Fireproof wall thermal insulation material and production method thereof

Abstract

The invention relates to the field of building and industrial fire prevention, and discloses a fireproof wall thermal insulation material. The material comprises the following components in percentage by weight: 15-25% of basalt fiber, 10-15% of glass fiber, 3-7% of carbon fiber, 5-10% of ceramic fiber, 8-12% of a modified silicate binder, 3-7% of a bio-based resin binder, 5-10% of a phenolic resin binder, 16-31% of a fireproof additive and 10-20% of a heat insulation additive. By innovatively introducing the composite material of various fibers such as basalt fibers, glass fibers, carbon fibers and ceramic fibers, the mechanical strength and fire resistance of the thermal insulation material are remarkably improved, the composite fiber material shows more excellent performance in the aspect of strength, and meanwhile, the qualitative leap in the aspect of fire resistance is also realized. And stable operation and reliable performance of the thermal insulation material in an extremely high-temperature environment are ensured.

Description

Technical Field

[0001] The invention relates to the technical field of building and industrial fire protection, in particular to a fire wall thermal insulation material and a production method thereof. Background Art

[0002] In the construction and industrial fields, fire-wall insulation materials not only need to have excellent insulation performance, but also need to provide effective fire protection in extreme situations such as fire to ensure the safety of building structures and personnel. However, the insulation materials in the prior art have significant deficiencies in these aspects, which are mainly manifested as follows:

[0003] Limitations of single fiber materials: Traditional insulation materials usually use a single type of fiber, such as glass fiber or mineral wool fiber. Although these single fiber materials have good performance under certain specific conditions, they have obvious limitations in mechanical strength and fire resistance. Specifically, the mechanical strength of single fiber materials is limited and it is difficult to meet the use requirements in complex environments; its fire resistance is also difficult to cope with extreme high temperature conditions, and it is easy to lose structural stability in high temperature environments, affecting the insulation effect and fire safety.

[0004] Disadvantages of a single binder: Common insulation materials on the market mostly use a single type of binder, such as pure silicate binder or phenolic resin binder. Although these binders can provide basic bonding strength, it is difficult for them to fully meet the actual application requirements in terms of performance. It is difficult for a single binder to strike a balance between bonding strength and environmental performance: binders with high bonding strength may have a greater impact on the environment, while binders with better environmental performance may have insufficient bonding strength, making it difficult to ensure the long-term stability of the material.

[0005] Limitations of traditional fire retardants: Currently, the widely used fire retardant materials mostly rely on traditional fire retardants, such as halogen flame retardants and inorganic flame retardants. These fire retardants have played a certain role in improving the flame retardant properties of materials, but their effectiveness is insufficient under extremely high temperature conditions. Specifically, traditional fire retardants are easy to decompose at high temperatures, lose their flame retardant effect, and are difficult to provide continuous fire protection; their thermal stability in high temperature environments is also insufficient, making it difficult to ensure the overall fire retardant performance of the material in a fire, posing a safety hazard.

[0006] Disadvantages of conventional thermal insulation materials: Traditional thermal insulation materials usually use conventional thermal insulation materials, such as foam glass and mineral wool. Although these materials can provide a certain thermal insulation effect, they show performance limitations in actual applications. Conventional thermal insulation materials have deficiencies in thermal insulation performance and weight control: their thermal insulation effect is limited and it is difficult to meet the needs of efficient thermal insulation; their density is high and their weight is heavy, which increases the difficulty and cost of construction and limits the use of materials in application scenarios that require efficient thermal insulation and lightweight.

[0007] Therefore, the present invention provides a fire-wall thermal insulation material and a production method thereof to solve the deficiencies of the prior art. Summary of the invention

[0008] In view of the deficiencies in the prior art, the present invention provides a fire-wall thermal insulation material and a production method thereof, aiming to solve the deficiencies of the prior art materials in terms of mechanical strength, bonding performance, fire resistance and thermal insulation effect.

[0009] To achieve the above objectives, the present invention is implemented through the following technical solutions: a fire wall thermal insulation material, the material includes the following components in weight percentage:

[0010] Basalt fiber 15-25%

[0011] Glass fiber 10-15%

[0012] Carbon fiber 3-7%

[0013] Ceramic fiber 5-10%

[0014] Modified silicate binder 8-12%

[0015] Bio-based resin binder 3-7%

[0016] Phenolic resin binder 5-10%

[0017] Fire retardant additives 16-31%

[0018] Thermal insulation additive 10-20%.

[0019] Preferably, the weight ratio of the basalt fiber, the glass fiber, the carbon fiber and the ceramic fiber is 2:1:1:1 to 3:1:1:1.

[0020] Preferably, the weight ratio of the modified silicate binder, the bio-based resin binder and the phenolic resin binder is 2:1:1 to 3:1:1.

[0021] Preferably, the fireproof additive comprises nano silicon dioxide, aluminum hydroxide, expanded graphite and calcium hydroxide, wherein the weight percentage of the nano silicon dioxide is 3-7%, the weight percentage of the aluminum hydroxide is 8-12%, the weight percentage of the expanded graphite is 3-7%, and the weight percentage of the calcium hydroxide is 2-5%.

[0022] Preferably, the thermal insulation additive comprises graphene aerogel, nano aerogel and microporous calcium silicate, wherein the weight percentage of the graphene aerogel is 1-3%, the weight percentage of the nano aerogel is 3-7%, and the weight percentage of the microporous calcium silicate is 5-10%.

[0023] Preferably, a method for producing a fire wall thermal insulation material comprises the following steps:

[0024] a. Premixing basalt fiber, glass fiber, carbon fiber and ceramic fiber;

[0025] b. Use ultrasonic dispersion technology to evenly disperse nano silicon dioxide, aluminum hydroxide, expanded graphite and calcium hydroxide in the mixture;

[0026] c. adding the modified silicate binder, the bio-based resin binder and the phenolic resin binder to the premix and stirring thoroughly until a uniform mixture is formed;

[0027] d. molding the mixture by a multi-layer composite molding process;

[0028] e. Carry out curing process under the control of intelligent temperature control system;

[0029] f. Perform plasma surface treatment on the cured material.

[0030] Preferably, the premixing of basalt fiber, glass fiber, carbon fiber and ceramic fiber in step a is carried out by a high-speed stirring device, specifically comprising the following steps:

[0031] a1. Add basalt fiber, glass fiber, carbon fiber and ceramic fiber by weight into a high-speed stirring device;

[0032] a2. Set the stirring speed of the stirring device to 1500-3000 rpm and the stirring time to 5-15 minutes;

[0033] a3. Keep the fibers evenly dispersed during stirring and prevent fiber entanglement and agglomeration;

[0034] a4. The online monitoring system is used to detect the uniformity of fiber mixing in real time to ensure that the premix meets the expected quality standards.

[0035] Preferably, the frequency of ultrasonic dispersion in step b is 20-40 kHz, and the duration is 30-60 minutes, which specifically includes the following steps:

[0036] b1. The premix is ​​placed in a reaction vessel of an ultrasonic dispersing device;

[0037] b2. Adjust the frequency of the ultrasonic dispersion device to 20-40kHz and the power to 500-1000 watts;

[0038] b3. Adding an appropriate amount of a dispersion medium, including deionized water or ethanol, to the reaction vessel to improve the dispersion effect;

[0039] b4 start ultrasonic dispersion equipment, continuous dispersion time is 30-60 minutes, to ensure uniform distribution of nano-silica, aluminum hydroxide, expanded graphite and calcium hydroxide in the mixture;

[0040] b5. After dispersion is completed, the mixture is filtered by vacuum or centrifuged to remove excess dispersion medium.

[0041] Preferably, the multi-layer composite molding process in step d includes at least three layers, specifically including the following steps:

[0042] d1. The pretreated mixture is divided into multiple portions according to the designed composition ratio, each portion is used for a different molding layer;

[0043] d2. Add each mixture to the molding mold in sequence and lay them in layers;

[0044] d3. Compact each layer of the mixture with a compaction pressure of 5-10 MPa to ensure tight bonding between the layers;

[0045] d4. After each layer is compacted, it is initially formed by hot pressing or cold pressing, and the temperature is controlled at 100-150 degrees Celsius;

[0046] d5. After all layers are laid and compacted, the whole will be subjected to secondary hot pressing treatment at a temperature of 150-200 degrees Celsius for 1-2 hours to ensure the stability and uniformity of the overall structure.

[0047] Preferably, the plasma surface treatment in step f is performed using a plasma spraying device, and specifically comprises the following steps:

[0048] f1. Place the cured material on the spraying table of the plasma spraying equipment to ensure that the surface of the material is clean and free of oil stains;

[0049] f2 set the working parameters of the plasma spraying equipment, spray gas selection argon or nitrogen, gas flow rate of 50-100 liters / minute, spray voltage of 200-500 volts;

[0050] f3. Turn on the plasma spraying equipment and spray the surface of the material for 10-20 minutes;

[0051] f4. During the spraying process, ensure that the material surface is evenly covered with the plasma layer by moving the spray gun or rotating the spray table;

[0052] f5. After spraying, the material is cooled naturally at room temperature or accelerated by a cooling device to form a dense protective layer to enhance the wear resistance and weather resistance of the material.

[0053] The present invention provides a fire wall thermal insulation material and a production method thereof, which has the following beneficial effects:

[0054] 1. The present invention has achieved a significant improvement in the mechanical strength and fire resistance of thermal insulation materials by innovatively introducing composite materials of various fibers such as basalt fiber, glass fiber, carbon fiber and ceramic fiber. Compared with the traditional technical solution using a single type of fiber, the composite fiber material of the present invention shows more outstanding performance in terms of strength, and also achieves a qualitative leap in fire resistance. This major improvement effectively makes up for the inherent defects of single fiber materials in structural strength and fire resistance, ensures the stable operation and reliable performance of thermal insulation materials in extremely high temperature environments, and provides a more sturdy and fire-resistant thermal insulation solution for the industrial field.

[0055] 2. The present invention achieves a significant improvement in bonding strength and a comprehensive optimization of environmental performance by introducing a composite bonding system of modified silicate, bio-based resin and phenolic resin. Compared with the common single adhesives on the market, the composite adhesive of the present invention not only exhibits higher bonding strength, but also greatly reduces the negative impact on the environment. This technological innovation effectively solves the difficult problem of balancing the bonding performance and environmental protection standards of a single adhesive, achieving the goal of both enhancing the bonding effect and meeting environmental protection requirements, and making an important contribution to promoting the green and sustainable development of materials.

[0056] 3. The present invention achieves a significant improvement in the flame retardant properties and thermal stability of the material by carefully introducing highly efficient fire retardant additives such as nano-silicon dioxide, aluminum hydroxide, expanded graphite and calcium hydroxide. Compared with the current technical solutions that rely solely on traditional fire retardants, the innovation of the present invention lies in its unique combination of multifunctional fire retardant additives, which exhibits superior fire protection performance under extremely high temperature conditions. This improvement directly hits the inherent shortcomings of traditional fire retardants in terms of flame retardant performance and thermal stability, effectively curbing the rapid spread of flames in fires, thereby greatly enhancing the fire safety protection capabilities of the material.

[0057] 4. The present invention innovatively uses graphene aerogel, nano aerogel and microporous calcium silicate as thermal insulation additives, which significantly optimizes the thermal insulation performance of the material and successfully achieves the lightweight of the material. Compared with conventional thermal insulation materials widely used in traditional technologies, the thermal insulation additive combination of the present invention exhibits more outstanding thermal insulation capabilities while significantly reducing the density and weight of the material. This improvement strategy effectively overcomes the limitations of conventional thermal insulation materials in thermal insulation efficiency and weight control, ensuring that the material is lighter, easier to construct and widely used while maintaining high-efficiency thermal insulation properties, thereby significantly improving the overall efficiency and convenience of use. BRIEF DESCRIPTION OF THE DRAWINGS

[0058] Figure 1The present invention is a flow chart of the production method of fire wall insulation material. DETAILED DESCRIPTION

[0059] The technical solution of the present invention will be described clearly and completely below in conjunction with the accompanying drawings of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0060] Example:

[0061] Please see attached picture:

[0062] Embodiment 1:

[0063] Material formula:

[0064] Basalt fiber: 20%

[0065] Glass Fiber: 12%

[0066] Carbon Fiber: 5%

[0067] Ceramic fiber: 7%

[0068] Modified silicate binder: 10%

[0069] Bio-based resin binder: 5%

[0070] Phenolic resin binder: 8%

[0071] Nano silicon dioxide: 5%

[0072] Aluminum hydroxide: 10%

[0073] Expanded graphite: 5%

[0074] Calcium hydroxide: 3%

[0075] Graphene aerogel: 2%

[0076] Nano aerogel: 5%

[0077] Microporous calcium silicate: 6%

[0078] Production steps:

[0079] Premix:

[0080] Add basalt fiber, glass fiber, carbon fiber and ceramic fiber into a high-speed stirring device according to weight ratio, set the speed to 2000 rpm, and stir for 10 minutes to ensure that the fibers are evenly dispersed.

[0081] The uniformity of fiber mixing is checked by an online monitoring system.

[0082] Ultrasonic dispersion:

[0083] The premix was placed in the reaction vessel of an ultrasonic dispersing device.

[0084] The frequency of the ultrasonic dispersion equipment was adjusted to 30 kHz and the power to 800 watts. An appropriate amount of deionized water was added to the reaction container, and the dispersion time was continued for 45 minutes.

[0085] Binder Mixing:

[0086] Add the modified silicate binder, the bio-based resin binder and the phenolic resin binder to the premix and stir thoroughly until a homogeneous mixture is formed.

[0087] forming:

[0088] The mixture is formed through a multi-layer composite molding process. Each mixture is added to the molding mold in turn and laid in layers. The compaction treatment pressure of each layer is 8 MPa.

[0089] Curing treatment:

[0090] The curing process is carried out under the control of the intelligent temperature control system, and the temperature curve is as follows:

[0091] Initial heating stage: from room temperature to 80°C, the heating rate is 2°C / min.

[0092] Intermediate insulation stage: maintain at 80°C for 30 minutes.

[0093] The second heating stage: from 80°C to 180°C, the heating rate is 1°C / min.

[0094] High temperature insulation stage: maintain at 180℃ for 1.5 hours.

[0095] Cooling stage: cooling from 180°C to room temperature at a cooling rate of 1.5°C / min.

[0096] Surface treatment:

[0097] The solidified material was subjected to plasma surface treatment, and argon was selected as the spraying gas, the gas flow rate was 75 liters / minute, the spraying voltage was 300 volts, and the spraying time was 15 minutes.

[0098] Summary of the embodiment: This embodiment prepares a high-performance fire-wall insulation material through fine proportioning and advanced technology. Its mechanical strength, bonding performance, fire resistance and thermal insulation effect are significantly better than traditional materials, especially in high temperature environment, it maintains good structural stability and fireproof performance.

[0099] Embodiment 2:

[0100] Material formula:

[0101] Basalt fiber: 18%

[0102] Glass Fiber: 14%

[0103] Carbon Fiber: 4%

[0104] Ceramic fiber: 8%

[0105] Modified silicate binder: 9%

[0106] Bio-based resin binder: 6%

[0107] Phenolic resin binder: 7%

[0108] Nano silicon dioxide: 6%

[0109] Aluminum hydroxide: 9%

[0110] Expanded graphite: 6%

[0111] Calcium hydroxide: 2%

[0112] Graphene aerogel: 3%

[0113] Nano aerogel: 6%

[0114] Microporous calcium silicate: 7%

[0115] Production steps:

[0116] Premix:

[0117] Add basalt fiber, glass fiber, carbon fiber and ceramic fiber into a high-speed stirring device according to weight ratio, set the speed to 2500 rpm, and stir for 12 minutes to ensure that the fibers are evenly dispersed.

[0118] The uniformity of fiber mixing is checked by an online monitoring system.

[0119] Ultrasonic dispersion:

[0120] The premix was placed in the reaction vessel of an ultrasonic dispersing device.

[0121] The frequency of the ultrasonic dispersion equipment was adjusted to 35 kHz and the power to 900 watts, and an appropriate amount of ethanol was added to the reaction container. The dispersion time was continued for 40 minutes.

[0122] Binder Mixing:

[0123] Add the modified silicate binder, the bio-based resin binder and the phenolic resin binder to the premix and stir thoroughly until a homogeneous mixture is formed.

[0124] forming:

[0125] The mixture is formed through a multi-layer composite molding process. Each mixture is added to the molding mold in turn and laid in layers. The compaction treatment pressure of each layer is 7 MPa.

[0126] Curing treatment:

[0127] The curing process is carried out under the control of the intelligent temperature control system, and the temperature curve is as follows:

[0128] Initial heating stage: from room temperature to 70°C, the heating rate is 2.5°C / min.

[0129] Intermediate insulation stage: maintain at 70°C for 40 minutes.

[0130] The second heating stage: from 70°C to 160°C, the heating rate is 1.2°C / min.

[0131] High temperature insulation stage: maintain at 160℃ for 1.2 hours.

[0132] Cooling stage: cooling from 160°C to room temperature at a cooling rate of 1.8°C / min.

[0133] Surface treatment:

[0134] The solidified material was subjected to plasma surface treatment, nitrogen was selected as the spraying gas, the gas flow rate was 80 liters / minute, the spraying voltage was 350 volts, and the spraying time was 12 minutes.

[0135] Summary of the embodiment: This embodiment further optimizes the environmental performance and bonding strength of the material by adjusting different ratios and process parameters while maintaining high performance. Although the mechanical strength and fire resistance are slightly lower than those of embodiment 1, it is more excellent in environmental protection and bonding strength.

[0136] Embodiment 3:

[0137] Material formula:

[0138] Basalt fiber: 22%

[0139] Glass Fiber: 10%

[0140] Carbon Fiber: 6%

[0141] Ceramic fiber: 7%

[0142] Modified silicate binder: 11%

[0143] Bio-based resin binder: 4%

[0144] Phenolic resin binder: 8%

[0145] Nano silicon dioxide: 7%

[0146] Aluminum hydroxide: 8%

[0147] Expanded graphite: 4%

[0148] Calcium hydroxide: 4%

[0149] Graphene aerogel: 2%

[0150] Nano aerogel: 4%

[0151] Microporous calcium silicate: 6%

[0152] Production steps:

[0153] Premix:

[0154] Add basalt fiber, glass fiber, carbon fiber and ceramic fiber into a high-speed stirring device according to weight ratio, set the speed to 2800 rpm, and stir for 10 minutes to ensure that the fibers are evenly dispersed.

[0155] The uniformity of fiber mixing is checked by an online monitoring system.

[0156] Ultrasonic dispersion:

[0157] The premix was placed in the reaction vessel of an ultrasonic dispersing device.

[0158] The frequency of the ultrasonic dispersion equipment was adjusted to 25 kHz and the power to 700 watts. An appropriate amount of deionized water was added to the reaction container and the dispersion time was continued for 50 minutes.

[0159] Binder Mixing:

[0160] Add the modified silicate binder, the bio-based resin binder and the phenolic resin binder to the premix and stir thoroughly until a homogeneous mixture is formed.

[0161] forming:

[0162] The mixture is formed through a multi-layer composite molding process. Each mixture is added to the molding mold in turn and laid in layers. The compaction treatment pressure of each layer is 9 MPa.

[0163] Curing treatment:

[0164] The curing process is carried out under the control of the intelligent temperature control system, and the temperature curve is as follows:

[0165] Initial heating stage: from room temperature to 90°C, the heating rate is 2°C / min.

[0166] Intermediate insulation stage: maintain at 90°C for 25 minutes.

[0167] The second heating stage: from 90°C to 190°C, the heating rate is 0.8°C / min.

[0168] High temperature insulation stage: maintain at 190℃ for 1.5 hours.

[0169] Cooling stage: cooling from 190°C to room temperature at a cooling rate of 2°C / min.

[0170] Surface treatment:

[0171] The solidified material was subjected to plasma surface treatment, and argon was selected as the spraying gas, the gas flow rate was 70 liters / minute, the spraying voltage was 300 volts, and the spraying time was 15 minutes.

[0172] Summary of the embodiment: This embodiment further improves the mechanical strength and fire resistance of the material by increasing the proportion of basalt fiber and modified silicate binder. Although the environmental performance is slightly lower than that of embodiment 2, it performs best in terms of high strength and stability.

[0173] Comparative experiment:

[0174] Experiment 1: Mechanical Strength Comparison

[0175] Experimental method: A universal mechanical testing machine is used to compare and test the compressive strength and tensile strength of the material of the present invention and the traditional single fiber material under different environmental conditions.

[0176] Prior art formula:

[0177] Glass Fiber: 100%

[0178] Mineral Wool: 100%

[0179] Experimental process:

[0180] Prepare samples of each material with a size of 100 mm x 100 mm x 100 mm.

[0181] The samples were placed on a universal mechanical testing machine for testing.

[0182] Test the compressive strength and tensile strength and record the data.

[0183] Experimental data:

[0184] Material Type Compressive strength(MPa) Tensile strength(MPa) Traditional fiberglass materials 50 30 Traditional mineral wool material 45 28 Composite fiber material of Example 1 75 55 Composite fiber material of Example 2 70 50 Composite fiber material of Example 3 72 53

[0185] Analysis: The composite fiber material of the present invention is significantly superior to the traditional material in terms of mechanical strength. This is due to the synergistic effect of multiple fibers to improve the overall strength. Example 1 performs best because its fiber ratio and process parameters are most optimized. Examples 2 and 3 also perform well, proving the effectiveness of the formula and process.

[0186] Experiment 2: Adhesion performance comparison

[0187] Experimental method: A peeling test method was used to compare and test the bonding strength between the material of the present invention and a traditional single adhesive material.

[0188] Prior art formula:

[0189] Pure silicate binder: 100%

[0190] Pure phenolic resin binder: 100%

[0191] Experimental process:

[0192] Prepare samples of each material with a size of 100 mm x 100 mm x 5 mm.

[0193] The samples were placed on a peel tester for testing.

[0194] Test the bonding strength and record the data.

[0195] Experimental data:

[0196] Material Type <![CDATA[Bond strength (N / mm 2 )]]> Pure silicate binder material 1.5 Pure phenolic resin binder material 2 Composite adhesive of Example 1 3.2 Composite adhesive of Example 2 3 Composite adhesive of Example 3 3.1

[0197] Analysis: The composite adhesive of the present invention is significantly superior to traditional materials in terms of bonding strength. Example 1 has the highest bonding strength, indicating that its adhesive formula and mixing process are the most optimized. Example 2 strikes a balance between environmental performance and bonding strength, while Example 3 performs better in terms of high strength and stability.

[0198] Experiment 3: Fire resistance comparison

[0199] Experimental method: Fire resistance testing equipment is used to compare the fire resistance of the material of the present invention and traditional fire retardant materials under high temperature conditions.

[0200] Prior art formula:

[0201] Halogen flame retardant: 100%

[0202] Inorganic flame retardant: 100%

[0203] Experimental process:

[0204] Prepare samples of each material with a size of 100 mm x 100 mm x 10 mm.

[0205] The samples are placed on the fire resistance testing equipment for testing.

[0206] Test the fire resistance time and record the data.

[0207] Experimental data:

[0208] Material Type Fire resistance time (minutes) Halogen flame retardant materials 30 Inorganic flame retardant materials 40 Fireproof material of embodiment 1 90 Fireproof material of embodiment 2 85 Fireproof material of embodiment 3 88

[0209] Analysis: The fireproof material of the present invention is significantly superior to the traditional fireproof material in terms of fire resistance. The fireproof time of Example 1 is the longest, indicating that its fireproof additive combination and process parameters are the most effective. Examples 2 and 3 also perform well in terms of fire resistance, further proving the effectiveness of the present invention.

[0210] Experiment 4: Comparison of thermal insulation effects

[0211] Experimental method: Using thermal insulation performance testing equipment, compare and test the thermal insulation effects of the material of the present invention and traditional thermal insulation materials under different temperature conditions.

[0212] Prior art formula:

[0213] Foam glass: 100%

[0214] Mineral Wool: 100%

[0215] Experimental process:

[0216] Prepare samples of each material with a size of 100 mm x 100 mm x 10 mm.

[0217] Place the sample on the thermal insulation performance testing equipment for testing.

[0218] Test thermal conductivity and density and record the data.

[0219] Experimental data:

[0220] Material Type Thermal conductivity (W / m·K) <![CDATA[Density (kg / m 3 )]]> Foam glass material 0.04 160 Mineral wool material 0.045 120 Thermal insulation material of Example 1 0.025 90 Thermal insulation material of Example 2 0.027 95 Thermal insulation material of Example 3 0.026 92

[0221] Analysis: The thermal insulation material of the present invention is significantly superior to traditional materials in terms of thermal insulation effect and weight control. Example 1 has the best thermal insulation effect and the lowest density, indicating that its thermal insulation additive combination and process are the most optimized. Examples 2 and 3 also perform well in terms of thermal insulation effect and lightweight, further proving the effectiveness of the present invention.

[0222] Summarize:

[0223] Through the above examples and comparative experiments, it can be clearly seen that the present invention is significantly superior to the traditional materials in the prior art in terms of mechanical strength, bonding performance, fire resistance and thermal insulation effect. The different results of each example are also reasonably explained by detailed formula and process analysis, proving the innovation and practicality of the present invention, which can effectively meet the needs of modern construction and industrial fields for high-performance fireproof and thermal insulation materials.

[0224] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A fire wall thermal insulation material, characterized in that: The material includes the following components in weight percentage: Basalt fiber 15-25% Glass fiber 10-15% Carbon fiber 3-7% Ceramic fiber 5-10% Modified silicate binder 8-12% Bio-based resin binder 3-7% Phenolic resin binder 5-10% Fire retardant additives 16-31% Thermal insulation additive 10-20%.

2. The fire wall insulation material according to claim 1, characterized in that: The weight ratio of the basalt fiber, the glass fiber, the carbon fiber and the ceramic fiber is 2:1:1:1 to 3:1:1:

1.

3. The fire wall insulation material according to claim 1, characterized in that: The weight ratio of the modified silicate binder, the bio-based resin binder and the phenolic resin binder is 2:1:1 to 3:1:

1.

4. The fire wall insulation material according to claim 1, characterized in that: The fireproof additive comprises nano silicon dioxide, aluminum hydroxide, expanded graphite and calcium hydroxide, wherein the weight percentage of the nano silicon dioxide is 3-7%, the weight percentage of the aluminum hydroxide is 8-12%, the weight percentage of the expanded graphite is 3-7%, and the weight percentage of the calcium hydroxide is 2-5%.

5. The fire wall insulation material according to claim 1, characterized in that: The heat insulation additive comprises graphene aerogel, nano aerogel and microporous calcium silicate, wherein the weight percentage of the graphene aerogel is 1-3%, the weight percentage of the nano aerogel is 3-7%, and the weight percentage of the microporous calcium silicate is 5-10%.

6. The method for producing a fire wall thermal insulation material according to any one of claims 1 to 5, characterized in that: The following steps are involved: a. Premixing basalt fiber, glass fiber, carbon fiber and ceramic fiber; b. Using ultrasonic dispersion technology to evenly disperse nano silicon dioxide, aluminum hydroxide, expanded graphite and calcium hydroxide in the mixture; c. adding the modified silicate binder, the bio-based resin binder and the phenolic resin binder to the premix and stirring thoroughly until a uniform mixture is formed; d. molding the mixture through a multi-layer composite molding process; e. Carry out curing process under the control of intelligent temperature control system; f. Perform plasma surface treatment on the cured material.

7. The method for producing a fire wall thermal insulation material according to claim 6, characterized in that: The premixing of basalt fiber, glass fiber, carbon fiber and ceramic fiber in step a is carried out by a high-speed stirring device, and specifically comprises the following steps: a1. Add basalt fiber, glass fiber, carbon fiber and ceramic fiber by weight into a high-speed stirring device; a2. Set the stirring speed of the stirring device to 1500-3000 rpm and the stirring time to 5-15 minutes; a3. Keep the fibers evenly dispersed during stirring and prevent fiber entanglement and agglomeration; a4. Real-time detection of fiber mixing uniformity through online monitoring system.

8. The method for producing a fire wall thermal insulation material according to claim 6, characterized in that: The frequency of the ultrasonic dispersion in step b is 20-40kHz, and the duration is 30-60 minutes, which specifically includes the following steps: b1. The premix is ​​placed in a reaction vessel of an ultrasonic dispersing device; b2. Adjust the frequency of the ultrasonic dispersion device to 20-40kHz and the power to 500-1000 watts; b3. Adding an appropriate amount of a dispersion medium, including deionized water or ethanol, to the reaction vessel to improve the dispersion effect; b4. Start the ultrasonic dispersion equipment and continue the dispersion for 30-60 minutes; b5. After dispersion is completed, the mixture is filtered by vacuum or centrifuged to remove excess dispersion medium.

9. The method for producing a fire wall thermal insulation material according to claim 6, characterized in that: The multi-layer composite molding process in step d includes at least three layers, specifically including the following steps: d1. The pretreated mixture is divided into multiple portions according to the designed composition ratio, each portion is used for a different forming layer; d2. Add each mixture to the molding mold in sequence and lay them out in layers; d3. Compact each layer of the mixture with a compaction pressure of 5-10 MPa to ensure tight bonding between the layers; d4. After each layer is compacted, it is initially formed by hot pressing or cold pressing, and the temperature is controlled at 100-150 degrees Celsius; d5. After all layers are laid and compacted, the whole will be subjected to secondary hot pressing treatment at a temperature of 150-200 degrees Celsius for 1-2 hours.

10. The method for producing a fire wall thermal insulation material according to claim 6, characterized in that: The plasma surface treatment in step f is performed using a plasma spraying device, and specifically comprises the following steps: f1. Place the cured material on the spraying table of the plasma spraying equipment to ensure that the surface of the material is clean and free of oil stains; f2 set the working parameters of the plasma spraying equipment, spray gas selection argon or nitrogen, gas flow rate of 50-100 liters / minute, spray voltage of 200-500 volts; f3. Turn on the plasma spraying equipment and spray the surface of the material for 10-20 minutes; f4. During the spraying process, ensure that the material surface is evenly covered with the plasma layer by moving the spray gun or rotating the spray table; f5. After spraying, the material is cooled naturally at room temperature or accelerated by a cooling device to form a dense protective layer.

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