Hot-press forming insulation board and preparation method thereof

Abstract

The invention relates to a thermoforming insulation board which comprises 65-80 wt% of polystyrene particles, 10-20 wt% of glass fiber composite cloth, 5-30 wt% of barium sulfate particles, 10-20 wt% of novolac epoxy resin and 5-10 wt% of a curing agent. The fireproof efficient insulation board has the advantages of excellent fireproof and waterproof performance, low volume weight, good thermal insulation effect, high mechanical property and the like.

Description

Technical Field

[0001] The present invention relates to the field of building materials, and specifically to a hot-pressed formed insulation board wall insulation material and a preparation method thereof. Technical Background

[0002] With the global energy shortage and rising energy prices, energy conservation and emission reduction in buildings has become an important issue in the global construction industry. The insulation treatment of building envelopes is an important measure to achieve building energy conservation. Wall insulation systems can help reduce the heat exchange or transfer between the building and the outside world, and reduce the energy used for indoor temperature regulation in the building. Building wall insulation materials have gradually become the main form of insulation for building walls.

[0003] The insulation materials of the wall external insulation system mainly include organic insulation materials and inorganic insulation materials. Organic insulation materials have the advantages of low thermal conductivity, high density, low water absorption, good insulation effect, and easy processing, but have disadvantages such as poor aging resistance, large deformation coefficient, poor stability, and easy combustion, such as polystyrene (PS) foam, polyurethane (PU) foam, phenolic resin (PF) foam, etc. Inorganic insulation materials have high mechanical strength, excellent fire resistance and good insulation performance, and are often used in high-rise buildings and buildings with special requirements, such as rock wool, glass wool, vacuum insulation panels, foam glass, etc.

[0004] The application of external wall insulation system is becoming more and more extensive, and the performance requirements are getting higher and higher. As the most important component of the external wall insulation system, the insulation material must have excellent fire resistance and thermal insulation performance. Therefore, the development of composite insulation materials with excellent comprehensive performance, stability and environmental friendliness has become the focus of future research. The selection of effective fire safety performance and durability test methods provides a strong guarantee for evaluating the performance and quality of the external wall insulation system.

[0005] Existing thermal insulation materials have low structural strength and poor water resistance, and require additional internal and external protective layers for fire and water resistance, which are costly, dense, and have poor thermal insulation effects.

[0006] CN102174839A discloses a sandwich insulation structural board and a manufacturing method thereof. A sandwich insulation structural board is composed of at least two structural board units (1), and is characterized in that: the structural board unit (1) is composed of fibers (11), organic resin (12), insulation material (13) and a support frame (14), the support frame (14) is a prism-shaped or prism-shaped frame, hooks (15) are provided on each side of the support frame (14), the fibers (11) are connected to the hooks (15), and the organic resin (12) penetrates into the inside of the fibers (11) and wraps around the outer surface of the fibers (11). The present invention greatly reduces the engineering cycle, reduces the work intensity, improves the structural modulus of the building wall, and improves the building quality.

[0007] CN115286328A discloses a composite fireproof and heat-insulating material and a preparation process thereof. The composite fireproof and heat-insulating material is made of the following components in parts by weight: 20-30 parts of aluminum silicate wool, 10-15 parts of epoxy resin, 10-20 parts of polystyrene particles, 5-9 parts of asbestos fiber, 2-5 parts of aluminum silicate wool, 15-20 parts of silicate cement, 10-15 parts of fly ash, 30-50 parts of aluminate cement, 15-25 parts of glass fiber, 5-10 parts of fly ash microbeads, 40-80 parts of ingredient additives and 300-500 parts of water. The ingredients are 5-10 parts of curing agent, 19-29 parts of diluent, 1-3 parts of catalyst, 2-5 parts of foaming agent, 1-5 parts of retarder, 8-15 parts of penetrant, 3-8 parts of flame retardant and 1-5 parts of polycarboxylic acid water reducer. The heat-insulating material is mixed with a variety of fire-proof materials to improve the fire-proof performance of the device.

[0008] CN107266120A discloses a sound insulation and heat preservation building material, which comprises the following components by weight: 40-50 parts of semi-hydrated gypsum cementitious material, 10-20 parts of modified bentonite, 5-10 parts of polystyrene foam, 5-15 parts of gypsum powder, 2-10 parts of organic fiber, 3-10 parts of graphene, 3-10 parts of calcium carbonate, 2-10 parts of dispersible latex powder, 3-9 parts of barium sulfate, 2-8 parts of chitosan, 2-10 parts of collagen fiber, 2-10 parts of polyurethane, 2-10 parts of diatomaceous earth, and 1.5-4.5 parts of retarder. The present invention provides a sound insulation and heat preservation building material and a preparation method thereof. The prepared sound insulation and heat preservation building material has small thickness, good sound insulation effect, and has a good market prospect. Summary of the invention

[0009] The present invention achieves the surface protection and decorative effects required by the application by laying glass fiber composite cloth density on the upper and lower surfaces of the thermal insulation material, and uses the three-dimensional characteristics of polystyrene particles to wrap phenolic epoxy resin to form a mesh structure as a horizontal and vertical support. After being cured by chemical reaction, it has a tight shell and a mesh three-dimensional structure, and has good waterproof and fireproof effects. Polystyrene particles and phenolic epoxy resin have lower thermal conductivity. The combination of the two materials gives full play to their advantages, makes up for their shortcomings of having thermal insulation but no strength, and further enhances the waterproof and fireproof properties.

[0010] The insulation board of the present invention can flexibly adjust the size according to the use requirements, and improve the strength by adjusting the built-in skeleton and density, which greatly shortens the construction period and reduces construction waste. It can be repeatedly disassembled and used without causing crushing damage, and is suitable for various construction, protection, equipment, transportation, aerospace and other industries.

[0011] The invention discloses a hot-pressed thermal insulation board, which comprises: 65-80wt% polystyrene particles, 10-20wt% glass fiber composite cloth, 5-30wt% barium sulfate particles, 10-20wt% phenolic epoxy resin, and 5-10wt% curing agent.

[0012] The glass fiber content in the glass fiber composite cloth is 200-500g / m 2 , more preferably 300-400g / m 2 .

[0013] The polystyrene particles have a particle size of 2-4 mm and a bulk density of 18-28 kg / m 3 .

[0014] The phenolic epoxy resin has a weight average molecular weight of 3000-10000.

[0015] The curing agent is composed of the following components: 10-25% concentrated sulfuric acid, 30-50% p-toluenesulfonic acid, 30-40% phosphoric acid, and 10-20% water; preferably, the curing agent is composed of 15-17% concentrated sulfuric acid, 38-42% p-toluenesulfonic acid, 33-35% phosphoric acid, and 12-15% water.

[0016] The particle size of the barium sulfate particles is 0.1-50 μm, more preferably 1-10 μm; the barium sulfate particles are used to adjust the viscosity of the phenolic epoxy resin, and can also improve the fireproof and waterproof properties of the board, and increase the compressive strength of the board, so that it has a certain wrapping property, and forms a three-dimensional irregular honeycomb after curing.

[0017] The present invention also discloses a method for preparing a wall insulation board, comprising the following steps:

[0018] (1) placing phenolic epoxy resin, curing agent, and barium sulfate powder in a stirring tank in sequence and stirring to obtain a slurry;

[0019] (2) evenly applying the slurry prepared in step (1) on the glass fiber composite cloth, the thickness of the slurry being 1-5 mm, to obtain a prefabricated sheet;

[0020] (3) adding polystyrene particles into a stirring tank and stirring, wherein the temperature of the stirring tank is set at 35° C., to obtain a mixture having polystyrene particles wrapped in slurry;

[0021] (4) placing the prefabricated sheet obtained in step (2) on the bottom plate of the frame mold, adding the mixed material obtained in step (3), and covering it with the prefabricated sheet obtained in step (2);

[0022] (5) placing the mold together with the placed mixed material into a hot press for hot pressing, releasing the pressure after the hot pressing is completed and removing the mold from the mold for cooling to obtain a wall insulation board.

[0023] The viscosity of the slurry in step (1) is 1500-2500 mPa.s; the viscosity of the mixture in step (3) is 2000-3000 mPa.s.

[0024] In step (5), a pressurizing speed of 4-10 N / s is used, the hot pressing temperature is set at 50-125° C., the pressure is 0.4-0.6 MPa, and the hot pressing time is 10-30 min; after the pressurization is completed, the pressure relief speed is 15-30 N / s.

[0025] The fireproof and high-efficiency thermal insulation board prepared by the method has the advantages of fireproof performance, waterproofness, low bulk density, good thermal insulation effect, and high mechanical properties.

[0026] The present invention has the following beneficial effects: the thermal insulation board material prepared by the method of the present invention has good fireproof performance, good thermal insulation effect, light weight, and good mechanical properties. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 Schematic diagram of the structure of thermal insulation material, where 1 is polystyrene particles; 2 is glass fiber composite cloth; 3 is the mesh structure after epoxy resin is cured;

[0028] Figure 2 The invention relates to a thermal insulation board prepared by the method of the present invention. DETAILED DESCRIPTION

[0029] In order to make the technical problems, technical solutions and advantages to be solved by the present invention more clear, a detailed description will be given below with reference to the accompanying drawings and specific embodiments.

[0030] Embodiment 1:

[0031] A hot-pressed heat-insulating board comprises: 65wt% polystyrene particles, 20wt% glass fiber composite cloth, 5wt% barium sulfate particles, 10wt% phenolic epoxy resin, and 5wt% curing agent.

[0032] The method for preparing the wall insulation board comprises the following steps:

[0033] (1) placing phenolic epoxy resin, curing agent, and barium sulfate powder in a stirring tank in sequence and stirring to obtain a slurry;

[0034] (2) evenly applying the slurry prepared in step (1) on the glass fiber composite cloth, the thickness of the slurry being 1-5 mm, to obtain a prefabricated sheet;

[0035] (3) adding polystyrene particles into a stirring tank and stirring to obtain a mixture having polystyrene particles wrapped in slurry;

[0036] (4) placing the prefabricated sheet obtained in step (2) on the bottom plate of the frame mold, adding the mixed material obtained in step (3), and covering it with the prefabricated sheet obtained in step (2);

[0037] (5) The mold and the mixed material are placed in a hot press for hot pressing at a press speed of 10 N / s. The hot pressing is performed at 125° C. and 0.4 MPa for 10 min. After the hot pressing is completed, the pressure is released at a rate of 15 N / S, and the mold is removed for cooling to obtain a wall insulation board.

[0038] Embodiment 2:

[0039] A hot-pressed heat-insulating board comprises: 65wt% polystyrene particles, 20wt% glass fiber composite cloth, 5wt% barium sulfate particles, 10wt% phenolic epoxy resin, and 5wt% curing agent.

[0040] The method for preparing the wall insulation board comprises the following steps:

[0041] (1) placing phenolic epoxy resin, curing agent, and barium sulfate powder in a stirring tank in sequence and stirring to obtain a slurry;

[0042] (2) evenly applying the slurry prepared in step (1) on the glass fiber composite cloth, the thickness of the slurry being 1-5 mm, to obtain a prefabricated sheet;

[0043] (3) adding polystyrene particles into a stirring tank and stirring to obtain a mixture having polystyrene particles wrapped in slurry;

[0044] (4) placing the prefabricated sheet obtained in step (2) on the bottom plate of the frame mold, adding the mixed material obtained in step (3), and covering it with the prefabricated sheet obtained in step (2);

[0045] (5) The mold and the mixed material are placed in a hot press for hot pressing at a pressurizing speed of 10 N / s. The hot pressing is performed at 95° C. and 0.4 MPa for 10 min. After the hot pressing is completed, the pressure is released at a speed of 15 N / S, and the mold is removed for cooling to obtain a wall insulation board.

[0046] Embodiment 3:

[0047] A hot-pressed heat-insulating board comprises: 65wt% polystyrene particles, 20wt% glass fiber composite cloth, 5wt% barium sulfate particles, 10wt% phenolic epoxy resin, and 5wt% curing agent.

[0048] The method for preparing the wall insulation board comprises the following steps:

[0049] (1) placing phenolic epoxy resin, curing agent, and barium sulfate powder in a stirring tank in sequence and stirring to obtain a slurry;

[0050] (2) evenly applying the slurry prepared in step (1) on the glass fiber composite cloth, the thickness of the slurry being 1-5 mm, to obtain a prefabricated sheet;

[0051] (3) adding polystyrene particles into a stirring tank and stirring to obtain a mixture having polystyrene particles wrapped in slurry;

[0052] (4) placing the prefabricated sheet obtained in step (2) on the bottom plate of the frame mold, adding the mixed material obtained in step (3), and covering it with the prefabricated sheet obtained in step (2);

[0053] (5) The mold and the mixed material are placed in a hot press for hot pressing at a pressurizing speed of 10 N / s. The hot pressing is performed at 95° C. and 0.4 MPa for 10 min. After the hot pressing is completed, the pressure is released at a speed of 15 N / S, and the mold is removed for cooling to obtain a wall insulation board.

[0054] Embodiment 4:

[0055] A hot-pressed heat-insulating board comprises: 65wt% polystyrene particles, 20wt% glass fiber composite cloth, 5wt% barium sulfate particles, 10wt% phenolic epoxy resin, and 5wt% curing agent.

[0056] The method for preparing the wall insulation board comprises the following steps:

[0057] (1) placing phenolic epoxy resin, curing agent, and barium sulfate powder in a stirring tank in sequence and stirring to obtain a slurry;

[0058] (2) evenly applying the slurry prepared in step (1) on the glass fiber composite cloth, the thickness of the slurry being 1-5 mm, to obtain a prefabricated sheet;

[0059] (3) adding polystyrene particles into a stirring tank and stirring to obtain a mixture having polystyrene particles wrapped in slurry;

[0060] (4) placing the prefabricated sheet obtained in step (2) on the bottom plate of the frame mold, adding the mixed material obtained in step (3), and covering it with the prefabricated sheet obtained in step (2);

[0061] (5) The mold and the mixed material are placed in a hot press for hot pressing at a pressurizing speed of 10 N / s. The hot pressing is performed at 95° C. and 0.4 MPa for 10 min. After the hot pressing is completed, the pressure is released at a speed of 15 N / S, and the mold is removed for cooling to obtain a wall insulation board.

[0062] Embodiment 5:

[0063] A hot-pressed heat-insulating board comprises: 65wt% polystyrene particles, 20wt% glass fiber composite cloth, 5wt% barium sulfate particles, 10wt% phenolic epoxy resin, and 5wt% curing agent.

[0064] The method for preparing the wall insulation board comprises the following steps:

[0065] (1) placing phenolic epoxy resin, curing agent, and barium sulfate powder in a stirring tank in sequence and stirring to obtain a slurry;

[0066] (2) evenly applying the slurry prepared in step (1) on the glass fiber composite cloth, the thickness of the slurry being 1-5 mm, to obtain a prefabricated sheet;

[0067] (3) adding polystyrene particles into a stirring tank and stirring to obtain a mixture having polystyrene particles wrapped in slurry;

[0068] (4) placing the prefabricated sheet obtained in step (2) on the bottom plate of the frame mold, adding the mixed material obtained in step (3), and covering it with the prefabricated sheet obtained in step (2);

[0069] (5) The mold and the mixed material are placed in a hot press for hot pressing at a pressurizing speed of 10 N / s. The hot pressing is performed at 95° C. and 0.4 MPa for 10 min. After the hot pressing is completed, the pressure is released at a speed of 15 N / S, and the mold is removed for cooling to obtain a wall insulation board.

[0070] Embodiment 6:

[0071] A hot-pressed heat-insulating board comprises: 65wt% polystyrene particles, 20wt% glass fiber composite cloth, 5wt% barium sulfate particles, 10wt% phenolic epoxy resin, and 5wt% curing agent.

[0072] The method for preparing the wall insulation board comprises the following steps:

[0073] (1) placing phenolic epoxy resin, curing agent, and barium sulfate powder in a stirring tank in sequence and stirring to obtain a slurry;

[0074] (2) evenly applying the slurry prepared in step (1) on the glass fiber composite cloth, the thickness of the slurry being 1-5 mm, to obtain a prefabricated sheet;

[0075] (3) adding polystyrene particles into a stirring tank and stirring to obtain a mixture having polystyrene particles wrapped in slurry;

[0076] (4) placing the prefabricated sheet obtained in step (2) on the bottom plate of the frame mold, adding the mixed material obtained in step (3), and covering it with the prefabricated sheet obtained in step (2);

[0077] (5) The mold and the mixed material are placed in a hot press for hot pressing at a pressurizing speed of 10 N / s. The hot pressing is performed at 95° C. and 0.4 MPa for 10 min. After the hot pressing is completed, the pressure is released at a speed of 15 N / S, and the mold is removed for cooling to obtain a wall insulation board.

[0078] The obtained embodiments 1-6 were subjected to performance tests, and the test results are shown in Table 1.

[0079] Table 1

[0080] Performance name unit Standard requirements Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Dry density <![CDATA[Kg / m 3 ]]> ≤220 195 220 170 180 210 200 Thermal conductivity W / mk ≤0.04 0.036 0·038 0·037 0·036 0·038 0·037 Compressive strength MPa ≥0.8 0.65 0·77 0·61 0·7 0·78 0·75 tensile strength MPa ≥0.42 0.38 0·41 0·36 0·4 0·41 0·38 Water absorption rate (V / V) ％ <1 0.12 0.1 0.3 0.27 0.15 0.12 Ten drying shrinkage values mm / m ≤0.80 0.15 0.13 0·15 0·13 0·15 0·15 Barcol hardness Hb >40 42 43 40 41 42 42

[0081] In order to better understand the technical solution of the present invention, the content of the present invention includes but is not limited to the specific implementation methods described below, and similar technologies and methods should be considered to be within the scope of protection of the present invention.

Claims

1. A thermoformed insulation board comprising: 65-80wt% polystyrene particles, 10-20wt% glass fiber composite cloth, 5-30wt% barium sulfate particles, 10-20wt% phenolic epoxy resin, and 5-10wt% curing agent.

2. The insulation board according to claim 1, characterized in that The glass fiber content in the glass fiber composite cloth is 200-500g / m 2 , more preferably 300-400g / m 2 .

3. The insulation board according to claim 1, characterized in that The polystyrene particles have a particle size of 2-4 mm and a bulk density of 18-28 kg / m 3 .

4. The thermal insulation board according to claim 1, characterized in that The phenolic epoxy resin has a weight average molecular weight of 3000-10000.

5. The insulation board according to claim 1, characterized in that The curing agent is composed of the following components: 10-25% concentrated sulfuric acid, 30-50% p-toluenesulfonic acid, 30-40% phosphoric acid, and 10-20% water; preferably, the curing agent is composed of 15-17% concentrated sulfuric acid, 38-42% p-toluenesulfonic acid, 33-35% phosphoric acid, and 12-15% water.

6. The thermal insulation board according to claim 1, characterized in that The particle size of the barium sulfate particles is 0.1-50 μm, more preferably 1-10 μm; the barium sulfate particles are used to adjust the viscosity of the phenolic epoxy resin, and can also improve the fireproof and waterproof properties of the board, and increase the compressive strength of the board, so that it has a certain wrapping property, and forms a three-dimensional irregular honeycomb after curing.

7. A method for preparing the hot-pressed thermal insulation board according to any one of claims 1 to 6, comprising the following steps: (1) placing phenolic epoxy resin, curing agent, and barium sulfate powder in a stirring tank in sequence and stirring to obtain a slurry; (2) evenly applying the slurry prepared in step (1) on the glass fiber composite cloth, the thickness of the slurry being 1-5 mm, to obtain a prefabricated sheet; (3) adding polystyrene particles into a stirring tank and stirring, wherein the temperature of the stirring tank is set at 35° C., to obtain a mixture having polystyrene particles wrapped in slurry; (4) placing the prefabricated sheet obtained in step (2) on the bottom plate of the frame mold, adding the mixed material obtained in step (3), and covering it with the prefabricated sheet obtained in step (2); (5) placing the mold together with the placed mixed material into a hot press for hot pressing, releasing the pressure after the hot pressing is completed and removing the mold from the mold for cooling to obtain a wall insulation board.

8. The method according to claim 7, characterized in that The viscosity of the slurry in step (1) is 1500-2500 mPa.s; the viscosity of the mixture in step (3) is 2000-3000 mPa.s.

9. The method according to claim 7, characterized in that In step (5), a pressurizing speed of 4-10 N / s is used, the hot pressing temperature is set at 50-125° C., the pressure is 0.4-0.6 MPa, and the hot pressing time is 10-30 min; after the pressurization is completed, the pressure relief speed is 15-30 N / s.

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