Wall thermal insulation layer structure and preparation method thereof

Abstract

The invention discloses a wall thermal insulation layer structure and a preparation method thereof, and relates to the technical field of building energy conservation, the wall thermal insulation layer structure comprises a fine powder layer, a transition layer, a porous layer and a composite bonding layer, the fine powder layer, the transition layer and the porous layer are stacked, and the composite bonding layer is arranged between the fine powder layer and the transition layer. And a composite bonding layer is arranged between the transition layer and the porous layer. By stacking the fine powder layer, the transition layer and the porous layer and adding the composite bonding layer, the reliability and functionality of the wall thermal insulation layer structure are improved. Moreover, according to the wall thermal insulation layer structure, the overall performance of the building thermal insulation layer is improved, the utilization mode of the industrial waste residues and the structure of the wall thermal insulation layer are optimized by utilizing the industrial waste residues, and the potential value of the industrial waste residues is fully exerted.

Description

Technical Field

[0001] The invention relates to the technical field of building energy conservation, and in particular to a wall insulation layer structure and a preparation method thereof. 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] 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 residues have been introduced into wall insulation materials as a cheap raw material. These waste residues are usually made into a part of the insulation layer through specific treatment and modification to improve the environmental performance and economic benefits of the insulation layer.

[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 structure and a preparation method thereof, 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 wall insulation layer structure proposed in the present invention includes a fine powder layer, a transition layer, a porous layer and a composite bonding layer. The fine powder layer, the transition layer and the porous layer are stacked, and the composite bonding layer is arranged between the fine powder layer and the transition layer, and between the transition layer and the porous layer.

[0007] In one embodiment, the composite bonding layer includes 100 parts by mass of polymer modified cement, 10 to 15 parts by mass of acrylic emulsion, 2 to 5 parts by mass of silicone adhesive, 30 to 40 parts by mass of fine-grained waste slag powder, 5 to 10 parts by mass of SiO2, 3 to 7 parts by mass of Al2O3, 5 to 10 parts by mass of expanded vermiculite, 1 to 3 parts by mass of polypropylene fiber, 1 to 3 parts by mass of basalt fiber, 1 to 3 parts by mass of silicate waterproofing agent and 20 to 30 parts by mass of water.

[0008] In one embodiment, the fine powder layer includes 100 parts by mass of fine-grained waste slag powder, 3 to 8 parts by mass of SiO2, 0.5 to 1.5 parts by mass of an organosilicon modifier, 15 to 25 parts by mass of water glass, and 6 to 10 parts by mass of water.

[0009] In one embodiment, the particle size of the fine-grained waste slag powder is A, 0.1 mm≤A≤0.3 mm.

[0010] In one embodiment, the transition layer includes 100 parts by mass of medium-sized waste slag powder, 8 to 12 parts by mass of expanded perlite, 2 to 5 parts by mass of Al2O3, 0.3 to 0.8 parts by mass of a composite plasticizer, 20 to 30 parts by mass of water glass, and 10 to 15 parts by mass of water.

[0011] In one embodiment, the particle size of the medium-sized waste slag powder is B, 0.3mm≤B≤0.6mm.

[0012] In one embodiment, the porous layer includes 100 parts by mass of coarse-grained waste slag powder, 15-25 parts by mass of hollow glass microspheres, 1-3 parts by mass of SiC, 0.1-0.3 parts by mass of a retarder, 2-4 parts by mass of a foaming agent, 25-35 parts by mass of water glass, and 15-20 parts by mass of water.

[0013] In one embodiment, the particle size of the coarse-grained waste slag powder is C, 0.6 mm ≤ C ≤ 1.2 mm.

[0014] In one embodiment, the thickness of the composite adhesive layer is H, 2mm≤H≤5mm.

[0015] The present invention also provides a method for preparing a wall insulation layer structure, which is used to prepare the wall insulation layer structure as described above. The method for preparing the wall insulation layer structure comprises:

[0016] 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;

[0017] The fine-particle waste slag powder, SiO2, an organic silicon modifier, water glass and water are used to prepare a fine powder layer slurry;

[0018] The transition layer slurry is prepared by using the medium-sized waste slag powder, expanded perlite, Al2O3, composite plasticizer, water glass and water;

[0019] 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;

[0020] The fine powder layer slurry, the transition layer slurry and the porous layer slurry are poured into a wall mold in layers to obtain the fine powder layer, the transition layer and the porous layer. During the layered pouring process, the composite bonding layer is applied between the fine powder layer and the transition layer, and between the transition layer and the porous layer to form the wall insulation layer structure.

[0021] The technical solution of the present invention improves the reliability and functionality of the wall insulation layer structure by stacking the fine powder layer, the transition layer and the porous layer and adding the composite bonding layer. The dense structure of the fine powder layer effectively blocks the infiltration of external moisture and water, and maintains the stable performance of the insulation material; the transition layer, as an intermediary connecting the fine powder layer and the porous layer, provides a smooth transition of physical properties, reduces stress concentration between materials, and avoids interlayer separation; the microscopic pore structure of the porous layer optimizes the insulation performance, while the lightweight design reduces the weight of the structure and increases the adsorption and sound absorption effects. The introduction of the composite bonding layer not only enhances the bonding strength between the layers, but also improves the stability and durability of the overall structure through its excellent environmental compatibility and mechanical anchoring effect. Therefore, the wall insulation layer structure not only improves the overall performance of the building insulation layer, but also optimizes the utilization method of industrial waste slag and the structure of the wall insulation layer by utilizing industrial waste slag, giving full play to the potential value of industrial waste slag. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] 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.

[0023] Figure 1 A schematic structural diagram of an embodiment of a wall insulation layer structure provided by the present invention;

[0024] Figure 2 A schematic diagram of a process of an embodiment of a method for preparing a wall insulation layer structure provided by the present invention;

[0025] Figure 3 for Figure 2 A detailed flow chart of step S50 in an embodiment;

[0026] Figure 4 for Figure 3 A detailed flow chart of step S55 in an embodiment;

[0027] Figure 5 for Figure 4 FIG. 5 is a schematic diagram of a detailed flow chart of an embodiment of step S552 in FIG.

[0028] Description of Figure Numbers:

[0029] 100, fine powder layer; 200, transition layer; 300, porous layer; 400, composite bonding layer.

[0030] 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

[0031] 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.

[0032] 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.

[0033] 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.

[0034] 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 residues have been introduced into wall insulation materials as a cheap raw material. These waste residues are usually made into a part of the insulation layer through specific treatment and modification to improve the environmental performance and economic benefits of the insulation layer.

[0035] 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.

[0036] In order to solve this technical problem, the present invention proposes a wall insulation layer structure and a preparation method thereof.

[0037] See also Figure 1 In one embodiment of the present invention, the wall insulation layer structure includes a fine powder layer 100, a transition layer 200, a porous layer 300 and a composite bonding layer 400. The fine powder layer 100, the transition layer 200 and the porous layer 300 are stacked, and a composite bonding layer 400 is provided between the fine powder layer 100 and the transition layer 200, and between the transition layer 200 and the porous layer 300.

[0038] Specifically, the structure includes a fine powder layer 100, a transition layer 200, a porous layer 300 and a composite bonding layer 400. The fine powder layer 100, the transition layer 200 and the porous layer 300 are stacked in sequence to form a multi-layer composite structure with a gradient porosity. At the same time, a composite bonding layer 400 is provided between the fine powder layer 100 and the transition layer 200, and between the transition layer 200 and the porous layer 300 to enhance the bonding strength and overall stability between the layers.

[0039] More specifically, the fine powder layer 100 is composed of waste slag powder material with a smaller particle size, and the powder particles are closely packed together to form a relatively dense structure. This dense structure is conducive to improving the strength and durability of the insulation layer, and can also effectively block the infiltration of external moisture and water, preventing the insulation material from being damp and causing performance degradation.

[0040] The transition layer 200 is located between the fine powder layer 100 and the porous layer 300. Its material composition and porosity are between the two, playing a role of buffering and transition. The transition layer 200 can effectively connect the fine powder layer 100 and the porous layer 300, making the entire insulation layer structure more uniform and stable, avoiding stress concentration and delamination caused by differences in material properties.

[0041] The porous layer 300 is composed of porous waste slag materials with large particle sizes. There are a large number of microscopic pores inside these porous materials, which can effectively block heat transfer, thereby achieving a good thermal insulation effect. At the same time, the porous structure also has a low density and a high specific surface area, which is conducive to reducing the overall weight of the thermal insulation layer and improving its adsorption and sound absorption performance.

[0042] In addition, in order to further enhance the bonding strength and synergy between the layers, a composite bonding layer 400 is provided between the fine powder layer 100 and the transition layer 200, and between the transition layer 200 and the porous layer 300. The composite bonding layer 400 is prepared by mixing high-performance bonding materials with waste slag powder, and has excellent bonding performance and environmental compatibility. During the construction process, the composite bonding layer 400 can penetrate into the pore structure of the two adjacent layers to form a firm anchoring and connection, effectively improving the overall strength and shear resistance of the thermal insulation layer, and preventing interlayer shedding or damage under the action of external forces.

[0043] In the technical solution provided by the present invention, the reliability and functionality of the wall insulation layer structure are improved by stacking the fine powder layer 100, the transition layer 200 and the porous layer 300 and adding the composite bonding layer 400. The dense structure of the fine powder layer 100 effectively blocks the infiltration of external moisture and water, and maintains the stable performance of the thermal insulation material; the transition layer 200, as an intermediary connecting the fine powder layer 100 and the porous layer 300, provides a smooth transition of physical properties, reduces stress concentration between materials, and avoids interlayer separation; the microscopic pore structure of the porous layer 300 optimizes the thermal insulation performance, and the lightweight design reduces the weight of the structure and increases the adsorption and sound absorption effects. The introduction of the composite bonding layer 400 not only enhances the bonding strength between the layers, but also improves the stability and durability of the overall structure through its excellent environmental compatibility and mechanical anchoring effect. Therefore, the wall insulation layer structure not only improves the overall performance of the building insulation layer, but also optimizes the utilization mode of industrial waste slag and the structure of the wall insulation layer by utilizing industrial waste slag, thereby giving full play to the potential value of industrial waste slag.

[0044] In an embodiment of the present invention, the composite bonding layer 400 includes 100 parts by mass of polymer modified cement, 10 to 15 parts by mass of acrylic emulsion, 2 to 5 parts by mass of silicone adhesive, 30 to 40 parts by mass of fine-grained waste slag powder, 5 to 10 parts by mass of SiO2, 3 to 7 parts by mass of Al2O3, 5 to 10 parts by mass of expanded vermiculite, 1 to 3 parts by mass of polypropylene fiber, 1 to 3 parts by mass of basalt fiber, 1 to 3 parts by mass of silicate waterproofing agent and 20 to 30 parts by mass of water.

[0045] Specifically, polymer-modified cement provides the necessary basic bonding properties for the composite bonding layer 400, while acrylic emulsion increases the elasticity and bonding strength of the bonding layer. The addition of silicone binder improves the water resistance and weather resistance of the bonding layer, making the insulation layer more suitable for different environmental conditions. The use of fine-grained waste slag powder not only utilizes industrial waste, but also improves the density and thermal insulation performance of the bonding layer. The addition of SiO2 and Al2O3 optimizes the mechanical properties and wear resistance of the bonding layer, while expanded vermiculite brings better thermal insulation and lightweight properties to the bonding layer. Polypropylene fiber and basalt fiber enhance the crack resistance and tensile strength of the bonding layer.

[0046] In addition, the use of silicate waterproofing agent further enhances the waterproof performance of the bonding layer, thereby ensuring the stability and durability of the wall insulation layer in a humid environment. The addition of water is to adjust the workability and fluidity of the bonding layer for easy application during construction.

[0047] In an embodiment of the present invention, the fine powder layer 100 includes 100 parts by mass of fine-grained waste slag powder, 3 to 8 parts by mass of SiO2, 0.5 to 1.5 parts by mass of an organic silicon modifier, 15 to 25 parts by mass of water glass and 6 to 10 parts by mass of water.

[0048] Specifically, the fine-grained waste powder is the main component of the fine powder layer 100. It is made from industrial waste and is not only environmentally friendly and economical, but also can form a tightly packed structure through its fine particle size, thereby improving the density and strength of the thermal insulation layer. The addition of SiO2 further enhances the hardness and wear resistance of the fine powder layer 100, enabling it to better resist the erosion of the external environment.

[0049] The organosilicon modifier plays a role in enhancing the hydrophobicity in the fine powder layer 100, which can significantly improve the waterproof performance of the thermal insulation layer and reduce the penetration of external moisture and water, thereby maintaining the stable performance of the thermal insulation material. As an inorganic binder, water glass can not only enhance the internal bonding strength of the fine powder layer 100, but also has good fire resistance and acid and alkali resistance, further improving the durability of the thermal insulation layer.

[0050] The purpose of adding water is to adjust the workability and formability of the fine powder layer 100 so as to facilitate its application during construction. By properly controlling the amount of water, the fine powder layer 100 can have appropriate fluidity and plasticity while ensuring its performance, so as to facilitate its application and shaping during construction.

[0051] In the embodiment of the present invention, the particle size of the fine-grained waste slag powder is A, 0.1mm≤A≤0.3mm.

[0052] Specifically, when the particle size of the waste slag powder is controlled within the range of 0.1 mm to 0.3 mm, the waste slag powder with a smaller particle size can be more evenly distributed in the wall insulation layer, forming a more compact structure. This compact structure is conducive to improving the mechanical strength of the entire insulation layer, making it more durable and stable.

[0053] Fine-grained materials have a larger specific surface area, which can increase the total thermal resistance of the insulation layer, thereby improving its thermal insulation performance. This means that the interior of the building can more effectively block external temperature changes and maintain the comfort of the indoor environment.

[0054] In addition, waste slag powder with finer particle size is easier to mix with other ingredients (such as binders, etc.), ensuring the uniformity of the mixture and fluidity during construction. This makes the application or spraying during construction smoother and improves construction efficiency.

[0055] In an embodiment of the present invention, the transition layer 200 includes 100 parts by mass of medium-sized waste slag powder, 8 to 12 parts by mass of expanded perlite, 2 to 5 parts by mass of Al2O3, 0.3 to 0.8 parts by mass of a composite plasticizer, 20 to 30 parts by mass of water glass and 10 to 15 parts by mass of water.

[0056] Specifically, the medium-sized waste slag powder is the main component of the transition layer 200, and its particle size is larger than the fine-sized waste slag powder in the fine powder layer 100, but smaller than the large-sized material in the porous layer 300. This particle size gradient design is conducive to forming a smooth transition inside the insulation layer, reducing stress concentration caused by differences in material properties, and improving the stability of the entire structure.

[0057] Expanded perlite is a lightweight, porous inorganic material with excellent thermal insulation performance. Introducing it into the transition layer 200 can further improve the thermal insulation effect of the thermal insulation layer while ensuring strength and reduce heat loss. The addition of Al2O3 is to enhance the hardness and wear resistance of the transition layer 200, so that it can better resist the erosion of the external environment and extend the service life of the thermal insulation layer.

[0058] The composite plasticizer plays a role in adjusting the plasticity and flexibility of the material in the transition layer 200. An appropriate amount of composite plasticizer can improve the crack resistance of the transition layer 200, so that it can maintain structural integrity under temperature changes or external forces, and avoid cracking or falling off.

[0059] The addition of water glass and water is to optimize the bonding performance and construction performance of the transition layer 200. As an inorganic binder, water glass can enhance the bonding strength of the materials inside the transition layer 200, while improving its fire resistance and chemical corrosion resistance. The addition of water can adjust the fluidity and plasticity of the mixture, making it easier to apply and shape during the construction process.

[0060] In the embodiment of the present invention, the particle size of the medium-sized waste slag powder is B, 0.3mm≤B≤0.6mm.

[0061] Specifically, when the particle size of the medium-sized waste slag powder is controlled within the range of 0.3 mm to 0.6 mm, the particle size of the medium-sized waste slag powder is larger than the fine-sized waste slag powder in the fine powder layer 100, but smaller than the large-sized material in the porous layer 300. This particle size gradient design is conducive to forming a continuous and smooth transition inside the insulation layer, reducing compatibility issues between layers, and improving the integrity and stability of the entire structure.

[0062] Compared with fine-grained waste slag powder, medium-grained waste slag powder has a larger porosity, which is beneficial to improving the thermal insulation performance of the transition layer 200. At the same time, a larger particle size also means a higher aggregate strength, so that the transition layer 200 can withstand a certain load and enhance the overall strength of the thermal insulation layer.

[0063] When the medium-sized waste slag powder is mixed with other ingredients (such as expanded perlite, Al2O3, etc.), a mixture with reasonable particle size distribution and good bonding performance can be formed. This is conducive to improving the construction performance of the transition layer 200, making it easier to apply or spray on the fine powder layer 100 and achieve reliable connection with the porous layer 300.

[0064] More specifically, applying industrial waste slag powder with a particle size ranging from 0.3 mm to 0.6 mm to the transition layer 200 not only expands the utilization range of waste slag, but also reduces the dependence on natural aggregates.

[0065] In an embodiment of the present invention, the porous layer 300 includes 100 parts by mass of coarse-grained waste slag powder, 15 to 25 parts by mass of hollow glass microspheres, 1 to 3 parts by mass of SiC, 0.1 to 0.3 parts by mass of a retarder, 2 to 4 parts by mass of a foaming agent, 25 to 35 parts by mass of water glass and 15 to 20 parts by mass of water.

[0066] Specifically, coarse-grained waste powder is used as the main material of the porous layer 300. The coarse-grained waste powder provides good structural support and high thermal resistance, which helps to improve the overall thermal insulation effect. Hollow glass microspheres are used to improve the thermal insulation performance of the thermal insulation layer due to their low density and good thermal insulation performance. Their addition can effectively reduce the weight of the thermal insulation layer while maintaining a high structural strength. The addition of SiC is mainly to enhance the wear resistance and compressive strength of the material, so that the porous layer 300 can maintain its shape and effectiveness when subjected to external pressure. The use of retarders is to control the setting time of the mixture, making the construction process more controllable and improving the construction quality. The foaming agent forms more voids by generating tiny bubbles in the mixture, which help to further improve the thermal insulation performance of the material and reduce the overall weight. Water glass, as an inorganic binder, enhances the bonding force and waterproof performance of the mixture. The addition of water adjusts the fluidity and workability of the mixture, facilitating construction operations.

[0067] In the embodiment of the present invention, the particle size of the coarse-grained waste slag powder is C, 0.6 mm ≤ C ≤ 1.2 mm.

[0068] Specifically, when the particle size of the coarse-grained waste powder is controlled within the range of 0.6 mm to 1.2 mm, the coarse-grained waste powder has a larger particle size and a higher porosity than the fine-grained and medium-grained waste powders. This characteristic is conducive to forming more closed air layers in the porous layer 300, thereby significantly improving the thermal insulation effect of the insulation layer and reducing heat loss. The particle size of the coarse-grained waste powder is relatively large, and a stable skeleton structure can be formed in the porous layer 300. This skeleton structure can effectively bear external loads, improve the compressive strength and durability of the insulation layer, and ensure that it maintains good performance during long-term use. And the larger gaps formed between the coarse-grained waste powders are conducive to the discharge of moisture and the circulation of air. This characteristic can prevent water accumulation inside the insulation layer, reduce the moisture content of the material, and at the same time promote the dissipation of internal moisture, maintain the dry state of the insulation layer, and extend its service life.

[0069] More specifically, applying industrial waste slag powder with a particle size ranging from 0.6 mm to 1.2 mm to the porous layer 300 not only expands the utilization range of waste slag, but also reduces the dependence on natural aggregates.

[0070] In the embodiment of the present invention, the thickness of the composite adhesive layer 400 is H, 2 mm ≤ H ≤ 5 mm.

[0071] Specifically, the main function of the composite bonding layer 400 is to connect and fix the various layers in the thermal insulation layer, including the fine powder layer 100, the transition layer 200 and the porous layer 300. Setting the thickness between 2 mm and 5 mm can ensure sufficient material coverage and form a strong bonding interface. This not only improves the stability of the overall structure, but also prevents moisture and other environmental factors from eroding the inner layer material, thereby improving the durability of the thermal insulation layer.

[0072] During construction, the thickness of the bonding layer needs to be moderate to facilitate uniform application and rapid curing. Too thin a bonding layer may result in uneven bonding, while too thick a bonding layer may increase material costs and extend construction time. Therefore, a thickness range of 2mm to 5mm can ensure good bonding effects while also helping to control construction costs and time.

[0073] In terms of material usage, appropriate bond line thickness helps balance performance and cost. By optimizing the thickness, unnecessary material waste can be reduced while ensuring that the performance requirements of the structure are met.

[0074] More specifically, the composite adhesive layer 400 with a thickness ranging from 2 mm to 5 mm can adapt to different environmental conditions, such as temperature changes, humidity changes, etc. The appropriate thickness can provide an additional protective layer for the insulation layer and reduce the impact of environmental factors on the internal structure.

[0075] Please continue reading Figure 1 , and see Figure 2 The present invention also provides a method for preparing a wall insulation layer structure, which is used to prepare the wall insulation layer structure as described above. The method for preparing the wall insulation layer structure comprises:

[0076] 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;

[0077] Step S20, preparing a fine powder layer slurry using the fine-grained waste slag powder, SiO2, an organic silicon modifier, water glass and water;

[0078] Step S30, preparing a transition layer slurry using the medium-sized waste slag powder, expanded perlite, Al2O3, composite plasticizer, water glass and water;

[0079] 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;

[0080] Step S50, pouring the fine powder layer slurry, the transition layer slurry and the porous layer slurry into the wall mold in layers to obtain the fine powder layer 100, the transition layer 200 and the porous layer 300, and during the layered pouring process, applying the composite bonding layer 400 between the fine powder layer 100 and the transition layer 200, and between the transition layer 200 and the porous layer 300 to form the wall insulation layer structure.

[0081] 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 100; 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 100, providing a solid foundation for the subsequent transition layer 200 and porous layer 300.

[0082] 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 a moderate particle size, which helps to form the skeleton structure of the transition layer 200; the expanded perlite is a lightweight material with the characteristics of low thermal conductivity and high strength, which can enhance the thermal insulation performance and mechanical strength of the transition layer 200; 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, which is convenient for 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 100 and the porous layer 300, which plays a role of buffering and connection, and improves the overall performance of the wall insulation layer.

[0083] The porous layer slurry in this embodiment is composed of coarse-grained waste slag powder, hollow glass microspheres, SiC, retarder, foaming agent, water glass and water. Among them, the coarse-grained waste slag powder is the main aggregate for forming the porous structure, and the particle size is large, which is conducive to the formation of 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 300; SiC is used as a high-temperature resistant filler to give 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 300, 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 standard requirements of building applications.

[0084] The three slurries prepared in steps S20, S30 and S40 are sequentially introduced into the wall mold by layered pouring to form a wall insulation layer with a gradient structure. Specifically, the fine powder layer slurry, the transition layer slurry and the porous layer slurry are sequentially poured into a special wall mold. Between each layer pouring, a composite bonding layer 400 is applied between adjacent layers to ensure the bonding strength between the layers and the overall waterproofness.

[0085] 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.

[0086] 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.

[0087] It should be understood that the specific structure of the wall insulation layer structure refers to the above-mentioned embodiments. Since the preparation method of the wall insulation layer structure 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 described one by one here.

[0088] Please continue reading Figure 2 , 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:

[0089] 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;

[0090] 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;

[0091] Step S53, after the fine powder layer 100 is initially solidified, the composite bonding layer 400 is coated thereon, and the transition layer slurry is poured with a pouring thickness of one third of the thickness of the wall insulation layer, and vibrated for 60 seconds to make the transition layer slurry dense;

[0092] Step S54: after the transition layer 200 is initially solidified, the composite bonding layer 400 is coated thereon, and the porous layer slurry is poured with a pouring thickness of one third of the thickness of the wall insulation layer, and vibrated for 30 seconds to promote the foaming of the porous layer slurry;

[0093] Step S55: After the porous layer slurry is initially solidified, the wall insulation layer is formed.

[0094] Specifically, in step S51, first, a release agent is applied to the bottom of the wall mold, and a vibration table is used to vibrate for 30 seconds to evenly spread the release agent. The purpose of this step is to facilitate the subsequent molding of the wall insulation layer from the mold to be smoothly demolded, while ensuring that the release agent is evenly distributed on the mold surface to prevent local adhesion.

[0095] In step S52, the fine powder layer slurry is poured into the mold, and the pouring thickness is one third of the thickness of the wall insulation layer. Subsequently, the fine powder layer slurry is vibrated for 60 seconds using a vibration table to fully compact the fine powder layer slurry. The vibration time of this step is relatively long in order to ensure the high density and uniformity of the fine powder layer 100 and provide a stable foundation for the pouring of subsequent layers.

[0096] In step S53, after the fine powder layer 100 is initially solidified, the composite bonding layer 400 is coated thereon, and the transition layer slurry is poured, and the pouring thickness is also one-third of the thickness of the wall insulation layer. Subsequently, vibration is performed for 60 seconds to make the transition layer slurry dense. The timing of coating the composite bonding layer 400 is crucial and must be performed after the initial solidification of the lower layer to ensure good bonding between the layers.

[0097] In step S54, after the transition layer 200 is initially set, the composite bonding layer 400 is applied again, and the porous layer slurry is poured, and the pouring thickness is one third of the thickness of the wall insulation layer. The vibration time this time is 30 seconds, the purpose is to promote the foaming of the porous layer slurry and form an ideal porous structure.

[0098] In step S55, after the porous layer slurry is initially set, the entire wall insulation layer is formed. This step marks the completion of the layered pouring process. The formed wall insulation layer has a clear three-layer structure, and each layer has been precisely poured, vibrated and bonded to ensure that its performance is optimal.

[0099] Please continue reading 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:

[0100] Step S551, after the porous layer slurry is initially solidified, demoulding is performed to obtain a gradient insulation layer;

[0101] Step S552, curing and drying the gradient thermal insulation layer;

[0102] Step S553: ​​polishing the gradient insulation layer to form the wall insulation layer.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] Please continue reading 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:

[0107] 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;

[0108] 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.

[0109] 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.

[0110] 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.

[0111] In an embodiment of the present invention, the industrial waste slag is steel waste slag and ferroalloy waste slag.

[0112] 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.

[0113] 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.

[0114] 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 wall insulation layer structure, characterized in that: It comprises a fine powder layer, a transition layer, a porous layer and a composite bonding layer. The fine powder layer, the transition layer and the porous layer are stacked, and the composite bonding layer is arranged between the fine powder layer and the transition layer, and between the transition layer and the porous layer.

2. The wall insulation layer structure according to claim 1, characterized in that: The composite bonding layer includes 100 parts by weight of polymer modified cement, 10 to 15 parts by weight of acrylic emulsion, 2 to 5 parts by weight of silicone adhesive, 30 to 40 parts by weight of fine-grained waste slag powder, 5 to 10 parts by weight of SiO2, 3 to 7 parts by weight of Al2O3, 5 to 10 parts by weight of expanded vermiculite, 1 to 3 parts by weight of polypropylene fiber, 1 to 3 parts by weight of basalt fiber, 1 to 3 parts by weight of silicate waterproofing agent and 20 to 30 parts by weight of water.

3. The wall insulation layer structure according to claim 1, characterized in that: The fine powder layer comprises 100 parts by mass of fine-grained waste slag powder, 3 to 8 parts by mass of SiO2, 0.5 to 1.5 parts by mass of an organic silicon modifier, 15 to 25 parts by mass of water glass and 6 to 10 parts by mass of water.

4. The wall insulation layer structure according to claim 2 or 3, characterized in that: The particle size of the fine-grained waste slag powder is A, 0.1mm≤A≤0.3mm.

5. The wall insulation layer structure according to claim 1, characterized in that: The transition layer comprises 100 parts by weight of medium-sized waste slag powder, 8 to 12 parts by weight of expanded perlite, 2 to 5 parts by weight of Al2O3, 0.3 to 0.8 parts by weight of a composite plasticizer, 20 to 30 parts by weight of water glass and 10 to 15 parts by weight of water.

6. The wall insulation layer structure according to claim 5, characterized in that: The particle size of the medium-sized waste slag powder is B, 0.3mm≤B≤0.6mm.

7. The wall insulation layer structure according to claim 1, characterized in that: The porous layer comprises 100 parts by weight of coarse-grained waste slag powder, 15 to 25 parts by weight of hollow glass microspheres, 1 to 3 parts by weight of SiC, 0.1 to 0.3 parts by weight of a retarder, 2 to 4 parts by weight of a foaming agent, 25 to 35 parts by weight of water glass and 15 to 20 parts by weight of water.

8. The wall insulation layer structure according to claim 7, characterized in that: The particle size of the coarse-grained waste slag powder is C, 0.6mm≤C≤1.2mm.

9. The wall insulation layer structure according to claim 1, characterized in that: The thickness of the composite bonding layer is H, 2mm≤H≤5mm.

10. A method for preparing a wall insulation layer structure, characterized in that: Used to prepare a wall insulation layer structure according to any one of claims 1 to 9, the wall insulation layer structure preparation method comprising: 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 a wall mold in layers to obtain the fine powder layer, the transition layer and the porous layer. During the layered pouring process, the composite bonding layer is applied between the fine powder layer and the transition layer, and between the transition layer and the porous layer to form the wall insulation layer structure.

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