. Detailed Implementation

[0037] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0038] Please see Figures 1 to 6 This invention provides a technical solution: a high-strength, non-combustible, heat-insulating, non-removable formwork, comprising a bottom insulation board 1, a middle insulation board 2, an upper insulation board 3, and a reinforcing mesh 4. Reinforcing mesh 4 is provided between the upper insulation board 3 and the middle insulation board 2, and between the middle insulation board 2 and the bottom insulation board 1. In use, when the heat-insulating, non-removable formwork is subjected to bending loads, firstly, the matrix in the bottom insulation board 1, the middle insulation board 2, and the upper insulation board 3 reaches the initiation strain under bending stress. Cracks originate from and propagate from defects in the matrix. However, due to the "bridging" effect of the fiber material in the matrix, on the one hand, crack development is constrained, crack width is controlled, and the relative displacement between the matrix and the reinforcing mesh 4 is reduced; on the other hand, it also... The stress at the crack can be transferred to the uncracked matrix, preventing the stress from being entirely borne by the longitudinal reinforcing wires at the moment the crack develops. The fiber material in the matrix effectively reduces the brittleness of the matrix, allowing the mechanical friction between the reinforcing mesh and the matrix to be maintained. The matrix, fibers, and reinforcing mesh deform and share the load together, ensuring the bending strength and bending deformation capacity of the thermal insulation template. When the thermal insulation template is subjected to bending load, the reinforcing mesh 4 transfers stress through mechanical friction with the matrix and thus plays a role in protecting the matrix from bending. The bonding force between the reinforcing mesh 4 and the matrix, as well as the flatness of the reinforcing mesh itself, affect the mechanical friction between it and the matrix, further affecting the overall bending load resistance of the board.

[0039] The raw material composition of the upper insulation board 3, the middle insulation board 2 and the bottom insulation board 1 all include 350-500 parts of basic mineral materials, 30-80 parts of mineral additives, 12-25 parts of redispersible latex powder, 1.5-3.5 parts of cellulose ether, 6-10 parts of water-reducing agent, 0-1.5 parts of air-entraining agent, 1-4 parts of water-repellent agent, 3-8 parts of fiber materials, 4-10 parts of surfactant, 2-6 parts of anti-caking agent, 50-100 parts of thermal insulation particles and 160-320 parts of water.

[0040] The reinforcing mesh 4 can be steel wire mesh, specifically hot-dip galvanized stainless steel wire mesh, with a wire diameter of 0.5-2mm, or more specifically 0.6-1.8mm. The mesh size is 10-20mm, or more specifically 11-18mm. The four sides of the steel wire mesh are made of thicker steel wire, with a wire diameter of 3mm. A composite chemical treatment solution is used to chemically treat the steel wires and welding points of the steel wire mesh to enhance the bonding strength between the steel wire mesh 4 and the bottom insulation board 1, the middle insulation board 2 and the top insulation board 3. The composite chemical treatment solution consists of 3 parts zinc phosphate, 6 parts sodium nitrate, 0.5 parts sodium fluoride, and 0.5 parts zinc oxide, dissolved in 90 parts water. After stirring evenly, the solution is heated to 70-80℃ to obtain the chemical treatment solution. The chemical treatment solution is sprayed onto the surface of the steel wire mesh for 20-25 minutes, followed by rinsing with water and drying the steel wire mesh.

[0041] To enhance the flatness of the wire mesh, the following modification treatment is applied:

[0042] The four sides of the wire mesh are made of thicker steel wire. The reinforcing mesh 4 is anchored to the upper insulation board 3 and the lower insulation board 1 by two sets of connecting anchors 5. Each connecting anchor 5 has a set of expansion wings 6 located above the reinforcing mesh 4 and a set of fixed wings 7 located below the reinforcing mesh 4. There are six expansion wings 6 and six fixed wings 7. The connecting anchors 5 are anchored between the upper insulation board 3, the lower insulation board 1, and the two layers of reinforcing mesh 4. The connecting anchors 5 are set in two sets, with five anchors in each set. The ten connecting anchors 5 are located at the center of the two layers of reinforcing mesh 4 and at one-quarter and three-quarter positions along the two diagonals of the reinforcing mesh 4. Figure 2As shown at points abcde. The six expansion wings 6 on the connecting anchor 5 are in a 30-degree outward-facing state when not under mold pressure, and are perpendicular to the anchor base at 90 degrees when under mold pressure. The six fixed wings 7 below the connecting anchor 5 are also perpendicular to the anchor base at 90 degrees. Through the gripping force between the wire mesh and the insulation board substrate material, combined with the physical anchoring effect of the connecting anchor, the anchor absorbs the impact force under external impact, maintains the flatness of the double-layer wire mesh, and enhances the flatness of the double-layer wire mesh in the silicone insulation board. This avoids the problem that when the wire mesh warps significantly in the insulation substrate material, the bending force cannot be fully transferred to the wire mesh under bending load, thus failing to fully utilize the reinforcing effect of the wire mesh and improving the overall bending load resistance of the board. The outer peripheral surface of the anchor base of the connecting anchor 5 has oblique threads, which are intended to increase the bonding force between the anchor and the insulation board substrate material.

[0043] The material of the connecting anchor 5 is one of the engineering plastic materials such as glass fiber polyurethane, polyamide (nylon), polyethylene, and polypropylene.

[0044] Material mechanical properties table:

[0045]

[0046] The connecting anchor 5 is primarily made of glass fiber polyurethane produced through a pultrusion process. Pultruded polyurethane generally possesses low viscosity, moderate to high reactivity, good impact strength and toughness, and short beam shear properties. Compared to other materials, polyurethane pultrusion offers several advantages. It can significantly increase the strength of the product by increasing the glass fiber content. Products made using polyurethane pultrusion technology not only have higher strength and better thermal insulation than traditional materials, but are also lighter and more environmentally friendly. It is precisely because of the material's unique properties, such as its lightweight, high strength and rigidity, and its skeletal fiber structure which enhances its impact strength and reduces warpage, that it maintains good mechanical properties even under high temperature and high humidity conditions.

[0047] The properties of fiberglass polyurethane compared to other commonly used organic materials are shown in the table above. Compared to materials such as nylon 66, nylon 6, polyethylene, and polypropylene, fiberglass polyurethane has the highest shear modulus, tensile modulus, and flexural modulus, and also has a lower thermal conductivity. Using fiberglass polyurethane connecting anchors provides good flatness to the wire mesh while having minimal negative impact on the thermal insulation performance of the insulated, non-removable formwork.

[0048] Reinforcing mesh 4 can be fiberglass mesh, with a wire diameter of 1-5mm, further 2-3mm, and even further 3mm. The mesh size of the fiberglass mesh is 5-30mm, further 20-30mm, and even further 25mm.

[0049] The reinforcing mesh 4 can be an alkali-resistant glass fiber mesh, with a basis weight of 150-300g, more preferably 300g, a weft width of 1-2mm, more preferably 1.5mm, a warp width of 0.5-1.5mm, more preferably 0.5mm, and a mesh spacing of 2-6mm, more preferably 4mm. The alkali-resistant glass fiber mesh is a product made from glass fiber yarn woven into a glass fiber mesh substrate, then coated with organic resin and dried. It features stable structure, high strength, good alkali resistance, corrosion resistance, and crack resistance. Used as a reinforcing mesh in insulation systems, it can effectively increase the tensile strength of the protective layer. Furthermore, due to its effective stress dispersion, it can break down potentially wide cracks into many finer cracks, thereby enhancing its crack resistance.

[0050] A high-strength, non-combustible, heat-insulating, and non-removable formwork includes the following steps:

[0051] S1: First, pre-expanded polystyrene granules or graphite polystyrene granules are foamed at a heating temperature of 150℃ and a steam pressure of 0.6MPa for 42-45s. The bulk density of the foamed polystyrene granules is 18-20kg / m3.

[0052] S2: Surface modification of thermal insulation particles; Dissolve surfactant in an appropriate amount of water to form a uniform solution, pour thermal insulation particles into a mixing pot and stir, while uniformly spraying surfactant solution onto the surface of thermal insulation particles that are tumbling during stirring, and uniformly sprinkling anti-caking agent onto the surface of thermal insulation particles, so that the surface of thermal insulation particles is uniformly coated with surfactant and anti-caking agent.

[0053] S3: Mix the raw materials with the surface-modified thermal insulation particles according to the designed weight ratio and add water to stir to obtain the slurry. According to the structural position of the template-free design, calculate the amount of slurry corresponding to the bottom layer, middle layer and top layer respectively. First, put the bottom layer slurry into the mold cavity, flatten and initially compact it, and then put the lower reinforcing mesh 4 straight in. Then, put the middle layer slurry into the mold cavity, flatten and initially compact it, and then put the upper reinforcing mesh 4 straight in. Finally, put the upper layer slurry into the mold cavity, flatten and initially compact it. Pressurize at 0.10-0.15MPa, with a compression ratio of 20%-30%, and maintain the pressure for 4-5 hours. Then demold.

[0054] S4: After demolding, cure at a temperature of 10-35℃. Cure for a specified time according to the curing temperature, then cut to the required dimensions.

[0055] Examples 1 to 6 below illustrate different compositions of the bottom insulation board 1, the middle insulation board 2, and the top insulation board 3. Some of the materials used in the comparative examples are general-purpose, while the specifications of other materials are as follows:

[0056] Fly ash, Class C ash;

[0057] Silica fume, with a particle size between 200-900 nm, and the most probable particle size is 500 nm;

[0058] Calcium oxide, industrial grade, content over 90%;

[0059] Modified hydroxyethyl methyl cellulose ether with a viscosity of 60,000 cps;

[0060] The hydrophobic agent for oleate is sodium oleate;

[0061] Styrene-acrylic emulsion with a solid content of 50%;

[0062] Metakaolin, with a mesh size of 400;

[0063] Heavy calcium carbonate, 400 mesh;

[0064] The silane coupling agent is a vinylsilane coupling agent.

[0065] The samples were grouped and tested according to the sample ratio. The test environment was prepared by pressurizing at 0.13 MPa, with a compression ratio (the ratio of the volume reduction before and after molding to the volume before molding) of 25%. The pressure was maintained for 5 hours. After demolding, the samples were cured at a temperature of 20℃.

[0066] Example 1

[0067] The raw material composition of the upper insulation board 3, the middle insulation board 2, and the bottom insulation board 1 all include the following: basic mineral materials: 240 parts of 52.5 white silicate cement, 120 parts of aluminate cement, 18 parts of β-hemihydrate gypsum, and 18 parts of anhydrous gypsum; mineral admixtures: 18 parts of fly ash and 36 parts of silica fume; redispersible latex powder: 18 parts of vinyl acetate-ethylene copolymer powder; cellulose ether: 2.3 parts of hydroxypropyl carboxymethyl cellulose ether; water-reducing agent: 7.2 parts of polyether-type polycarboxylate water-reducing agent; air-entraining agent: 0.9 parts of alkyl sulfonate air-entraining agent; water-repellent agent: 2.7 parts of silicon-based water-repellent agent; fiber material: 4.5 parts of polypropylene fiber; surfactants: 4.0 parts of triethanolamine and 2.8 parts of polyvinyl alcohol; anti-caking agent: 3.4 parts of metakaolin; and thermal insulation particles: 68 parts of graphite polystyrene particles.

[0068] Example 2

[0069] The raw material compositions of the upper insulation board 3, the middle insulation board 2, and the bottom insulation board 1 all include the following: basic mineral materials: 240 parts of 52.5 ordinary silicate cement, 120 parts of aluminate cement, and 36 parts of β-hemihydrate gypsum; mineral admixtures: 18 parts of fly ash and 18 parts of silica fume; redispersible latex powder: 17 parts of ethylene-vinyl laurate-vinyl chloride terpolymer powder; cellulose ether: 2.2 parts of hydroxypropyl carboxymethyl cellulose ether; water-reducing agent: 7.2 parts of polyether-type polycarboxylate water-reducing agent; water-repellent agent: 2.2 parts of oleate water-repellent agent; fiber material: 4.4 parts of polypropylene fiber; surfactants: 2.6 parts of styrene-acrylic emulsion and 2.6 parts of polyvinyl alcohol; anti-caking agent: 3.3 parts of heavy calcium carbonate; and thermal insulation particles: 52 parts of graphite polystyrene particles and 13 parts of hollow glass microspheres.

[0070] Example 3

[0071] The raw material compositions of the upper insulation board 3, the middle insulation board 2, and the bottom insulation board 1 all include the following: basic mineral materials: 240 parts of 52.5 white silicate cement, 120 parts of aluminate cement, and 36 parts of anhydrous gypsum; mineral admixtures: 18 parts of fly ash and 36 parts of silica fume; redispersible latex powder: 18 parts of ethylene-vinyl laurate-vinyl chloride terpolymer powder; cellulose ether: 2.3 parts of hydroxypropyl carboxymethyl cellulose ether; water-reducing agent: 7.2 parts of polyether-type polycarboxylate water-reducing agent; air-entraining agent: 0.9 parts of alkyl sulfonate air-entraining agent; water-repellent agent: 2.3 parts of oleate water-repellent agent; fiber material: 4.5 parts of polypropylene fiber; surfactants: 4.0 parts of triethanolamine and 2.8 parts of polyvinyl alcohol; anti-caking agent: 3.4 parts of metakaolin; and thermal insulation particles: 54 parts of graphite polystyrene particles and 14 parts of expanded vitrified microspheres.

[0072] Example 4

[0073] The raw material compositions of the upper insulation board 3, the middle insulation board 2, and the bottom insulation board 1 all include: basic mineral materials: 240 parts of 52.5 ordinary silicate cement, 168 parts of aluminate cement, 20 parts of β-hemihydrate gypsum, and 20 parts of anhydrous gypsum; mineral admixtures: 20 parts of fly ash and 20 parts of silica fume; redispersible latex powder: 19 parts of vinyl acetate-ethylene copolymer powder; cellulose ether: 2.4 parts of hydroxypropyl carboxymethyl cellulose ether; water-reducing agent: 8.2 parts of polyether-type polycarboxylate water-reducing agent; water-repellent agent: 2.9 parts of silicon-based water-repellent agent; fiber materials: 4.8 parts of polypropylene fiber; surfactants: 3.7 parts of styrene-acrylic emulsion and 3.7 parts of polyvinyl alcohol; anti-caking agent: 3.4 parts of metakaolin; and thermal insulation particles: 73 parts of graphite polystyrene particles.

[0074] Example 5

[0075] The raw material compositions of the upper insulation board 3, the middle insulation board 2, and the bottom insulation board 1 all include: basic mineral materials: 240 parts of 52.5 ordinary silicate cement, 168 parts of aluminate cement, and 40 parts of β-hemihydrate gypsum; mineral admixtures: 40 parts of fly ash and 20 parts of silica fume; redispersible latex powder: 20 parts of vinyl acetate-ethylene copolymer powder; cellulose ether: 2.5 parts of hydroxypropyl carboxymethyl cellulose ether; water-reducing agent: 8.2 parts of polyether-type polycarboxylate water-reducing agent; water-repellent agent: 2.9 parts of oleate water-repellent agent; fiber material: 5.1 parts of polypropylene fiber; surfactant: 3.0 parts of styrene-acrylic emulsion and 3.1 parts of polyvinyl alcohol; anti-caking agent: 3.1 parts of heavy calcium carbonate; thermal insulation particles: 61 parts of graphite polystyrene particles; and 15 parts of hollow glass microspheres.

[0076] Example 6

[0077] The raw material composition of the upper insulation board 3, the middle insulation board 2, and the bottom insulation board 1 all include the following: basic mineral materials: 240 parts of 52.5 ordinary silicate cement, 168 parts of aluminate cement, and 40 parts of anhydrous gypsum; mineral admixtures: 20 parts of fly ash and 40 parts of silica fume; redispersible latex powder: 20 parts of ethylene-vinyl laurate-vinyl chloride terpolymer powder; cellulose ether: 2.5 parts of hydroxypropyl carboxymethyl cellulose ether; water-reducing agent: 8.2 parts of polyether-type polycarboxylate water-reducing agent; water-repellent agent: 2.9 parts of oleate water-repellent agent; fiber material: 5.1 parts of polypropylene fiber; surfactant: 4.0 parts of triethanolamine and 2.8 parts of polyvinyl alcohol; anti-caking agent: 3.1 parts of heavy calcium carbonate; thermal insulation particles: 61 parts of graphite polystyrene particles; and 15 parts of expanded vitrified microspheres.

[0078] Short-term and long-term performance tests were conducted on the bottom insulation board 1, the middle insulation board 2, and the top insulation board 3 prepared in Examples 1-6. Thermal conductivity was tested according to GB / T10294-2008 "Determination of Steady-State Thermal Resistance and Related Properties of Thermal Insulation Materials - Protective Hot Plate Method". Dry density, compressive strength, tensile bond strength with XPS board, tensile bond strength with concrete, and softening coefficient of the boards were tested according to DG / TJ08-XXXX-20XX "Technical Standard for Application of Cast-in-Place Concrete Insulated Exterior Walls with Integrated Exterior Wall Insulation System". Flexural strength was tested according to GB / T17671-1999 "Test Method for Strength of Cement Mortar". Perpendicular strength of the boards was tested according to JGJ144-2008 "Technical Specification for Exterior Wall Insulation Engineering". The tensile strength in the axial direction was tested according to GB / T8813-2008 "Determination of Compression Properties of Rigid Foamed Plastics"; the compressive modulus of elasticity was tested according to GB / T5486.3-2001 "Test Methods for Inorganic Rigid Thermal Insulation Products - Density, Moisture Content and Water Absorption"; the flexural deformation was tested according to GB / T10801.1-2021 "Molded Polystyrene Foamed Plastics for Thermal Insulation (EPS)"; the impact resistance was tested according to GB-T29906-2013 "Materials for Thin-Plastered Exterior Wall Insulation Systems of Molded Polystyrene Boards"; the shrinkage rate was tested according to JGT536-2017 "Thermosetting Composite Polystyrene Foam Insulation Boards"; and the combustion performance was tested according to GB8624-2012 "Classification of Burning Performance of Building Materials and Products". The test results are as follows:

[0079]

[0080] The average thermal conductivity of Examples 1-6 is 0.050 W / (mK), which is close to that of rock wool boards / rock wool strips (0.040-0.046 W / (mK)). However, the mechanical properties, such as the average tensile strength (0.29 MPa) and the average 28-day compressive strength (0.64 MPa), are more than ten times higher than those of rock wool boards / rock wool strips (the tensile strength of rock wool boards is 0.01-0.02 MPa and the compressive strength is about 0.04 MPa, while the tensile strength of rock wool strips is about 0.1 MPa and the compressive strength is about 0.04 MPa). Meanwhile, through the test results of the average 7-day flexural strength (0.47 MPa), average 28-day flexural strength (0.50 MPa), average 7-day compressive strength (0.61 MPa), average 28-day compressive strength (0.64 MPa), average 7-day shrinkage rate (0.17%), average 28-day shrinkage rate (0.21%), and average 60-day shrinkage rate (0.25%) in Examples 1-6, it can be found that the bottom insulation board 1, the middle insulation board 2, and the top insulation board 3 have high short-term mechanical strength and stable and increasing long-term mechanical strength. The short-term and long-term volume stability performance is good (the risk of cracking due to shrinkage is low), and a good balance between short-term and long-term performance is achieved.

[0081] Based on the comprehensive performance test results, Examples 2 and 6 were used as the basic material composition of the bottom insulation board 1, the middle insulation board 2, and the top insulation board 3. The composition of fiber materials and thermal insulation particles was adjusted, and different reinforcing meshes (steel wire mesh, fiberglass mesh, and alkali-resistant fiberglass mesh) and their arrangement in the boards were tested to assess bending load performance and thermal insulation performance (with a layer of reinforcing mesh on the upper surface). Specifically, three different wire diameters and mesh sizes of steel wire mesh were tested: fine steel mesh (0.7mm wire diameter, 15.75mm mesh), medium steel mesh (0.85mm wire diameter, 11.68mm mesh), and coarse steel mesh (1.7mm wire diameter, 17mm mesh). Different arrangement positions of the reinforcing mesh in the boards (distance from the upper and lower surfaces of the board) were also tested: 10mm / 10mm, 20mm / 10mm, and 20mm / 20mm. As shown in the table, the following examples and comparative examples are included:

[0082] Examples 7-14 are based on the material composition of Example 2, with adjustments made to the composition of the fiber material or thermal insulation particles. Examples 15-17 are based on the material composition of Example 6, with adjustments made to the composition of the fiber material.

[0083]

[0084]

[0085] Example Example 15 Example 16 Example 17 +18 parts steel fiber - 5.1 parts polypropylene fiber √ √ √ Fine steel mesh √ China Steel Network √ Rough steel mesh √ Surface chemical treatment √ √ √ Install connection anchors √ √ √ 10mm / 10mm √ √ √ Bending load / N 3529 3958 4474 Thermal conductivity (25℃) W / (mK) 0.053 0.054 0.054

[0086] The average bending load of Examples 7-17 is 3717N, which meets the current domestic standards for the bending load performance of formwork without removal (≥2000-3000N). Furthermore, the average thermal conductivity (with a reinforcing mesh layer on the upper surface) of Examples 7-17 is 0.052W / (mK), indicating good thermal insulation performance.

[0087] Comparative Examples 1-7 are based on the material composition of Example 2, with some adjustments to the fiber material composition; Comparative Examples 8-14 are based on the material composition of Example 6, with some adjustments to the fiber material composition.

[0088]

[0089]

[0090] The average bending load of Comparative Examples 1-14 was 2649 N, and the average thermal conductivity (with a reinforcing mesh on the upper surface) was 0.053 W / (mK). Compared with Examples 7-17, the bending load performance of the comparative examples was significantly reduced, while the thermal insulation performance was comparable.

[0091] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A high-strength, non-combustible, heat-insulating, non-removable formwork, characterized in that: The material includes a bottom insulation board (1), a middle insulation board (2), an upper insulation board (3), and a reinforcing mesh (4). A reinforcing mesh (4) is provided between the upper insulation board (3) and the middle insulation board (2) and between the middle insulation board (2) and the bottom insulation board (1). The raw material composition of the upper insulation board (3), the middle insulation board (2), and the bottom insulation board (1) all include 350-500 parts of basic mineral materials, 30-80 parts of mineral additives, 12-25 parts of redispersible latex powder, 1.5-3.5 parts of cellulose ether, 6-10 parts of water-reducing agent, 0-1.5 parts of air-entraining agent, 1-4 parts of water-repellent agent, 3-8 parts of fiber material, 4-10 parts of surfactant, 2-6 parts of anti-caking agent, 50-100 parts of thermal insulation particles, and 160-320 parts of water. The reinforcing mesh (4) can be a steel wire mesh, and the steel wire mesh is a hot-dip galvanized stainless steel wire mesh with a wire diameter of 0.5-2mm and a mesh size of 10-20mm; The reinforcing mesh (4) is anchored together with the upper insulation board (3) and the lower insulation board (1) by two sets of connecting anchors (5). The connecting anchors (5) are provided with a set of expansion wings (6) located on the reinforcing mesh (4) and a set of fixed wings (7) located below the reinforcing mesh (4). There are six expansion wings (6) and six fixed wings (7). The connecting anchors (5) are anchored between the upper insulation board (3), the lower insulation board (1) and the two layers of reinforcing mesh (4). The connecting anchors (5) are set in two sets, with five in each set. The ten connecting anchors (5) are located at the center of the two layers of reinforcing mesh (4) and at one-quarter and three-quarter positions of the two diagonals on the reinforcing mesh (4).

2. The high-strength, non-combustible, heat-insulating, non-removable formwork according to claim 1, characterized in that: The four sides of the wire mesh are made of thicker steel wire, with a wire diameter of 3mm.

3. The high-strength, non-combustible, heat-insulating, non-removable formwork according to claim 1, characterized in that: The reinforcing mesh (4) can be a fiberglass mesh, the wire diameter of which is 1-5 mm and the mesh size of which is 5-30 mm.

4. The high-strength non-combustible thermal insulation formwork according to claim 1, characterized in that: The reinforcing mesh (4) can be an alkali-resistant glass fiber mesh, the weight of which is 150-300g and the weft width is 1-2mm.

5. The preparation method of the high-strength non-combustible thermal insulation formwork according to any one of claims 1-4, characterized in that: Includes the following steps: S1: First, the thermal insulation particles are pre-expanded polystyrene particles or graphite polystyrene particles: foaming is carried out under the conditions of heating temperature of 150℃ and steam pressure of 0.6MPa, the foaming time is 42-45s, and the bulk density of the foamed polystyrene particles is 18-20kg / m³. S2: Surface modification of thermal insulation particles; Dissolve surfactant in an appropriate amount of water to form a uniform solution, pour thermal insulation particles into a mixing pot and stir, while uniformly spraying surfactant solution onto the surface of thermal insulation particles that are tumbling during stirring, and uniformly sprinkling anti-caking agent onto the surface of thermal insulation particles, so that the surface of thermal insulation particles is uniformly coated with surfactant and anti-caking agent. S3: Mix the raw materials with the surface-modified thermal insulation particles according to the designed weight ratio and add water to stir to obtain the slurry. According to the structural position of the template-free design, calculate the amount of slurry corresponding to the bottom layer, middle layer and top layer respectively. First, put the bottom layer slurry into the mold cavity and flatten and initially compact it. Then, put the bottom layer reinforcing mesh (4) straight in. Put the middle layer slurry into the mold cavity and flatten and initially compact it. Then, put the top layer reinforcing mesh (4) straight in. Put the top layer slurry into the mold cavity and flatten and initially compact it. Pressurize at 0.10-0.15MPa, the compression ratio is 20%-30%, and maintain the pressure for 4-5 hours. Then demold. S4: After demolding, perform curing at a temperature of 10-35℃. Depending on the curing temperature, cure for a certain period of time, and then cut to the required size specifications.

6. The method according to claim 5, wherein the method is characterized by: S3 involves mixing the raw materials with surface-modified thermal insulation particles according to the designed weight ratio and adding water to obtain a slurry. Based on the structural position designed for the template-free installation, the slurry quantities corresponding to the bottom, middle, and top layers are calculated. First, the bottom layer slurry is input into the mold cavity, leveled, and initially compacted. The lower reinforcing mesh (4) is then placed horizontally. Next, the middle layer slurry is input, leveled, and initially compacted. The upper reinforcing mesh (4) is then placed horizontally. Finally, the upper layer slurry is input, leveled, and initially compacted. Pressure is applied at 0.10-0.15 MPa, with a compression ratio of 20%-30%, and the pressure is maintained for 4-5 hours. Then, in the demolding step, if steel wire mesh is used, it is necessary to chemically treat the steel wire mesh. The specific method is as follows: use a composite chemical treatment liquid to chemically treat the steel wire and welding points of the steel wire mesh to enhance the bonding force between the steel wire mesh and the insulation board substrate material. The composition of the composite chemical treatment liquid is: 3 parts zinc phosphate, 6 parts sodium nitrate, 0.5 parts sodium fluoride, and 0.5 parts zinc oxide, dissolved in 90 parts water, stirred evenly, and heated to 70-80℃ to obtain the chemical treatment liquid. Spray the chemical treatment liquid onto the surface of the steel wire mesh for 20-25 minutes, wash with water, and then dry the steel wire mesh.

7. The method according to claim 5, wherein the method is characterized by: S3 mixes the raw materials with the surface-modified thermal insulation particles according to the designed weight ratio and adds water to stir to obtain slurry. According to the structural position of the template-free design, calculate the amount of slurry corresponding to the bottom layer, middle layer and top layer respectively. First, the bottom layer slurry is input into the mold cavity and flattened and initially compacted. The bottom layer reinforcing mesh (4) is placed straight in the mold. The middle layer slurry is input and flattened and initially compacted. The top layer reinforcing mesh (4) is placed straight in the mold. The top layer slurry is input and flattened and initially compacted. Pressurize at 0.10-0.15MPa, the compression ratio is 20%-30%, and maintain the pressure for 4-5 hours. Then demolding is carried out. If the reinforcing mesh (4) is made of steel wire mesh, connecting anchors (5) are required. The connecting anchors (5) are made of glass fiber polyurethane produced by pultrusion process.

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