An external thermal insulation integrated formwork and a preparation method thereof

Abstract

The application relates to the technical field of building materials, and discloses an external thermal insulation integrated non-dismantling formwork and a preparation method thereof.The external thermal insulation integrated non-dismantling formwork comprises a hard polyurethane layer and an ultrahigh-performance concrete layer poured on the surface of the hard polyurethane layer, and the material of the ultrahigh-performance concrete layer comprises the following components in parts by weight: cement 500-800 parts, light aggregate 95-152 parts, fine sand 450-720 parts, composite fiber 30-55 parts, titanate coupling agent 1-3 parts, water 100-400 parts and paraffin 10-15 parts; the composite fiber is a mixture of polyformaldehyde fiber and polylactic acid fiber; the material of the hard polyurethane layer comprises the following components in parts by weight: polyether polyol 90-100 parts, isocyanate 120-130 parts, foaming agent 1-3 parts, uniform foaming agent 2-4 parts and catalyst 0.5-3 parts.Through the technical scheme, the problem that the toughness of the non-dismantling thermal insulation formwork and the strength of the thermal insulation layer are poor in the prior art is solved.

Description

An integrated external insulation template that does not require disassembly and its preparation method Technical Field

[0001] This invention relates to the field of building materials technology, specifically to an integrated external insulation formwork that does not require disassembly and its preparation method. Background Technology

[0002] In recent years, with the rapid development of the construction industry, building energy consumption has been rising year by year, making the construction industry one of the largest energy consumers. Therefore, energy conservation and emission reduction are becoming increasingly important for the development of the construction industry. Currently, external insulation of buildings generally involves applying insulation material to the exterior using cement mortar after the main structure is completed, and then protecting the external insulation material with cement mortar. Most of these applications use adhesive bonding technology, but this often leads to problems such as detachment, cracking of the insulation layer, and energy-saving failure, seriously affecting safety and project quality.

[0003] Composite non-removable insulated formwork exterior wall insulation system is a brand-new integrated building energy-saving structural system. It boasts numerous advantages, including high safety, excellent thermal insulation performance, no need for formwork removal, and convenient construction. The application of non-removable insulated formwork in buildings plays a positive role in energy conservation and emission reduction. The non-removable insulated formwork consists of a structural layer, an insulation layer, and connectors, giving the wall panel a certain degree of thermal insulation performance, reducing energy loss due to heat conduction, and achieving a lifespan equal to that of the insulation and the structure.

[0004] The structural layers of non-removable thermal insulation formwork mostly use concrete materials. Among them, ultra-high performance concrete (UHPC) is a cement-based material with ultra-high durability and strength. However, for UHPC composite formwork, excessively high concrete strength can easily lead to brittle failure. Therefore, existing technologies generally use metal fibers, such as steel fibers and copper-plated steel fibers, to prevent brittle failure of UHPC and improve its toughness. However, metal fibers have drawbacks such as high cost and high density, which limits the improvement in toughness of UHPC and affects the service life of non-removable thermal insulation formwork. Although rigid polyurethane foam boards in the insulation layer of non-removable thermal insulation formwork are ideal building insulation and energy-saving materials, existing rigid polyurethane foam boards still have the problem of low strength, making them prone to damage and affecting the durability of non-removable thermal insulation formwork. Therefore, developing a non-removable formwork with excellent comprehensive performance and integrated external insulation will be of great significance for broadening the application of non-removable thermal insulation formwork and ensuring the engineering quality of the construction industry. Summary of the Invention

[0005] This invention proposes an integrated external insulation template that does not require disassembly and its preparation method, which solves the problems of poor toughness and insulation layer strength of the template in related technologies.

[0006] The technical solution of the present invention is as follows:

[0007] This invention proposes an integrated external insulation formwork that does not require dismantling, comprising a rigid polyurethane foam layer and an ultra-high performance concrete layer poured onto the surface of the rigid polyurethane foam layer. The ultra-high performance concrete layer comprises the following components by weight: 500-800 parts cement, 95-152 parts lightweight aggregate, 450-720 parts fine sand, 30-55 parts composite fiber, 1-3 parts titanate coupling agent, 100-400 parts water, and 10-15 parts phase change material; the composite fiber is a mixture of polyoxymethylene fiber and polylactic acid fiber; the phase change material is paraffin powder; and the composite fiber is a mixture of polyoxymethylene fiber and polylactic acid fiber.

[0008] The material of the rigid polyurethane foam layer includes the following components in parts by weight: 90-100 parts of polyether polyol, 120-130 parts of isocyanate, 1-3 parts of foaming agent, 2-4 parts of foam leveling agent, 0.5-3 parts of catalyst, and 0.5-1 part of antioxidant.

[0009] As a further technical solution, the mass ratio of polyoxymethylene fiber to polylactic acid fiber in the composite fiber is 1~3:5.

[0010] As a further technical solution, the lightweight aggregate is silica fume and / or fly ash; the particle size of the fine sand is 0.125~0.25mm.

[0011] As a further technical solution, the material of the rigid polyurethane foam layer also includes the following components in parts by weight: 8-12 parts of silicon carbide.

[0012] As a further technical solution, the silicon carbide is polyvinyl alcohol modified silicon carbide.

[0013] As a further technical solution, the preparation method of the polyvinyl alcohol modified silicon carbide includes the following steps: dissolving polyvinyl alcohol in water and mixing it with silicon carbide, drying it, and obtaining polyvinyl alcohol modified silicon carbide.

[0014] As a further technical solution, the mass ratio of polyvinyl alcohol to silicon carbide is 1:3~5.

[0015] As a further technical solution, the foaming agent is one of cyclopentane and isopentane; the catalyst is one or more of N,N-dimethylcyclohexylamine, triethylamine, and dibutyltin dilaurate; and the antioxidant is one or more of antioxidant 5057, antioxidant 1135, and antioxidant L-20.

[0016] This invention also proposes a method for preparing an integrated external insulation template that does not require disassembly, comprising the following steps:

[0017] S1. Mix the components of the rigid polyurethane foam layer and mold them to obtain rigid polyurethane foam;

[0018] S2. Mix the components of the ultra-high performance concrete layer to obtain ultra-high performance concrete;

[0019] S2. The ultra-high performance concrete is poured onto the surface of the rigid polyurethane foam layer to obtain an integrated external insulation formwork that does not require disassembly.

[0020] This invention also proposes a method for preparing an integrated external insulation template that does not require disassembly, comprising the following steps:

[0021] A1. Mix the components of the rigid polyurethane foam layer and mold them to obtain rigid polyurethane foam;

[0022] A2. First, mix polyoxymethylene fiber and polylactic acid fiber evenly, then immerse them in a solution containing titanate coupling agent to obtain modified fiber.

[0023] A3. Mix the modified fiber and the remaining components of the ultra-high performance concrete layer to obtain ultra-high performance concrete;

[0024] A4. The ultra-high performance concrete is poured onto the surface of the rigid polyurethane foam layer to obtain an integrated external insulation formwork that does not require disassembly.

[0025] The working principle and beneficial effects of this invention are as follows:

[0026] 1. In this invention, by introducing polylactic acid fibers into the material of the ultra-high performance concrete layer of the integrated external insulation formwork, the polylactic acid fibers and polyoxymethylene fibers jointly toughen the ultra-high performance concrete, significantly improving the toughness of the integrated external insulation formwork.

[0027] 2. In this invention, by using titanate coupling agent to modify polylactic acid fiber and polyoxymethylene fiber, not only is the dispersion of fiber in concrete improved and the bonding force between fiber and concrete enhanced, but also the synergistic effect of polyoxymethylene fiber and polylactic acid fiber is further improved, thus enhancing the toughness of the integrated external insulation formwork.

[0028] 3. In this invention, by introducing polyvinyl alcohol-modified silicon carbide into the rigid polyurethane foam layer of the integrated external insulation template, the foam structure of the rigid polyurethane foam is supported, thereby improving the strength of the rigid polyurethane foam. Detailed Implementation

[0029] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0030] In the following examples and comparative examples, the length of polylactic acid fiber is 4-6 mm; the length of polyoxymethylene fiber is 10-20 mm; chlorogenic acid has a purity of 98%; polyvinyl alcohol is PVA0059; silicon carbide has a particle size of 1000 mesh; titanate coupling agent is TM-7; and paraffin powder has a melting point of 60°C and a particle size of 200 mesh.

[0031] Example 1

[0032] The external insulation integrated formwork that does not need to be removed includes an ultra-high performance concrete layer and a rigid polyurethane foam layer. The ultra-high performance concrete layer consists of the following components by weight: 500 parts cement, 95 parts silica fume, 450 parts fine sand, 15 parts polyoxymethylene fiber, 15 parts polylactic acid fiber, 1 part titanate coupling agent, 100 parts water, and 10 parts paraffin powder.

[0033] The rigid polyurethane foam layer comprises the following components in parts by weight: 90 parts polyether polyol, 120 parts isocyanate, 1 part cyclopentane, 2 parts homogenizing agent HY-193, 0.5 parts triethylamine, and 0.5 parts antioxidant 1135.

[0034] The preparation method of the integrated external insulation formwork that does not require disassembly includes the following steps:

[0035] S1. Mix the components of rigid polyurethane foam and mold them to obtain rigid polyurethane foam;

[0036] S2. Mix the components of ultra-high performance concrete to obtain ultra-high performance concrete;

[0037] S2. High-performance concrete is poured onto the surface of rigid polyurethane foam to obtain an integrated external insulation formwork that does not require disassembly.

[0038] Example 2

[0039] The external insulation integrated formwork that does not require dismantling includes an ultra-high performance concrete layer and a rigid polyurethane foam layer. The ultra-high performance concrete layer consists of the following components by weight: 650 parts cement, 75 parts silica fume, 45 parts fly ash, 600 parts fine sand, 20 parts polyoxymethylene fiber, 20 parts polylactic acid fiber, 2 parts titanate coupling agent, 250 parts water, and 12 parts paraffin powder.

[0040] The rigid polyurethane foam layer comprises the following components in parts by weight: 95 parts polyether polyol, 125 parts isocyanate, 2 parts isopentane, 3 parts uniform foaming agent OFX-0913, 1 part N,N-dimethylcyclohexylamine, 1 part dibutyltin dilaurate, and 0.5 parts antioxidant 5057.

[0041] The preparation method of the integrated external insulation formwork that does not require disassembly includes the following steps:

[0042] S1. Mix the components of rigid polyurethane foam and mold them to obtain rigid polyurethane foam;

[0043] S2. Mix the components of ultra-high performance concrete to obtain ultra-high performance concrete;

[0044] S2. High-performance concrete is poured onto the surface of rigid polyurethane foam to obtain an integrated external insulation formwork that does not require disassembly.

[0045] Example 3

[0046] The external insulation integrated formwork that does not need to be removed includes an ultra-high performance concrete layer and a rigid polyurethane foam layer. The ultra-high performance concrete layer consists of the following components by weight: 800 parts cement, 152 parts fly ash, 720 parts fine sand, 30 parts polyoxymethylene fiber, 25 parts polylactic acid fiber, 3 parts titanate coupling agent, 400 parts water, and 15 parts paraffin powder.

[0047] The rigid polyurethane foam layer comprises the following components in parts by weight: 100 parts polyether polyol, 130 parts isocyanate, 3 parts cyclopentane, 4 parts homogenizer HY-193, 3 parts triethylamine, 0.5 parts antioxidant 1135, and 0.5 parts antioxidant 5057.

[0048] The preparation method of the integrated external insulation formwork that does not require disassembly includes the following steps:

[0049] S1. Mix the components of rigid polyurethane foam and mold them to obtain rigid polyurethane foam;

[0050] S2. Mix the components of ultra-high performance concrete to obtain ultra-high performance concrete;

[0051] S2. High-performance concrete is poured onto the surface of rigid polyurethane foam to obtain an integrated external insulation formwork that does not require disassembly.

[0052] Example 4

[0053] The only difference between this embodiment and Embodiment 1 is the preparation method of the integrated external insulation template, which includes the following steps:

[0054] A1. Mix the components of rigid polyurethane foam and mold them to obtain rigid polyurethane foam;

[0055] A2. First, immerse polyoxymethylene fiber and polylactic acid fiber in a solution containing 1% titanate coupling agent by mass to obtain modified fiber; wherein the solvent is an 80% ethanol solution by volume.

[0056] A3. Mix the modified fiber and the remaining components of ultra-high performance concrete to obtain ultra-high performance concrete;

[0057] A4. High-performance concrete is poured onto the surface of rigid polyurethane foam to obtain an integrated external insulation formwork that does not require disassembly.

[0058] Example 5

[0059] The only difference between this embodiment and Embodiment 1 is the preparation method of the integrated external insulation template, which includes the following steps:

[0060] A1. Mix the components of rigid polyurethane foam and mold them to obtain rigid polyurethane foam;

[0061] A2. First, immerse polyoxymethylene fiber and polylactic acid fiber in a solution containing 2% titanate coupling agent by mass to obtain modified fiber; wherein the solvent is an 80% ethanol solution by volume.

[0062] A3. Mix the modified fiber and the remaining components of ultra-high performance concrete to obtain ultra-high performance concrete;

[0063] A4. High-performance concrete is poured onto the surface of rigid polyurethane foam to obtain an integrated external insulation formwork that does not require disassembly.

[0064] Example 6

[0065] The difference between this embodiment and Embodiment 5 lies only in the material of the rigid polyurethane foam layer, which also includes the following components by weight: 8 parts of silicon carbide.

[0066] Example 7

[0067] The difference between this embodiment and Embodiment 5 lies only in the material of the rigid polyurethane foam layer, which also includes the following components by weight: 12 parts of silicon carbide.

[0068] Example 8

[0069] The difference between this embodiment and embodiment 5 lies only in the material of the rigid polyurethane foam layer, and it also includes the following components by weight: 10 parts of polyvinyl alcohol modified silicon carbide;

[0070] A method for preparing polyvinyl alcohol modified silicon carbide includes the following steps: dissolving polyvinyl alcohol in water and mixing it with silicon carbide, then drying the mixture to obtain polyvinyl alcohol modified silicon carbide; wherein the mass ratio of polyvinyl alcohol to silicon carbide is 1:2.

[0071] Example 9

[0072] The only difference between this embodiment and Embodiment 8 is that the mass ratio of polyvinyl alcohol to silicon carbide is 1:6.

[0073] Example 10

[0074] The only difference between this embodiment and Embodiment 8 is that the mass ratio of polyvinyl alcohol to silicon carbide is 1:3.

[0075] Example 11

[0076] The only difference between this embodiment and Embodiment 8 is that the mass ratio of polyvinyl alcohol to silicon carbide is 1:5.

[0077] Example 12

[0078] The only difference between this embodiment and Embodiment 5 is that 3 parts of polyoxymethylene fiber and 27 parts of polylactic acid fiber are added to the components of the ultra-high performance concrete layer.

[0079] Example 13

[0080] The only difference between this embodiment and embodiment 5 is that 5 parts of polyoxymethylene fiber and 25 parts of polylactic acid fiber are added to the components of the ultra-high performance concrete layer.

[0081] Example 14

[0082] The only difference between this embodiment and embodiment 5 is that 11.25 parts of polyoxymethylene fiber and 18.75 parts of polylactic acid fiber are added to the composition of the ultra-high performance concrete layer.

[0083] Comparative Example 1

[0084] The only difference between this comparative example and Example 1 is that polylactic acid fiber is replaced with polyoxymethylene fiber.

[0085] Comparative Example 2

[0086] The only difference between this comparative example and Example 1 is that the polyoxymethylene fiber is replaced with polylactic acid fiber.

[0087] Comparative Example 3

[0088] The only difference between this comparative example and Example 4 is that the titanate coupling agent is replaced with the silane coupling agent KH550.

[0089] According to the tensile performance test method described in section 5.6 of the standard for test methods of ultra-high performance concrete T / CECS 864-2021, the tensile strength of the integrated external insulation formwork prepared in Examples 1-5, Examples 12-14, and Comparative Examples 1-3 was tested under uniaxial tensile test conditions. A control group was set up (the only difference from Example 1 was the absence of polyoxymethylene fiber and polylactic acid fiber). The tensile strength of the control group was measured to be 20.55 MPa. The tensile strength improvement rate of Examples 1-5, Examples 12-14, and Comparative Examples 1-3 compared to the control group was calculated. The tensile strength improvement rate = [(tensile strength of the present invention examples or comparative examples - tensile strength of the control group) / tensile strength of the control group] × 100%. The calculation results are shown in Table 1.

[0090] Table 1 Performance test results of integrated external thermal insulation formwork

[0091]

[0092] By comparing the data from Examples 1-5, Examples 12-14 and Comparative Examples 1-3, it was found that the tensile strength improvement rate of the integrated external insulation formwork prepared in Examples 1-5 and Examples 12-14 was higher than that of Comparative Examples 1-3. This indicates that by introducing polylactic acid fibers into the ultra-high performance concrete layer of the integrated external insulation formwork, the toughness of the integrated external insulation formwork can be significantly improved by allowing polylactic acid fibers and polyoxymethylene fibers to jointly toughen the ultra-high performance concrete.

[0093] By comparing the data of Example 1, Examples 4-5 and Comparative Example 3, it was found that the tensile strength of the integrated external insulation template prepared in Examples 4-5 was improved more than that of Example 1 and Comparative Example 3. This indicates that by using titanate coupling agent to modify polylactic acid fiber and polyoxymethylene fiber, the toughness of the integrated external insulation template can be further improved.

[0094] By comparing the data from Examples 5 and 12-14, it was found that the tensile strength of the integrated external insulation template prepared in Examples 13-14 was higher than that of Examples 5 and 12, indicating that the toughness of the integrated external insulation template can be further improved by adjusting the ratio of polylactic acid fiber and polyoxymethylene fiber.

[0095] The compressive strength of the rigid polyurethane foams prepared in Examples 5 to 11 was tested according to the standard GB / T 8813-2020 "Compression Properties of Rigid Foamed Plastics". The test results are shown in Table 2.

[0096] Table 2 Performance Tests of Rigid Polyurethane Foam

[0097]

[0098] By comparing the data from Examples 5 to 11, it was found that the rigid polyurethane foam prepared in Examples 6 to 11 had higher compressive strength than that in Example 5, indicating that the strength of rigid polyurethane foam can be improved by introducing silicon carbide into the rigid polyurethane foam layer of the integrated external insulation template.

[0099] By comparing the data from Examples 6 to 11, it was found that the rigid polyurethane foam prepared in Examples 8 to 11 had higher compressive strength than that in Examples 6 to 7. This indicates that by introducing polyvinyl alcohol-modified silicon carbide into the rigid polyurethane foam layer of the integrated external insulation template, the strength of the rigid polyurethane foam can be further improved.

[0100] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A non-removable, integrated external insulation formwork, characterized in that, The system comprises a rigid polyurethane foam layer and an ultra-high performance concrete layer cast on the surface of the rigid polyurethane foam layer. The ultra-high performance concrete layer comprises the following components by weight: 500-800 parts cement, 95-152 parts lightweight aggregate, 450-720 parts fine sand, 30-55 parts composite fiber, 1-3 parts titanate coupling agent, 100-400 parts water, and 10-15 parts phase change material. The composite fiber is a mixture of polyoxymethylene fiber and polylactic acid fiber. The phase change material is paraffin powder. The lightweight aggregate is silica fume and / or fly ash. The rigid polyurethane foam layer comprises the following components by weight: 90-100 parts polyether polyol, 120-130 parts isocyanate, 1-3 parts foaming agent, 2-4 parts foam leveling agent, 0.5-3 parts catalyst, and 0.5-1 part antioxidant.

2. The integrated external insulation formwork that does not require disassembly according to claim 1, characterized in that, The mass ratio of polyoxymethylene fiber to polylactic acid fiber in the composite fiber is 1~3:

5.

3. The integrated external insulation formwork that does not require disassembly according to claim 1, characterized in that, The fine sand has a particle size of 0.125~0.25mm.

4. The integrated external insulation formwork that does not require disassembly according to claim 1, characterized in that, The material of the rigid polyurethane foam layer also includes the following components in parts by weight: 8-12 parts of silicon carbide.

5. The integrated external insulation formwork that does not require disassembly according to claim 4, characterized in that, The silicon carbide is polyvinyl alcohol modified silicon carbide.

6. The integrated external insulation formwork that does not require disassembly according to claim 5, characterized in that, The method for preparing polyvinyl alcohol modified silicon carbide includes the following steps: dissolving polyvinyl alcohol in water and mixing it with silicon carbide, then drying to obtain polyvinyl alcohol modified silicon carbide.

7. The integrated external insulation formwork that does not require disassembly according to claim 6, characterized in that, The mass ratio of polyvinyl alcohol to silicon carbide is 1:3~5.

8. The integrated external insulation formwork that does not require disassembly according to claim 1, characterized in that, The foaming agent is one of cyclopentane and isopentane; the catalyst is one or more of N,N-dimethylcyclohexylamine, triethylamine, and dibutyltin dilaurate; the antioxidant is one or more of antioxidant 5057, antioxidant 1135, and antioxidant L-20.

9. A method for preparing an integrated external insulation template that does not require disassembly, according to any one of claims 1 to 8, characterized in that, Includes the following steps: S1. Mix the components of the rigid polyurethane foam layer and mold them to obtain rigid polyurethane foam; S2. Mix the components of the ultra-high performance concrete layer to obtain ultra-high performance concrete; S3. Pour the ultra-high performance concrete onto the surface of the rigid polyurethane foam layer to obtain an integrated external insulation formwork that does not require removal.

10. A method for preparing an integrated external insulation template that does not require disassembly, according to any one of claims 1 to 8, characterized in that, Includes the following steps: A1. Mix the components of the rigid polyurethane foam layer and mold them to obtain rigid polyurethane foam; A2. First, mix polyoxymethylene fiber and polylactic acid fiber evenly, and then immerse them in a solution containing titanate coupling agent to obtain modified fiber. A3. Mix the modified fiber and the remaining components of the ultra-high performance concrete layer to obtain ultra-high performance concrete; A4. The ultra-high performance concrete is poured onto the surface of the rigid polyurethane foam layer to obtain an integrated external insulation formwork that does not require disassembly.

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