Wall insulation layer production device and production method

Abstract

The invention discloses a wall thermal insulation layer production device and method and relates to the technical field of building energy conservation, and the wall thermal insulation layer production method comprises the steps that industrial waste residues are subjected to particle size grading; preparing a plurality of slurries from the fine-particle-size waste residue powder, the medium-particle-size waste residue powder and the coarse-particle-size waste residue powder; and the multiple pieces of slurry are poured into a wall mold in a layered mode, and a wall heat preservation layer is formed. According to the invention, industrial waste residue resources are reasonably utilized, and a material formula and a production process are optimized, so that the high-performance wall thermal insulation layer with a gradient structure is prepared. The method has the advantages that the potential value of the industrial waste residues is exerted, the resource utilization rate of the industrial waste residues is increased, the production cost is reduced, the gradient-structure wall heat insulation layer which is low in heat conductivity coefficient, high in compressive strength and good in durability can be prepared, and the production cost and the environmental load are greatly reduced while the building energy-saving level is increased.

Description

Technical Field

[0001] The invention relates to the technical field of building energy conservation, and in particular to a wall insulation layer production device and a production method. Background Art

[0002] With the rapid development of the construction industry, energy conservation and environmental protection have become important considerations in modern building design. In this context, the research and development and application of wall insulation materials have received widespread attention. The technology of using industrial waste to produce wall insulation layer has gradually become a research hotspot as an environmentally friendly and innovative method. This method not only helps to reduce the environmental impact of industrial waste, but also provides a new resource channel for building materials.

[0003] At present, traditional wall insulation layers mainly use organic or inorganic materials such as polystyrene boards and rock wool. In recent years, with the development of waste resource utilization technology, industrial waste residue has been introduced into wall insulation materials as a cheap raw material. By using industrial waste residue as one of the raw materials and combining it with other chemical and mineral components, insulation materials for construction are produced.

[0004] However, the thermal insulation performance and material strength of the wall insulation layer produced using industrial waste residues in the related art are not ideal, and the potential value of the industrial waste residues cannot be fully utilized. Summary of the invention

[0005] The main purpose of the present invention is to propose a wall insulation layer production device and production method, aiming to optimize the utilization of industrial waste slag and the production process of the wall insulation layer, and give full play to the potential value of industrial waste slag.

[0006] To achieve the above-mentioned purpose, the present invention provides a method for producing a wall insulation layer, which comprises:

[0007] The industrial waste slag is subjected to particle size classification to obtain fine particle size waste slag powder, medium particle size waste slag powder and coarse particle size waste slag powder;

[0008] The fine-particle waste slag powder, SiO2, an organic silicon modifier, water glass and water are used to prepare a fine powder layer slurry;

[0009] The transition layer slurry is prepared by using the medium-sized waste slag powder, expanded perlite, Al2O3, composite plasticizer, water glass and water;

[0010] The porous layer slurry is prepared by using the coarse-grained waste slag powder, hollow glass microspheres, SiC, a retarder, a foaming agent, water glass and water;

[0011] The fine powder layer slurry, the transition layer slurry and the porous layer slurry are poured into the wall mold in layers to form the wall insulation layer.

[0012] In one embodiment, the step of classifying the industrial waste slag into fine-grained waste slag powder, medium-grained waste slag powder and coarse-grained waste slag powder comprises:

[0013] Screening the industrial waste slag to obtain the fine-grained waste slag powder with a particle size of A, 0.1 mm ≤ A ≤ 0.3 mm;

[0014] Screening the industrial waste slag to obtain the medium-sized waste slag powder with a particle size of B, 0.3 mm ≤ B ≤ 0.6 mm;

[0015] The industrial waste slag is screened to obtain the coarse particle size waste slag powder with a particle size of C, 0.6 mm ≤ C ≤ 1.2 mm.

[0016] In one embodiment, the step of preparing a fine powder layer slurry using the fine particle size waste slag powder, SiO2, an organosilicon modifier, water glass and water comprises:

[0017] The fine powder layer slurry is prepared using 100 parts by mass of the fine-grained waste powder, 3 to 8 parts by mass of SiO2, 0.5 to 1.5 parts by mass of the organosilicon modifier, 15 to 25 parts by mass of the water glass and 6 to 10 parts by mass of the water.

[0018] In one embodiment, the step of preparing a transition layer slurry using the medium-sized waste slag powder, expanded perlite, Al2O3, a composite plasticizer, water glass and water comprises:

[0019] The transition layer slurry is prepared using 100 parts by mass of the medium-sized waste slag powder, 8 to 12 parts by mass of the expanded perlite, 2 to 5 parts by mass of the Al2O3, 0.3 to 0.8 parts by mass of the composite plasticizer, 20 to 30 parts by mass of the water glass and 10 to 15 parts by mass of the water.

[0020] In one embodiment, the step of preparing a porous layer slurry using the coarse-grained waste powder, hollow glass microspheres, SiC, a retarder, a foaming agent, water glass and water comprises:

[0021] The porous layer slurry is prepared using 100 parts by mass of the coarse-grained waste powder, 15-25 parts by mass of the hollow glass microspheres, 1-3 parts by mass of the SiC, 0.1-0.3 parts by mass of the retarder, 2-4 parts by mass of the foaming agent, 25-35 parts by mass of the water glass and 15-20 parts by mass of the water.

[0022] In one embodiment, the step of pouring the fine powder layer slurry, the transition layer slurry and the porous layer slurry into a wall mold in layers to form the wall insulation layer includes:

[0023] Apply a release agent to the bottom of the wall mold and vibrate it on a vibration table for 30 seconds to spread the release agent evenly;

[0024] The fine powder layer slurry is poured into a mold with a pouring thickness of one third of the thickness of the wall insulation layer, and vibrated on a vibration table for 60 seconds to make the fine powder layer slurry dense;

[0025] After the fine powder layer is initially solidified, the transition layer slurry is poured thereon, the pouring thickness is one third of the thickness of the wall insulation layer, and vibrated for 60 seconds to make the transition layer slurry dense;

[0026] After the transition layer is initially solidified, the porous layer slurry is poured, the pouring thickness is one third of the thickness of the wall insulation layer, and vibrated for 30 seconds to promote the foaming of the porous layer slurry;

[0027] After the porous layer slurry is initially solidified, the wall insulation layer is formed.

[0028] In one embodiment, the step of forming the wall insulation layer after the porous layer slurry is initially set comprises:

[0029] After the porous layer slurry is initially solidified, demoulding is performed to obtain a gradient thermal insulation layer;

[0030] Curing and drying the gradient thermal insulation layer;

[0031] The gradient insulation layer is polished to form the wall insulation layer.

[0032] In one embodiment, the step of curing and drying the gradient thermal insulation layer comprises:

[0033] The gradient insulation layer is transferred to a curing room, and the temperature of the curing room is controlled to be set to P, 18°C ​​≤ P ≤ 22°C;

[0034] After the curing is completed, the gradient insulation layer is transferred to a drying box, the temperature of the drying box is set to 60° C., and dried under this condition for 48 hours.

[0035] In one embodiment, the industrial waste slag is steel waste slag and ferroalloy waste slag.

[0036] The present invention also provides a wall insulation layer production device, which uses the wall insulation layer production method as described above.

[0037] The technical solution of the present invention prepares a high-performance wall insulation layer with a gradient structure by rationally utilizing industrial waste slag resources, optimizing material formulas and production processes. The potential value of industrial waste slag is brought into play, which not only improves the resource utilization rate of industrial waste slag and reduces production costs, but also improves the thermal insulation performance, mechanical strength and durability of the wall insulation layer. Specifically, the present invention can prepare a gradient structure wall insulation layer with low thermal conductivity, high compressive strength and good durability by grading industrial waste slag according to particle size, preparing various slurries and pouring them in layers. While improving the energy-saving level of buildings, it also greatly reduces production costs and environmental loads. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying creative work.

[0039] Figure 1 A schematic diagram of a process of an embodiment of a method for producing a wall thermal insulation layer provided by the present invention;

[0040] Figure 2 for Figure 1 A detailed flow chart of step S10 in an embodiment;

[0041] Figure 3 for Figure 1 A detailed flow chart of step S50 in an embodiment;

[0042] Figure 4 for Figure 3 A detailed flow chart of step S55 in an embodiment;

[0043] Figure 5 for Figure 4 FIG. 5 is a schematic diagram of a detailed flow chart of an embodiment of step S552 in FIG.

[0044] The realization of the purpose, functional features and advantages of the present invention will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0045] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments 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.

[0046] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back, etc.), the directional indications are only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture. If the specific posture changes, the directional indication will also change accordingly.

[0047] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present invention, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features limited to "first" and "second" may explicitly or implicitly include at least one of the features. In addition, if "and / or" or "and / or" appears in the full text, its meaning includes three parallel solutions. Taking "A and / or B" as an example, it includes solution A, solution B, or solutions that satisfy both A and B. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the ability of ordinary technicians in this field to implement. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0048] Currently, thermal insulation materials for construction are produced by using industrial waste as one of the raw materials, combined with other chemical and mineral components.

[0049] However, the thermal insulation performance and material strength of the wall insulation layer produced using industrial waste residues in the related art are not ideal, and the potential value of the industrial waste residues cannot be fully utilized.

[0050] In order to solve this technical problem, the present invention proposes a wall insulation layer production device and a production method.

[0051] See also Figure 1 In one embodiment of the present invention, the wall insulation layer production method comprises:

[0052] Step S10, classifying the industrial waste slag into fine-particle-size waste slag powder, medium-particle-size waste slag powder and coarse-particle-size waste slag powder;

[0053] Step S20, preparing a fine powder layer slurry using the fine particle size waste slag powder, SiO2, an organosilicon modifier, water glass and water;

[0054] Step S30, preparing a transition layer slurry using the medium-sized waste slag powder, expanded perlite, Al2O3, composite plasticizer, water glass and water;

[0055] Step S40, preparing a porous layer slurry using the coarse-grained waste slag powder, hollow glass microspheres, SiC, a retarder, a foaming agent, water glass and water;

[0056] Step S50: pouring the fine powder layer slurry, the transition layer slurry and the porous layer slurry into a wall mold in layers to form the wall insulation layer.

[0057] Specifically, the fine powder layer slurry in this embodiment is composed of fine-grained waste slag powder, SiO2, organosilicon modifier, water glass and water. Among them, fine-grained waste slag powder is used as the main raw material to utilize industrial waste slag resources and reduce environmental burden; SiO2 is used as an auxiliary filler to improve the strength and durability of the material; the organosilicon modifier is used to improve the fluidity and adhesion of the slurry to ensure the uniformity of the fine powder layer; water glass is used as an inorganic binder to enhance the compressive strength of the material; an appropriate amount of water is used to adjust the consistency of the slurry to facilitate subsequent casting and molding. With the above raw materials, a fine powder layer slurry with excellent performance can be prepared. The slurry has good fluidity and adhesion, and can fully fill the mold during the casting process to form a dense and uniform fine powder layer, providing a solid foundation for the subsequent transition layer and porous layer.

[0058] The composition of the transition layer slurry includes medium-sized waste slag powder, expanded perlite, Al2O3, composite plasticizer, water glass and water. Among them, the medium-sized waste slag powder is the main aggregate with moderate particle size, which helps to form the skeleton structure of the transition layer; the expanded perlite is a lightweight material with low thermal conductivity and high strength, which can enhance the thermal insulation performance and mechanical strength of the transition layer; Al2O3 is a high-strength filler to further improve the compressive resistance of the material; the composite plasticizer is used to improve the plasticity and adhesion of the slurry for easy molding; the role of water glass and water is similar to that in step S20, and they play the role of binder and consistency regulator respectively. Through the above raw materials, a transition layer slurry with both thermal insulation performance and mechanical strength can be prepared. After casting and molding, the slurry can form a transition area between the fine powder layer and the porous layer, which plays a role of buffering and connection, and improves the overall performance of the wall insulation layer.

[0059] In this embodiment, the porous layer slurry is composed of coarse-grained waste slag powder, hollow glass microspheres, SiC, retarder, foaming agent, water glass and water. Among them, coarse-grained waste slag powder is the main aggregate for forming a porous structure, and its particle size is large, which is conducive to forming an open pore structure; hollow glass microspheres are a new type of thermal insulation material, which has the characteristics of ultra-low thermal conductivity and high strength, and can significantly improve the thermal insulation performance of the porous layer; SiC, as a high-temperature resistant filler, gives the material good fire resistance; the retarder is used to control the setting time of the slurry to ensure the operability of casting; the foaming agent forms uniform bubbles in the slurry, increases the porosity of the porous layer, and further reduces the thermal conductivity; the role of water glass and water is similar to the above steps. Through the above raw materials, a high-performance porous layer slurry can be prepared. After casting, the slurry can form a dense porous structure, greatly improve the thermal insulation performance of the wall insulation layer, and at the same time has excellent fire resistance and mechanical strength, meeting the high standards of building applications.

[0060] By means of layered pouring, the three slurries prepared in steps S20, S30 and S40 are sequentially introduced into the wall mold to form a wall insulation layer with a gradient structure. Specifically, a fine powder layer slurry of a certain thickness is first poured at the bottom of the mold, and after vibration compaction, a transition layer slurry is poured thereon, and finally a porous layer slurry is poured. During the pouring process, the thickness ratio of each layer must be strictly controlled, and appropriate vibration or compaction processes must be adopted to ensure the close bonding between the layers. Through the above-mentioned layered pouring process, a wall insulation layer with a gradient structure having excellent performance can be obtained. The internal structure of the insulation layer presents a fine, transitional and porous gradient change from the inside to the outside, which can effectively block heat transfer and provide excellent thermal insulation performance. At the same time, due to the use of waste slag resources and lightweight insulation materials, the comprehensive performance of the wall insulation layer is significantly improved, achieving a perfect combination of energy saving, environmental protection and high performance.

[0061] More specifically, taking the construction of a wall insulation layer at a certain construction site as an example, according to the above steps, how to apply the method of this embodiment to produce the wall insulation layer is described in detail. First, the steel slag and ferroalloy slag collected at the construction site are used as industrial waste slag raw materials, and three types of waste slag powder with fine particle size, medium particle size and coarse particle size are obtained after crushing and screening. Then, the waste slag powder is mixed with other functional materials according to the optimized ratio to prepare a fine powder layer slurry, a transition layer slurry and a porous layer slurry. Then, the three slurries are poured from bottom to top in the wall mold in a thickness ratio of 3:3:4, and vibrated and compacted with an inserted vibrating rod. After the pouring is completed, it is left to stand for 24 hours, and the slurry is demoulded after initial setting. After 28 days of standard curing, a high-performance wall insulation layer product can be obtained. The thermal conductivity of this product is as low as 0.05W / (m·K) and the compressive strength reaches 15MPa, which reflects the excellent thermal insulation performance and high strength characteristics. It can be directly applied to building walls, providing reliable guarantee for building energy conservation and comfortable living environment.

[0062] In the technical solution provided by the present invention, a high-performance wall insulation layer with a gradient structure is prepared by rationally utilizing industrial waste slag resources, optimizing material formulas and production processes. The potential value of industrial waste slag is brought into play, which not only improves the resource utilization rate of industrial waste slag and reduces production costs, but also improves the thermal insulation performance, mechanical strength and durability of the wall insulation layer. Specifically, the present invention can prepare a gradient structure wall insulation layer with low thermal conductivity, high compressive strength and good durability by grading industrial waste slag according to particle size, preparing various slurries and pouring them in layers. While improving the energy-saving level of buildings, it also greatly reduces production costs and environmental loads.

[0063] See also Figure 1 , and refer to Figure 2 In an embodiment of the present invention, the step of classifying the industrial waste slag into fine-grained waste slag powder, medium-grained waste slag powder and coarse-grained waste slag powder comprises:

[0064] Step S11, sieving the industrial waste slag to obtain the fine-grained waste slag powder with a particle size of A, 0.1 mm≤A≤0.3 mm;

[0065] Step S12, screening the industrial waste slag to obtain the medium-sized waste slag powder with a particle size of B, 0.3 mm ≤ B ≤ 0.6 mm;

[0066] Step S13, sieving the industrial waste slag to obtain the coarse particle size waste slag powder with a particle size of C, 0.6 mm ≤ C ≤ 1.2 mm.

[0067] In one embodiment of the present invention, the step of classifying industrial waste slag into particle sizes includes: step S11, screening the industrial waste slag to obtain fine-particle waste slag powder with a particle size of A, wherein 0.1mm≤A≤0.3mm; step S12, screening the industrial waste slag to obtain medium-particle waste slag powder with a particle size of B, wherein 0.3mm≤B≤0.6mm; step S13, screening the industrial waste slag to obtain coarse-particle waste slag powder with a particle size of C, wherein 0.6mm≤C≤1.2mm.

[0068] Specifically, when the industrial waste slag is subjected to particle size classification in step S10, a multi-stage screening method is adopted, and the industrial waste slag is screened into three waste slag powder materials with different particle sizes, namely, fine particle size waste slag powder, medium particle size waste slag powder and coarse particle size waste slag powder, by setting screens with different apertures. Among them, the particle size range of the fine particle size waste slag powder is controlled between 0.1mm and 0.3mm, the particle size range of the medium particle size waste slag powder is controlled between 0.3mm and 0.6mm, and the particle size range of the coarse particle size waste slag powder is controlled between 0.6mm and 1.2mm. By performing fine particle size classification on the industrial waste slag, a waste slag powder material with uniform particle size distribution and moderate fineness can be obtained, providing high-quality raw materials for the subsequent preparation of slurries of different functional layers.

[0069] In actual operation, appropriate crushing and grinding equipment, such as jaw crusher, ball mill, etc., can be selected according to the nature and source of industrial waste slag to pre-treat the industrial waste slag to a suitable particle size range. Then, by using screening equipment such as vibrating screen or cyclone screen, by adjusting the aperture size and vibration frequency of the screen, fine particle size waste slag powder, medium particle size waste slag powder and coarse particle size waste slag powder of the required particle size can be obtained respectively. In the screening process, multi-stage series or parallel screening processes can be used to improve the screening efficiency and the uniformity of the powder.

[0070] Through the above-mentioned particle size classification steps, industrial waste slag resources can be fully utilized to obtain waste slag powder materials with reasonable particle size distribution and stable quality. These waste slag powders of different particle sizes can be reasonably proportioned and applied according to the performance requirements of each functional layer when preparing the wall insulation layer slurry in the subsequent process. Among them, fine-grained waste slag powder can be used to prepare dense and uniform fine powder layer slurry to improve the strength and toughness of the base layer; medium-grained waste slag powder can be used to prepare transition layer slurry to play a buffering and connecting role; coarse-grained waste slag powder can be used to prepare porous layer slurry to form a porous structure for thermal insulation. Through the scientific classification and directional application of waste slag powder, the potential value of industrial waste slag can be maximized, the performance of the wall insulation layer can be optimized, and the goals of energy conservation, environmental protection and efficient use of resources can be achieved.

[0071] In an embodiment of the present invention, the step of preparing a fine powder layer slurry using the fine-grained waste slag powder, SiO2, an organic silicon modifier, water glass and water comprises:

[0072] Step S21, preparing the fine powder layer slurry using 100 parts by mass of the fine-grained waste slag powder, 3 to 8 parts by mass of SiO2, 0.5 to 1.5 parts by mass of the organosilicon modifier, 15 to 25 parts by mass of the water glass and 6 to 10 parts by mass of the water.

[0073] Specifically, when preparing the fine powder layer slurry, fine-grained waste slag powder is used as the main raw material, and appropriate amounts of SiO2, silicone modifier, water glass and water are added, and mixed and stirred according to the optimized ratio. Among them, the amount of fine-grained waste slag powder is 100 parts, which plays a filling and reinforcing role; the amount of SiO2 is 3 to 8 parts, which is used as an auxiliary filler to improve the strength and durability of the slurry; the amount of silicone modifier is 0.5 to 1.5 parts, which is used to improve the fluidity and adhesion of the slurry; the amount of water glass is 15 to 25 parts, which is used as an inorganic binder to enhance the compressive strength of the slurry; the amount of water is 6 to 10 parts, which is used to adjust the consistency and fluidity of the slurry.

[0074] In actual operation, fine-grained waste slag powder, SiO2 and silicone modifier can be premixed, and then water glass and water are added, and mixed thoroughly with a high-speed mixer until a uniform, non-agglomerated fine powder layer slurry is obtained. During the mixing process, the amount of water can be appropriately adjusted according to the consistency and fluidity of the slurry to achieve the best construction performance. At the same time, a small amount of defoaming agent can be added to prevent the slurry from generating too many bubbles during the mixing and pouring process, which affects the density of the fine powder layer.

[0075] By adopting the above-mentioned ratio and process, a fine powder layer slurry with excellent performance can be prepared. The slurry has good fluidity and adhesion, and can fully fill the mold during the pouring process to form a dense and uniform fine powder layer. At the same time, due to the filling effect of fine-grained waste powder and the reinforcing effect of SiO2, the fine powder layer has high strength and toughness, which can provide a solid foundation for the subsequent transition layer and porous layer. In addition, the addition of organosilicon modifier not only improves the working performance of the slurry, but also improves the adhesion between the fine powder layer and the substrate, ensuring the integrity and durability of the entire wall insulation layer.

[0076] In an embodiment of the present invention, the step of preparing a transition layer slurry using the medium-sized waste slag powder, expanded perlite, Al2O3, composite plasticizer, water glass and water comprises:

[0077] Step S31, preparing the transition layer slurry using 100 parts by mass of the medium-sized waste slag powder, 8 to 12 parts by mass of the expanded perlite, 2 to 5 parts by mass of the Al2O3, 0.3 to 0.8 parts by mass of the composite plasticizer, 20 to 30 parts by mass of the water glass and 10 to 15 parts by mass of the water.

[0078] Specifically, when preparing the transition layer slurry, medium-sized waste slag powder is used as the main aggregate, and appropriate amounts of expanded perlite, Al2O3, composite plasticizer, water glass and water are added, and mixed and stirred according to the optimized ratio. Among them, the amount of medium-sized waste slag powder is 100 parts, which plays the role of forming the skeleton structure of the transition layer; the amount of expanded perlite is 8-12 parts, which is used as a lightweight thermal insulation material to reduce the thermal conductivity of the transition layer and improve the thermal insulation performance; the amount of Al2O3 is 2-5 parts, which is used as a high-strength filler to improve the compressive strength of the transition layer; the amount of composite plasticizer is 0.3-0.8 parts, which is used to improve the plasticity and adhesion of the slurry; the amount of water glass is 20-30 parts, which is used as an inorganic binder to enhance the cohesion and crack resistance of the transition layer; the amount of water is 10-15 parts, which is used to adjust the consistency and fluidity of the slurry.

[0079] In actual operation, medium-sized waste slag powder, expanded perlite and Al2O3 can be premixed, and then composite plasticizer, water glass and water can be added and fully mixed using a mixer until a uniform, non-agglomerated transition layer slurry is obtained. During the mixing process, the amount of water can be appropriately adjusted according to the consistency and fluidity of the slurry to achieve the best construction performance. At the same time, a small amount of air entraining agent can be added to form tiny bubbles in the slurry to further reduce the thermal conductivity of the transition layer and improve the thermal insulation effect.

[0080] By adopting the above-mentioned ratio and process, a transition layer slurry with excellent performance can be prepared. The slurry has good plasticity and adhesion, and can be closely combined with the fine powder layer during the pouring process to form a dense and uniform transition layer. At the same time, due to the skeleton effect of the medium-sized waste slag powder and the reinforcing effect of Al2O3, the transition layer has high compressive strength and crack resistance, and can effectively buffer and transfer the stress between the upper and lower layers. In addition, the addition of expanded perlite significantly reduces the thermal conductivity of the transition layer, improves the overall thermal insulation performance of the wall insulation layer, and helps to achieve the goal of building energy saving.

[0081] In an embodiment of the present invention, the step of preparing a porous layer slurry by using the coarse-grained waste slag powder, hollow glass microspheres, SiC, a retarder, a foaming agent, water glass and water comprises:

[0082] Step S41, preparing the porous layer slurry using 100 parts by mass of the coarse-grained waste powder, 15-25 parts by mass of the hollow glass microspheres, 1-3 parts by mass of the SiC, 0.1-0.3 parts by mass of the retarder, 2-4 parts by mass of the foaming agent, 25-35 parts by mass of the water glass and 15-20 parts by mass of the water.

[0083] Specifically, in the present embodiment, the porous layer slurry is prepared by mixing raw materials in reasonable proportions, which plays a key role in heat insulation and thermal insulation. Coarse-grained waste slag powder is used as the main raw material, and its coarse particle size helps to form a larger pore structure and improve the thermal insulation effect. The addition of hollow glass microspheres and SiC further reduces the thermal conductivity of the slurry and enhances the heat resistance and mechanical stability of the material. The retarder regulates the curing time of the slurry so that the foaming agent can fully play its role during the curing process to form a uniform pore distribution. The use of the foaming agent provides a large number of tiny closed bubbles for the porous layer, which can effectively block heat transfer and improve thermal insulation performance. Water glass, as a binder, not only improves the overall structural strength, but also increases the moisture resistance of the material.

[0084] During the preparation process, the coarse-grained waste slag powder is first mixed with hollow glass microspheres and SiC, and then the prepared mixed solution of water glass, foaming agent and retarder is added. After adding water to adjust to the appropriate consistency, it is fully mixed to ensure that each component is evenly distributed in the slurry. The mixture is then poured into a pre-prepared mold and allowed to solidify under controlled conditions to form a porous insulation layer with uniform structure and consistent pore distribution.

[0085] The porous layer slurry prepared by the above steps has excellent thermal insulation performance, and the overall strength and durability of the material are guaranteed. The porous layer effectively solves the problems of thermal bridge effect and insufficient structural strength in traditional thermal insulation materials, providing an economical and efficient solution.

[0086] See also Figure 1 , and refer to Figure 3 In an embodiment of the present invention, the step of pouring the fine powder layer slurry, the transition layer slurry and the porous layer slurry into a wall mold in layers to form the wall insulation layer comprises:

[0087] Step S51, applying a release agent to the bottom of the wall mold, and vibrating it on a vibration table for 30 seconds to spread the release agent evenly;

[0088] Step S52, pouring the fine powder layer slurry into a mold with a pouring thickness of one third of the thickness of the wall insulation layer, and vibrating the mold with a vibration table for 60 seconds to make the fine powder layer slurry dense;

[0089] Step S53, after the fine powder layer is initially solidified, pouring the transition layer slurry thereon, with a pouring thickness of one third of the thickness of the wall insulation layer, and vibrating for 60 seconds to make the transition layer slurry dense;

[0090] Step S54, after the transition layer is initially solidified, pour the porous layer slurry, the pouring thickness is one third of the thickness of the wall insulation layer, and vibrate for 30 seconds to promote the foaming of the porous layer slurry;

[0091] Step S55: After the porous layer slurry is initially solidified, the wall insulation layer is formed.

[0092] Specifically, step S51 involves applying a release agent to the bottom of the wall mold and vibrating it on a vibration table for 30 seconds to ensure that the release agent is evenly spread. This step is to ensure that after the final pouring is completed, the insulation layer can be easily and completely separated from the mold to avoid product damage due to excessive adhesion.

[0093] In step S52, the fine powder layer slurry is poured into the mold, and the pouring thickness is set to one-third of the thickness of the wall insulation layer, and then a vibration table is used to vibrate for 60 seconds to ensure that the fine powder layer slurry is dense. A dense fine powder layer helps to improve the structural stability and bearing capacity of the insulation layer, and is the foundation of the entire insulation layer.

[0094] In step S53, after the fine powder layer is initially solidified, a transition layer slurry is poured on top, and the pouring thickness is also one-third of the thickness of the wall insulation layer, and vibrated for 60 seconds to ensure compactness. The transition layer slurry, as an intermediate layer connecting the fine powder layer and the porous layer, is crucial for distributing the stress between the upper and lower layers and enhancing the overall insulation performance.

[0095] In step S54, after the transition layer is initially set, a porous layer slurry is poured, the thickness of which is also one-third of the thickness of the wall insulation layer, and vibrated for 30 seconds to promote foaming. The porous layer provides excellent thermal insulation by forming pores in the material and is a key layer for achieving efficient thermal insulation.

[0096] In step S55, after the porous layer slurry is initially set, the entire wall insulation layer is formed. After the material is completely solidified, subsequent processing or direct application can be performed.

[0097] See also Figure 3 , and refer to Figure 4 In an embodiment of the present invention, the step of forming the wall insulation layer after the porous layer slurry is initially set comprises:

[0098] Step S551, after the porous layer slurry is initially solidified, demoulding is performed to obtain a gradient insulation layer;

[0099] Step S552, curing and drying the gradient thermal insulation layer;

[0100] Step S553: ​​polishing the gradient insulation layer to form the wall insulation layer.

[0101] Specifically, in step S551, after the porous layer slurry is initially solidified, demolding is performed to obtain a gradient insulation layer. This step ensures that the material is removed from the mold in a timely manner after reaching a certain strength, avoiding demolding difficulties or product damage caused by excessive adhesion. At the same time, this also indicates that the molding process of the entire gradient insulation layer has been completed.

[0102] In step S552, the obtained gradient insulation layer is cured and dried. The curing process helps to further solidify the material and improve its strength, ensuring the long-term stability and durability of the insulation layer. The drying step can remove excess moisture from the material to prevent performance degradation in a humid environment, and also create conditions for subsequent polishing.

[0103] In step S553, the gradient insulation layer is polished to finally form the required wall insulation layer. The polishing process can remove burrs and unevenness on the surface of the insulation layer, improve its aesthetics and construction convenience. At the same time, precise control of the polishing depth can also ensure that the thickness of the insulation layer meets the design requirements and ensure its thermal insulation performance.

[0104] See also Figure 4 , and refer to Figure 5 In an embodiment of the present invention, the step of curing and drying the gradient thermal insulation layer comprises:

[0105] Step S5521, transferring the gradient insulation layer to a curing room, and setting the temperature of the curing room to P, 18°C≤P≤22°C;

[0106] Step S5522: After the curing is completed, the gradient insulation layer is transferred to a drying box, the temperature of the drying box is set to 60° C., and dried under this condition for 48 hours.

[0107] Specifically, in step S5521, the gradient insulation layer is transferred to the curing room, and the temperature of the curing room is controlled to be set between 18°C ​​and 22°C. The selection of this temperature range is crucial, because too low a temperature will slow down the curing process of the material, while too high a temperature may lead to the accumulation of internal stress in the material, causing cracking and other problems. By precisely controlling the temperature of the curing room, an optimal environment can be created for the strength development of the gradient insulation layer, ensuring its long-term stability and durability.

[0108] Step S5522 is the drying process after the curing is completed. The gradient insulation layer is transferred to the drying box, and the temperature of the drying box is set to 60°C, and the drying is continued for 48 hours under this condition. The purpose of this step is to remove excess moisture inside the material to prevent performance degradation in a humid environment. The drying temperature of 60°C is sufficient to accelerate the evaporation of moisture without damaging the material structure. The 48-hour drying time ensures the full removal of moisture, providing a good foundation for subsequent polishing.

[0109] In an embodiment of the present invention, the industrial waste slag is steel waste slag and ferroalloy waste slag.

[0110] Specifically, steel waste slag mainly comes from the tailings in the steel smelting process, and its chemical composition mainly includes CaO, SiO2, Al2O3 and Fe2O3. These components give steel waste slag higher strength and fire resistance, making it an ideal aggregate for thermal insulation materials. Ferroalloy waste slag mainly comes from the ferroalloy smelting process, and its chemical composition varies depending on the type of alloy, but is usually rich in MgO, Al2O3 and SiO2. These components can further optimize the performance of thermal insulation materials and improve their corrosion resistance and durability.

[0111] In practical applications, steel waste slag and ferroalloy waste slag can be appropriately pre-treated according to their properties and sources, such as crushing, screening and drying, to ensure that their particle size and moisture content meet the requirements. After that, the two waste slags are mixed with other functional materials in a certain ratio to prepare a wall insulation slurry with excellent performance. By rationally utilizing steel waste slag and ferroalloy waste slag, not only can the production cost of insulation materials be significantly reduced, but also their thermal insulation performance and physical stability can be improved, making a positive contribution to building energy conservation and environmental protection.

[0112] For ease of understanding, a specific implementation is shown here:

[0113] Step S10, raw material preparation: according to the designed formula, prepare the industrial waste slag powder (0.1-0.3mm, 0.3-0.6mm, 0.6-1.2mm) after particle size classification, nano-SiO2, nano-Al2O3, SiC nanofiber, expanded perlite, and hollow glass microspheres.

[0114] Prepare admixtures: silicone modifier, composite plasticizer, retarder, hydrogen peroxide foaming agent.

[0115] Calculate the amount of water glass and water according to the recipe and keep them ready for use.

[0116] Step S20 to step S40, batching and mixing: using an electronic scale, weigh the waste slag powder required for the fine powder layer, the transition layer, and the porous layer respectively according to the respective mass fractions.

[0117] Functional fillers (nano SiO2, nano Al2O3, SiC nanofiber) are weighed according to the formula requirements, added into the waste slag powder with corresponding particle sizes, and mixed evenly.

[0118] Lightweight aggregates (expanded perlite and hollow glass microspheres) are weighed according to the formula requirements, added into the industrial waste residue powder of the transition layer and the porous layer respectively, and mixed evenly.

[0119] Weigh the admixtures according to the formula, add them into the mixtures of the fine powder layer, transition layer and porous layer respectively, and mix them evenly.

[0120] The mixed materials of each sub-layer were transferred to a blender and stirred at 60 rpm for 10 min to ensure that the components were fully dispersed.

[0121] Preparation of slurry: According to the formula, calculate the amount of water glass and water required for each sublayer.

[0122] Add the measured water glass and water into the mixture of the fine powder layer, transition layer and porous layer three times respectively, adding one third each time.

[0123] Stir evenly in a mixer at a speed of 120 rpm and adjust the water-binder ratio of each sub-layer slurry to meet the design requirements.

[0124] The hydrogen peroxide foaming agent was slowly added to the porous layer slurry and gently stirred for 30 seconds to make it evenly dispersed.

[0125] Step S50, layered pouring: apply a release agent on the bottom of the steel mold and vibrate it on a vibration table for 30 seconds to spread the release agent evenly.

[0126] Pour the fine powder layer slurry into the mold with a pouring thickness of one third of the designed thickness and vibrate it on a vibration table for 60 seconds to make the slurry dense.

[0127] After the fine powder layer initially solidifies (about 2 hours), pour the transition layer slurry on it with a pouring thickness of one-third of the designed thickness and vibrate for 60 seconds to compact it.

[0128] After the transition layer has initially solidified (about 2 hours), the porous layer slurry is poured with a pouring thickness of one-third of the designed thickness. It is gently vibrated for 30 seconds to promote foaming and obtain a gradient insulation layer.

[0129] Allow to stand and cure at room temperature for 24 hours to allow the gradient insulation layer to fully set.

[0130] Demoulding and curing: After the gradient insulation layer has initially solidified for 24 hours, use a pneumatic tool to demould it from the steel mould.

[0131] Carefully transfer the demoulded gradient insulation layer to a standard curing room.

[0132] Control the temperature in the curing room at 20±2℃, keep the relative humidity above 95%, and cure for 7 days.

[0133] Drying and post-treatment: After curing, transfer the gradient insulation layer to the drying oven.

[0134] Set the temperature of the drying box to 60°C and dry under this condition for 48 hours to ensure that the moisture inside the gradient insulation layer is fully evaporated.

[0135] After drying, use sandpaper to polish the six surfaces of the gradient insulation layer until the surface is smooth and without obvious bumps.

[0136] Wall connection method: Clean the surface of the building structure wall to ensure that there is no floating dust, oil stains and other impurities.

[0137] Apply interface agent on the wall surface to promote the adhesion between the insulation layer and the wall.

[0138] Apply special bonding mortar on the bottom surface of the gradient insulation layer, and control the thickness to 3-5mm.

[0139] Aluminum alloy connectors are used to mechanically fix the gradient insulation layer to the wall.

[0140] The connecting parts are arranged in a plum blossom pattern with a spacing of 300mm and are reliably connected to the embedded parts of the wall.

[0141] Inject foamed polyurethane into the gap between the gradient insulation layer and the wall for sealing.

[0142] Apply elastic weather-resistant finishing paint on the outer surface of the gradient insulation layer, with a coating thickness of not less than 2mm.

[0143] After the finishing paint solidifies, an external wall insulation system is formed that integrates insulation, decoration and protection.

[0144] The present invention also provides a wall insulation layer production device, which uses the wall insulation layer production method as described above.

[0145] It should be understood that the specific implementation steps of the wall insulation layer production method refer to the above-mentioned embodiments. Since the wall insulation layer production device adopts all the technical solutions of all the above-mentioned embodiments, it at least has all the beneficial effects brought by the technical solutions of the above-mentioned embodiments, which will not be repeated here one by one.

[0146] The above description is only an exemplary embodiment of the present invention, and does not limit the patent scope of the present invention. All equivalent structural changes made by using the contents of the present invention specification and drawings under the technical concept of the present invention, or directly / indirectly applied in other related technical fields are included in the patent protection scope of the present invention.

Claims

1. A method for producing a wall insulation layer, characterized in that: The wall insulation layer production method comprises: The industrial waste slag is subjected to particle size classification to obtain fine particle size waste slag powder, medium particle size waste slag powder and coarse particle size waste slag powder; The fine-particle waste slag powder, SiO2, an organic silicon modifier, water glass and water are used to prepare a fine powder layer slurry; The transition layer slurry is prepared by using the medium-sized waste slag powder, expanded perlite, Al2O3, composite plasticizer, water glass and water; The porous layer slurry is prepared by using the coarse-grained waste slag powder, hollow glass microspheres, SiC, a retarder, a foaming agent, water glass and water; The fine powder layer slurry, the transition layer slurry and the porous layer slurry are poured into the wall mold in layers to form the wall insulation layer.

2. The method for producing a wall insulation layer according to claim 1, characterized in that: The step of classifying the particle size of the industrial waste slag to obtain fine particle size waste slag powder, medium particle size waste slag powder and coarse particle size waste slag powder comprises: Screening the industrial waste slag to obtain the fine-grained waste slag powder with a particle size of A, 0.1 mm ≤ A ≤ 0.3 mm; Screening the industrial waste slag to obtain the medium-sized waste slag powder with a particle size of B, 0.3 mm ≤ B ≤ 0.6 mm; The industrial waste slag is screened to obtain the coarse particle size waste slag powder with a particle size of C, 0.6 mm ≤ C ≤ 1.2 mm.

3. The method for producing a wall insulation layer according to claim 2, characterized in that: The step of preparing fine powder layer slurry by using the fine particle size waste slag powder, SiO2, organic silicon modifier, water glass and water comprises: The fine powder layer slurry is prepared using 100 parts by mass of the fine-grained waste powder, 3 to 8 parts by mass of SiO2, 0.5 to 1.5 parts by mass of the organosilicon modifier, 15 to 25 parts by mass of the water glass and 6 to 10 parts by mass of the water.

4. The method for producing a wall insulation layer according to claim 2, characterized in that: The step of preparing the transition layer slurry by using the medium-sized waste slag powder, expanded perlite, Al2O3, composite plasticizer, water glass and water comprises: The transition layer slurry is prepared using 100 parts by mass of the medium-sized waste slag powder, 8 to 12 parts by mass of the expanded perlite, 2 to 5 parts by mass of the Al2O3, 0.3 to 0.8 parts by mass of the composite plasticizer, 20 to 30 parts by mass of the water glass and 10 to 15 parts by mass of the water.

5. The method for producing a wall insulation layer according to claim 2, characterized in that: The step of preparing the porous layer slurry by using the coarse-grained waste slag powder, hollow glass microspheres, SiC, a retarder, a foaming agent, water glass and water comprises: The porous layer slurry is prepared using 100 parts by mass of the coarse-grained waste powder, 15-25 parts by mass of the hollow glass microspheres, 1-3 parts by mass of the SiC, 0.1-0.3 parts by mass of the retarder, 2-4 parts by mass of the foaming agent, 25-35 parts by mass of the water glass and 15-20 parts by mass of the water.

6. The method for producing a wall insulation layer according to any one of claims 1 to 5, characterized in that: The step of pouring the fine powder layer slurry, the transition layer slurry and the porous layer slurry into the wall mold in layers to form the wall insulation layer comprises: Apply a release agent to the bottom of the wall mold and vibrate it on a vibration table for 30 seconds to spread the release agent evenly; The fine powder layer slurry is poured into a mold with a pouring thickness of one third of the thickness of the wall insulation layer, and vibrated on a vibration table for 60 seconds to make the fine powder layer slurry dense; After the fine powder layer is initially solidified, the transition layer slurry is poured thereon, the pouring thickness is one third of the thickness of the wall insulation layer, and vibrated for 60 seconds to make the transition layer slurry dense; After the transition layer is initially solidified, the porous layer slurry is poured, the pouring thickness is one third of the thickness of the wall insulation layer, and vibrated for 30 seconds to promote the foaming of the porous layer slurry; After the porous layer slurry is initially solidified, the wall insulation layer is formed.

7. The method for producing a wall insulation layer according to claim 6, characterized in that: After the porous layer slurry is initially solidified, the step of forming the wall insulation layer comprises: After the porous layer slurry is initially solidified, demoulding is performed to obtain a gradient thermal insulation layer; Curing and drying the gradient thermal insulation layer; The gradient insulation layer is polished to form the wall insulation layer.

8. The method for producing a wall insulation layer according to claim 7, characterized in that: The step of curing and drying the gradient thermal insulation layer comprises: The gradient insulation layer is transferred to a curing room, and the temperature of the curing room is controlled to be set to P, 18°C ​​≤ P ≤ 22°C; After the curing is completed, the gradient insulation layer is transferred to a drying box, the temperature of the drying box is set to 60° C., and dried under this condition for 48 hours.

9. The method for producing a wall insulation layer according to any one of claims 1 to 5, characterized in that: The industrial waste slag is steel waste slag and ferroalloy waste slag.

10. A wall insulation layer production device, characterized in that: The method for producing a wall insulation layer as claimed in any one of claims 1 to 9 is used.

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