Aerogel-graphite-polystyrene insulation board and preparation method thereof

Abstract

The invention provides an aerogel-graphite-polystyrene insulation board, which is prepared from the following raw materials in parts by weight: 10 to 20 parts of deionized water, 0.3 to 0.6 part of defoaming agent, 1 to 3 parts of acrylic emulsion, 0.3 to 0.5 part of PVA (Polyvinyl Alcohol) aqueous solution, 0.1 to 0.2 part of sodium dodecyl benzene sulfonate, 0.2 to 0.4 part of sodium hexametaphosphate, 3 to 5 parts of EPS (Expandable Polystyrene) foaming particles, 0.3 to 0.6 part of glass fiber, 7 to 9 parts of Cabot particles and 0.5 to 1 part of graphite. And 70-75 parts of silicon dioxide aerogel slurry. The invention also provides a preparation method of the aerogel-graphite-polystyrene insulation board. The aerogel-graphite-polystyrene insulation board provided by the invention has relatively good thermal insulation performance, mechanical property and flame retardant property.

Description

Technical Field

[0001] The invention relates to a thermal insulation board, in particular to an aerogel-graphite-polystyrene thermal insulation board and a preparation method thereof. Background Art

[0002] Traditional thermal insulation materials are difficult to meet the requirements of building energy conservation and building fire protection standards at the same time. Thermal insulation materials with better thermal insulation and fire protection properties have become a research hotspot, and the development of high-efficiency, energy-saving and Class A fireproof thermal insulation materials has become the main theme of the market.

[0003] Expandable polystyrene (EPS) materials have been widely used in the construction and industrial fields due to their good thermal insulation, corrosion resistance and low product cost. However, expandable EPS materials are thermoplastic materials with a maximum fire rating of only B1. They are not fire-resistant enough and will shrink, melt and flow when exposed to fire, and the flames spread quickly.

[0004] Silica aerogel is a material with a unique three-dimensional network structure. Its porosity is as high as 99%. It is the lightest solid material at present. It has the characteristics of low thermal conductivity, high porosity, low dielectric constant, good sound absorption performance, and excellent flame retardant performance. It does not decompose or burn at high temperatures and does not emit harmful gases. It is a green and environmentally friendly thermal insulation material that meets Class A fire protection requirements. Silica aerogel is often incorporated into other substrates, such as glass fiber or other lightweight materials, to improve the thermal insulation performance of the material.

[0005] The composite of silica aerogel and EPS is expected to improve the thermal insulation and flame retardant properties of EPS. However, due to the limited amount of silica aerogel added, the composite board is still Class B fireproof and the thermal conductivity is still relatively high. The application of silica aerogel in building insulation materials has made some progress, but it is still in the primary stage and there are still many problems that have not been solved. Pure silica aerogel is brittle, low in strength, easy to break, and difficult to form and process. In addition, there is a lack of chemical connection between silica aerogel and inorganic gelling materials, and the compatibility is poor. When it is added to inorganic gelling materials, its thermal insulation performance is enhanced while the mechanical properties will be greatly reduced. Summary of the invention

[0006] The technical problem to be solved by the present invention is to provide an aerogel-graphite-polystyrene insulation board, which has good thermal insulation performance, mechanical properties and flame retardant properties.

[0007] In order to solve the above technical problems, the technical solution of the present invention is:

[0008] An aerogel-graphite-polystyrene insulation board is prepared from the following raw materials in parts by weight: 10-20 parts of deionized water, 0.3-0.6 parts of defoaming agent, 1-3 parts of acrylic emulsion, 0.3-0.5 parts of PVA aqueous solution, 0.1-0.2 parts of sodium dodecylbenzene sulfonate, 0.2-0.4 parts of sodium hexametaphosphate, 3-5 parts of EPS foamed particles, 0.3-0.6 parts of glass fiber, 7-9 parts of Cabot particles, 0.5-1 parts of graphite and 70-75 parts of silica aerogel slurry.

[0009] Furthermore, the defoaming agent of the present invention is a silicone oil-based defoaming agent.

[0010] Furthermore, the acrylic emulsion of the present invention is a pure acrylic emulsion.

[0011] Furthermore, the concentration of the PVA aqueous solution of the present invention is 5wt%.

[0012] Furthermore, the particle size of the EPS foamed particles of the present invention is 2-5 mm.

[0013] Furthermore, the glass fiber of the present invention has a length of 3-6 mm and a diameter of 9-12 μm.

[0014] Furthermore, the particle size of the Cabot particles of the present invention is 0.5-4 mm.

[0015] Furthermore, the particle size of the graphite in the present invention is 800 mesh.

[0016] Furthermore, the silica aerogel slurry of the present invention is composed of silica aerogel, water and hydroxypropyl cellulose in a weight ratio of 15:82:3.

[0017] Another technical problem to be solved by the present invention is to provide a method for preparing the above-mentioned aerogel-graphite-polystyrene insulation board.

[0018] To solve the above technical problems, the technical solution is:

[0019] A method for preparing an aerogel-graphite-polystyrene insulation board comprises the following steps:

[0020] S1. Weigh the raw materials according to the formula, mix deionized water, defoamer, acrylic emulsion, PVA aqueous solution, sodium dodecylbenzene sulfonate, sodium hexametaphosphate, and stir at a speed of 300-500r / min to obtain a mixed solution;

[0021] S2. The EPS foam particles, glass fiber, Cabot particles, and graphite are mixed and stirred at a speed of 500-1000 r / min to obtain a dry mixed material;

[0022] S3. The silica aerogel slurry is added to the mixed solution obtained in step S1, stirred at a speed of 300-500 r / min, and then the dry mixed material obtained in step S2 is added, and stirring is continued for 20-40 min to obtain an insulating slurry;

[0023] S4. The insulation slurry obtained in step S3 is vacuum degassed for 30 minutes at a pressure of 0.1-0.5MPa and a rotation speed of 30r / min, then poured into a plate mold of a predetermined size, and repeatedly smeared until the surface is smooth and flat to obtain a green insulation board. The green insulation board is dried at room temperature for 48 hours, and then moved to a 50°C oven for drying for 60-84 hours to obtain an aerogel-graphite-polystyrene insulation board.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] The present invention uses EPS foamed particles as aggregates, PVA aqueous solution as a binder, and glass fiber as a reinforcing material to prepare an aerogel-graphite-polystyrene insulation board through a wet process. Silica aerogel is a material with a unique three-dimensional network structure, with a porosity of up to 99% and a thermal conductivity as low as 0.020w / m·k, but its mechanical properties are low and its processing and molding process is poor. In this regard, the present invention uses EPS foamed particles as aggregates and evenly disperses them in silica aerogel, which plays a role in particle reinforcement while ensuring that the thermal conductivity of the composite material does not increase; in addition, under the action of dispersant sodium hexametaphosphate and surfactant sodium dodecylbenzene sulfonate, the surface of the glass fiber is tightly coated with a layer of silica aerogel, and effectively interspersed to form a three-dimensional network structure, which not only plays a role in fiber toughening, but also improves the strength and flame retardant properties of the composite insulation board. According to tests, the thermal conductivity of the aerogel-graphite-polystyrene insulation board prepared by the present invention is 0.020-0.023w / m·k, and the maximum compressive strength can reach 0.18MPa. Compared with the existing EPS insulation board, the thermal insulation performance is significantly improved, and the thickness of the insulation board can be significantly reduced while achieving the same thermal insulation performance. DETAILED DESCRIPTION

[0026] The present invention will be described in detail below in conjunction with specific embodiments. The illustrative embodiments of the present invention and their descriptions are used to explain the present invention but are not intended to limit the present invention.

[0027] Example 1

[0028] The aerogel-graphite-polystyrene insulation board is made of the following raw materials in parts by weight: 15 parts of deionized water, 0.5 parts of silicone oil-based defoaming agent, 2 parts of pure acrylic emulsion, 0.4 parts of PVA aqueous solution with a concentration of 5wt%, 0.1 parts of sodium dodecylbenzene sulfonate, 0.3 parts of sodium hexametaphosphate, 4 parts of EPS foamed particles with a particle size of 2-5mm, 0.4 parts of glass fiber with a length of 3-6mm and a diameter of 9-12μm, 8 parts of Cabot particles with a particle size of 0.5-4mm, 0.8 parts of graphite with a particle size of 800 mesh, and 72 parts of silica aerogel slurry composed of silica aerogel, water, and hydroxypropyl cellulose in a weight ratio of 15:82:3.

[0029] The preparation method of Example 1 comprises the following steps:

[0030] S1. Weigh the raw materials according to the formula, mix deionized water, silicone oil-based defoamer, pure acrylic emulsion, PVA aqueous solution, sodium dodecylbenzene sulfonate, sodium hexametaphosphate, and stir at a speed of 400r / min to obtain a mixed solution;

[0031] S2. The EPS foam particles, glass fiber, Cabot particles, and graphite were mixed and stirred at a speed of 800 r / min to obtain a dry mixed material;

[0032] S3. The silica aerogel slurry is added to the mixed solution obtained in step S1, stirred at 400 r / min, and then the dry mixed material obtained in step S2 is added, and stirring is continued for 30 min to obtain an insulating slurry;

[0033] S4. The insulation slurry obtained in step S3 is vacuum degassed for 30 minutes at a pressure of 0.3 MPa and a rotation speed of 30 r / min, then poured into a plate mold of a predetermined size, and repeatedly smeared until the surface is smooth and flat to obtain a green insulation board. The green insulation board is dried at room temperature for 48 hours, and then moved to an oven at 50°C and dried for 72 hours to obtain an aerogel-graphite-polystyrene insulation board.

[0034] Example 2

[0035] The aerogel-graphite-polystyrene insulation board is made of the following raw materials in parts by weight: 10 parts of deionized water, 0.3 parts of silicone oil-based defoaming agent, 1 part of pure acrylic emulsion, 0.3 parts of PVA aqueous solution with a concentration of 5wt%, 0.2 parts of sodium dodecylbenzene sulfonate, 0.2 parts of sodium hexametaphosphate, 3 parts of EPS foamed particles with a particle size of 2-5mm, 0.3 parts of glass fiber with a length of 3-6mm and a diameter of 9-12μm, 7 parts of Cabot particles with a particle size of 0.5-4mm, 0.5 parts of graphite with a particle size of 800 mesh, and 70 parts of silica aerogel slurry composed of silica aerogel, water, and hydroxypropyl cellulose in a weight ratio of 15:82:3.

[0036] The preparation method of Example 2 comprises the following steps:

[0037] S1. Weigh the raw materials according to the formula, mix deionized water, silicone oil-based defoamer, pure acrylic emulsion, PVA aqueous solution, sodium dodecylbenzene sulfonate, sodium hexametaphosphate, and stir at a speed of 300r / min to obtain a mixed solution;

[0038] S2. The EPS foam particles, glass fiber, Cabot particles, and graphite were mixed and stirred at a speed of 500 r / min to obtain a dry mixed material;

[0039] S3. The silica aerogel slurry is added to the mixed solution obtained in step S1, stirred at a speed of 300 r / min, and then the dry mixed material obtained in step S2 is added, and stirring is continued for 40 min to obtain an insulating slurry;

[0040] S4. The insulation slurry obtained in step S3 is vacuum degassed for 30 minutes at a pressure of 0.5 MPa and a rotation speed of 30 r / min, then poured into a plate mold of a predetermined size, and repeatedly smeared until the surface is smooth and flat to obtain a green insulation board. The green insulation board is dried at room temperature for 48 hours, and then moved to an oven at 50°C and dried for 60 hours to obtain an aerogel-graphite-polystyrene insulation board.

[0041] Example 3

[0042] The aerogel-graphite-polystyrene insulation board is made of the following raw materials in parts by weight: 20 parts of deionized water, 0.6 parts of silicone oil-based defoaming agent, 3 parts of pure acrylic emulsion, 0.5 parts of PVA aqueous solution with a concentration of 5wt%, 0.2 parts of sodium dodecylbenzene sulfonate, 0.4 parts of sodium hexametaphosphate, 5 parts of EPS foamed particles with a particle size of 2-5mm, 0.6 parts of glass fiber with a length of 3-6mm and a diameter of 9-12μm, 9 parts of Cabot particles with a particle size of 0.5-4mm, 1 part of graphite with a particle size of 800 mesh, and 75 parts of silica aerogel slurry composed of silica aerogel, water, and hydroxypropyl cellulose in a weight ratio of 15:82:3.

[0043] The preparation method of Example 3 comprises the following steps:

[0044] S1. Weigh the raw materials according to the formula, mix deionized water, silicone oil-based defoamer, pure acrylic emulsion, PVA aqueous solution, sodium dodecylbenzene sulfonate, sodium hexametaphosphate, and stir at a speed of 500r / min to obtain a mixed solution;

[0045] S2. The EPS foam particles, glass fiber, Cabot particles, and graphite were mixed and stirred at a speed of 1000 r / min to obtain a dry mixed material;

[0046] S3. The silica aerogel slurry is added to the mixed solution obtained in step S1, stirred at a speed of 500 r / min, and then the dry mixed material obtained in step S2 is added, and stirring is continued for 20 min to obtain an insulation slurry;

[0047] S4. The insulation slurry obtained in step S3 is vacuum degassed for 30 minutes at a pressure of 0.1 MPa and a rotation speed of 30 r / min, then poured into a plate mold of a predetermined size, and repeatedly smeared until the surface is smooth and flat to obtain a green insulation board. The green insulation board is dried at room temperature for 48 hours, and then moved to an oven at 50°C and dried for 84 hours to obtain an aerogel-graphite-polystyrene insulation board.

[0048] Example 4

[0049] The aerogel-graphite-polystyrene insulation board is made of the following raw materials in parts by weight: 18 parts of deionized water, 0.4 parts of silicone oil-based defoaming agent, 2.5 parts of pure acrylic emulsion, 0.4 parts of PVA aqueous solution with a concentration of 5wt%, 0.1 parts of sodium dodecylbenzene sulfonate, 0.3 parts of sodium hexametaphosphate, 4.5 parts of EPS foamed particles with a particle size of 2-5mm, 0.5 parts of glass fiber with a length of 3-6mm and a diameter of 9-12μm, 7.5 parts of Cabot particles with a particle size of 0.5-4mm, 0.7 parts of graphite with a particle size of 800 mesh, and 74 parts of silica aerogel slurry composed of silica aerogel, water, and hydroxypropyl cellulose in a weight ratio of 15:82:3.

[0050] The preparation method of Example 4 comprises the following steps:

[0051] S1. Weigh the raw materials according to the formula, mix deionized water, silicone oil-based defoamer, pure acrylic emulsion, PVA aqueous solution, sodium dodecylbenzene sulfonate, sodium hexametaphosphate, and stir at a speed of 400r / min to obtain a mixed solution;

[0052] S2. The EPS foam particles, glass fiber, Cabot particles, and graphite were mixed and stirred at a speed of 700 r / min to obtain a dry mixed material;

[0053] S3. The silica aerogel slurry is added to the mixed solution obtained in step S1, stirred at 400 r / min, and then the dry mixed material obtained in step S2 is added, and stirring is continued for 35 min to obtain an insulating slurry;

[0054] S4. The insulation slurry obtained in step S3 is vacuum degassed for 30 minutes at a pressure of 0.2 MPa and a rotation speed of 30 r / min, then poured into a plate mold of a predetermined size, and repeatedly smeared until the surface is smooth and flat to obtain a green insulation board. The green insulation board is dried at room temperature for 48 hours, and then moved to an oven at 50°C and dried for 78 hours to obtain an aerogel-graphite-polystyrene insulation board.

[0055] Reference Example 1

[0056] The raw materials do not include silica aerogel slurry, and other raw materials and preparation methods are the same as those in Example 1.

[0057] Reference Example 2

[0058] The raw materials do not include sodium hexametaphosphate and sodium dodecylbenzene sulfonate, and other raw materials and preparation methods are the same as those in Example 1.

[0059] Reference Example 3

[0060] The raw materials do not include glass fiber, and other raw materials and preparation methods are the same as those in Example 1.

[0061] Comparative Example

[0062] Example 1 of patent application number CN201811131298.4.

[0063] Experimental Example 1: Thermal Insulation Performance Test

[0064] The thermal conductivity of Examples 1-4, Reference Example 1, and Comparative Example was measured with reference to GB / T 3399-1982. The lower the thermal conductivity, the better the thermal insulation performance. The test results are shown in Table 1:

[0065]

[0066]

[0067] Table 1

[0068] As can be seen from Table 1, the thermal conductivity of Examples 1-4 of the present invention is lower than that of the comparative example, indicating that the present invention has good thermal insulation performance. Some raw materials of Reference Example 1 are different from those of Example 1. Compared with Example 1, the thermal conductivity of Reference Example 1 is increased, indicating that the silica aerogel slurry used in the present invention can improve the thermal insulation performance of the insulation board.

[0069] Experimental Example 2: Mechanical Properties Test

[0070] The compressive strength of Examples 1-4, Reference Example 2, and Comparative Example was measured with reference to GB / T 8813-2020. The sample size was 40 mm × 40 mm × 10 mm. The greater the compressive strength, the better the mechanical properties. The test results are shown in Table 2:

[0071] Compressive strength(MPa) Example 1 0.18 Example 2 0.16 Example 3 0.17 Example 4 0.17 Reference Example 2 0.14 Comparative Example 0.11

[0072] Table 2

[0073] As can be seen from Table 2, the compressive strength of Examples 1-4 of the present invention is greater than that of the comparative example, indicating that the present invention has good mechanical properties. Some of the raw materials of Reference Example 2 are different from those of Example 1. Compared with Example 1, the compressive strength of Reference Example 2 is reduced, indicating that the sodium hexametaphosphate and sodium dodecylbenzene sulfonate used in the present invention help the glass fiber to better play a reinforcing role.

[0074] Experimental Example 3: Flame retardant performance test

[0075] The oxygen index (LOI) of Examples 1-4, Reference Example 1, Reference Example 3 and Comparative Example was measured with reference to GB / T 2406-2008. The sample size was 125 mm×10 mm×10 mm. The higher the oxygen index, the better the flame retardant performance. The test results are shown in Table 3:

[0076] Oxygen index (%) Example 1 31.7 Example 2 32.1 Example 3 31.2 Example 4 31.5 Reference Example 1 28.3 Reference Example 3 27.6 Comparative Example 25.8

[0077] Table 3

[0078] As can be seen from Table 3, the oxygen indexes of Examples 1-4 of the present invention are all higher than those of the comparative example, indicating that the present invention has good flame retardant properties. Some of the raw materials of Reference Examples 1 and 3 are different from those of Example 1. Compared with Example 1, the oxygen indexes of Reference Examples 1 and 3 are reduced, indicating that the silica aerogel slurry and glass fiber used in the present invention can improve the flame retardant properties of the thermal insulation board.

[0079] The above embodiments are merely illustrative of the principles and effects of the present invention, and are not intended to limit the present invention. Anyone familiar with the art may modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by a person of ordinary skill in the art without departing from the spirit and technical concept disclosed by the present invention shall still be covered by the claims of the present invention.

Claims

1. An aerogel-graphite-polystyrene insulation board, characterized in that: The invention is prepared from the following raw materials in parts by weight: 10-20 parts of deionized water, 0.3-0.6 parts of defoaming agent, 1-3 parts of acrylic emulsion, 0.3-0.5 parts of PVA aqueous solution, 0.1-0.2 parts of sodium dodecylbenzene sulfonate, 0.2-0.4 parts of sodium hexametaphosphate, 3-5 parts of EPS foaming particles, 0.3-0.6 parts of glass fiber, 7-9 parts of Cabot particles, 0.5-1 parts of graphite and 70-75 parts of silica aerogel slurry.

2. The aerogel-graphite-polystyrene insulation board according to claim 1, characterized in that: The defoamer is a silicone oil-based defoamer.

3. The aerogel-graphite-polystyrene insulation board according to claim 1, characterized in that: The acrylic emulsion is pure acrylic emulsion.

4. The aerogel-graphite-polystyrene insulation board according to claim 1, characterized in that: The concentration of the PVA aqueous solution is 5 wt %.

5. The aerogel-graphite-polystyrene insulation board according to claim 1, characterized in that: The particle size of the EPS foamed particles is 2-5 mm.

6. The aerogel-graphite-polystyrene insulation board according to claim 1, characterized in that: The glass fiber has a length of 3-6 mm and a diameter of 9-12 μm.

7. The aerogel-graphite-polystyrene insulation board according to claim 1, characterized in that: The particle size of the Cabot particles is 0.5-4 mm.

8. The aerogel-graphite-polystyrene insulation board according to claim 1, characterized in that: The particle size of the graphite is 800 meshes.

9. The aerogel-graphite-polystyrene insulation board according to claim 1, characterized in that: The silica aerogel slurry is composed of silica aerogel, water and hydroxypropyl cellulose in a weight ratio of 15:82:

3.

10. The method for preparing an aerogel-graphite-polystyrene insulation board according to any one of claims 1 to 9, characterized in that: The following steps are involved: S1. Weigh the raw materials according to the formula, mix the deionized water, defoamer, acrylic emulsion, PVA aqueous solution, and stir at a speed of 300-500r / min to obtain a mixed solution; S2. The EPS foam particles, glass fiber, Cabot particles, and graphite are mixed and stirred at a speed of 500-1000 r / min to obtain a dry mixed material; S3. The silica aerogel slurry is added to the mixed solution obtained in step S1, stirred at a speed of 300-500 r / min, and then the dry mixed material obtained in step S2 is added, and stirring is continued for 20-40 min to obtain an insulating slurry; S4. The insulation slurry obtained in step S3 is vacuum degassed for 30 minutes at a pressure of 0.1-0.5MPa and a rotation speed of 30r / min, then poured into a plate mold of a predetermined size, and repeatedly smeared until the surface is smooth and flat to obtain a green insulation board. The green insulation board is dried at room temperature for 48 hours, and then moved to a 50°C oven for drying for 60-84 hours to obtain an aerogel-graphite-polystyrene insulation board.

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