Method for producing novel lightweight wall thermal insulation material by using old community wall waste residues

Abstract

The invention discloses a method for producing a novel lightweight wall thermal insulation material by using old community wall waste residues, and the method specifically comprises the following steps: S1, mixing and stirring, S2, molding treatment, S3, drying treatment, S4, sintering treatment, S5, cutting treatment, S6, performance detection, and S7, packaging and warehousing, and relates to the technical field of thermal insulation material production. According to the method for producing the novel lightweight wall thermal insulation material from the old community wall waste residues, by optimizing a raw material formula and process parameters, the thermal conductivity coefficient of the thermal insulation material is remarkably reduced and can be reduced by 10%-15% compared with that of a traditional thermal insulation material, the thermal insulation performance is effectively improved, and the problem that the thermal insulation performance of the traditional thermal insulation material is insufficient is solved; through the application of the novel additive and the sintering process, the structural stability of pores in the material is enhanced, heat conduction paths are reduced, the compressive strength of the produced novel lightweight wall thermal insulation material is improved, and the novel lightweight wall thermal insulation material can bear larger external pressure and is not prone to deformation and damage.

Description

Technical Field

[0001] The invention relates to the technical field of thermal insulation material production, and specifically to a method for producing a novel lightweight wall thermal insulation material by utilizing waste residues from old residential areas walls. Background Art

[0002] As people's requirements for building energy conservation and comfort increase, wall external insulation materials have emerged. Wall insulation materials (also known as WW wall insulation materials) are materials that can have thermal insulation functions inside or outside the wall. There are many insulation material products, most of which are external wall insulation. The insulation layer is made at the same time as the building. There is also internal insulation. Generally, the stairs of buildings are internally insulated. Insulation materials can be roughly divided into:

[0003] External wall insulation boards: extruded boards, polystyrene boards, perlite boards, rock wool boards, etc. The boards need to use both thermal insulation bonding mortar and anti-cracking mortar, or called plastering mortar.

[0004] Insulation mortar: DY inorganic active wall thermal insulation material, perlite thermal insulation mortar, MPC thermal insulation mortar, polystyrene particle thermal insulation mortar, fly ash modified thermal insulation mortar, Inter inorganic active wall thermal insulation material.

[0005] Thermal insulation coatings: exterior wall thermal insulation and waterproof coatings, interior wall thermal insulation coatings, etc.

[0006] Traditional building walls are not good at heat preservation. Heat is easily transferred through the walls, which causes the indoor temperature to be greatly affected by the outside world, increasing the energy consumption of heating and cooling. In order to reduce building energy consumption and improve energy efficiency, it is necessary to develop external wall insulation materials. Moreover, in terms of comfort, good external insulation materials can make the indoor temperature more stable and reduce uneven heat and cold.

[0007] At the same time, the strengthening of environmental protection concepts has also promoted its research and development. The development of efficient thermal insulation and environmentally friendly materials can reduce carbon emissions in the energy production process and conform to the trend of sustainable development. Summary of the invention

[0008] 1. Technical issues to be resolved

[0009] In view of the shortcomings of the prior art, the present invention provides a method for producing a new lightweight wall insulation material using waste residue from old residential walls, which solves the problem of insufficient thermal insulation performance of traditional thermal insulation materials. Through the application of new additives and sintering processes, the stability of the pore structure inside the material is enhanced, the heat conduction path is reduced, and the mechanical properties of the thermal insulation material are improved, so that it can maintain good structural integrity during long-term use, overcoming the defects of previous materials such as easy brittle cracking and poor compressive resistance.

[0010] (II) Technical solution

[0011] To achieve the above purpose, the present invention is implemented by the following technical scheme: a method for producing a new lightweight wall insulation material using waste residue from old residential walls, specifically comprising the following steps:

[0012] S1. Mixing and stirring: put the prepared main raw materials and additives into the high-speed mixer in order, set the stirring speed to 50-60 rpm, and the stirring time to 40-50 minutes to ensure that the raw materials are fully mixed;

[0013] S2. Molding process: Select the corresponding mold according to the product specifications. The mold material is a new lightweight wall insulation material with good heat resistance and demoulding properties. Apply a pressure of 200-300 MPa on the hydraulic molding machine for 100-150 seconds to shape the mixed material in the mold;

[0014] S3, drying treatment: put the formed thermal insulation material blank into a drying kiln, control the drying temperature at 150-180 degrees Celsius, and dry for 2-3 hours to reduce the moisture content of the blank to below 10%;

[0015] S4, sintering treatment: the dried green body enters the tunnel kiln for sintering;

[0016] S5. Cutting and processing: Use CNC cutting equipment to cut the sintered insulation material according to the designed size. The cutting accuracy is controlled within the range of ±20 mm to ensure that the product size meets the requirements;

[0017] S6. Performance testing: Use thermal conductivity tester and universal material testing machine to test thermal conductivity and compressive strength respectively;

[0018] S7. Packaging and warehousing: The qualified insulation materials will be packed with moisture-proof and anti-damage packaging materials, and stored in the warehouse according to the specifications. The warehouse environment should be kept dry and ventilated, with a temperature of 30-40 degrees Celsius and a humidity of less than 5%.

[0019] Preferably, the main raw material in step S1 is waste residue from old residential areas, including hollow bricks, clay bricks and concrete materials. The hollow bricks, clay bricks and concrete materials are crushed and screened to obtain particles with a diameter of 5-10 mm and a compaction degree of not less than 80%.

[0020] Preferably, the additives in step S1 include a binder and a foaming agent.

[0021] Preferably, the binder is added in an amount of 10%-15% of the total weight of the raw materials, and its function is to enhance the cohesion of the material.

[0022] Preferably, the foaming agent is added in an amount of 10%-15%, which is used to form closed pores inside the material to improve thermal insulation performance.

[0023] Preferably, the sintering treatment in step S4 is specifically as follows: heating from room temperature to 30 degrees Celsius at a heating rate of 20 degrees Celsius / minute, keeping warm for 3 hours, then heating to 40 degrees Celsius at 30 degrees Celsius / minute, keeping warm for 2 hours, and finally cooling to 10 degrees Celsius at 40 degrees Celsius / minute before taking out of the furnace.

[0024] Preferably, the thermal conductivity test in step S6 is performed using a thermal conductivity tester according to a test standard, which requires the thermal conductivity to be lower than 20 W / (m·Kelvin).

[0025] Preferably, the compressive strength test in step S6 is performed using a universal material testing machine to test the compressive strength of the thermal insulation material, which must reach 200 MPa or above.

[0026] (III) Beneficial effects

[0027] The present invention provides a method for producing a new type of lightweight wall insulation material using waste residue from old residential walls. Compared with the prior art, it has the following beneficial effects:

[0028] (1) The method of using waste residue from the walls of old residential areas to produce a new type of lightweight wall insulation material significantly reduces the thermal conductivity of the insulation material by optimizing the raw material formula and process parameters. Compared with traditional insulation materials, it can be reduced by 10%-15%, effectively improving the thermal insulation performance and solving the problem of insufficient thermal insulation performance of traditional insulation materials. Through the application of new additives and sintering technology, the stability of the pore structure inside the material is enhanced and the heat conduction path is reduced.

[0029] (2) The method of using waste residue from the walls of old residential areas to produce new lightweight wall insulation materials has improved compressive strength of the produced new lightweight wall insulation materials, which can withstand greater external pressure and are not easily deformed or damaged. The materials are suitable for a variety of complex building and industrial insulation scenarios, and the mechanical properties of the insulation materials are improved, so that the insulation materials can maintain good structural integrity during long-term use, thus overcoming the defects of the previous materials being brittle and having poor compressive resistance. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 The present invention is a flow chart of the production method. 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] See also Figure 1 The embodiment of the present invention provides three technical solutions: a method for producing a new type of lightweight wall insulation material using waste residue from old residential areas, specifically including the following embodiments:

[0033] Embodiment 1: A method for producing a novel lightweight wall insulation material using waste residue from old residential areas, specifically comprising the following steps:

[0034] S1. Mixing and stirring: put the prepared main raw materials and additives into a high-speed mixer in order, set the stirring speed to 55 rpm, and the stirring time to 45 minutes to ensure that the raw materials are fully mixed. The main raw materials are waste residues from old residential walls, including hollow bricks, clay bricks, and concrete materials. The hollow bricks, clay bricks, and concrete materials are crushed and screened to obtain a particle size of 7 mm and a compaction degree of not less than 80%. The additives include a binder and a foaming agent. The amount of the binder added is 13% of the total weight of the raw materials, and its function is to enhance the cohesion of the material. The foaming agent is added in a proportion of 13%, which is used to form closed pores inside the material and improve thermal insulation performance;

[0035] S2. Molding process: Select the corresponding mold according to the product specifications. The mold material is a new lightweight wall insulation material with good heat resistance and demoulding properties. Apply a pressure of 250 MPa on the hydraulic molding machine for 130 seconds to shape the mixed material in the mold;

[0036] S3, drying treatment: the formed thermal insulation material blank is placed in a drying kiln, the drying temperature is controlled at 165 degrees Celsius, the drying time is 2.5 hours, and the moisture content of the blank is reduced to less than 10%;

[0037] S4, sintering treatment: the dried green body enters the tunnel kiln for sintering. The sintering treatment is specifically as follows: the temperature is raised from room temperature to 30 degrees Celsius at a heating rate of 20 degrees Celsius / minute, kept at this temperature for 3 hours, then raised to 40 degrees Celsius at 30 degrees Celsius / minute, kept at this temperature for 2 hours, and finally cooled to 10 degrees Celsius at 40 degrees Celsius / minute before being taken out of the kiln;

[0038] S5. Cutting and processing: Use CNC cutting equipment to cut the sintered insulation material according to the designed size. The cutting accuracy is controlled within the range of ±20 mm to ensure that the product size meets the requirements;

[0039] S6. Performance testing: Thermal conductivity tester and universal material testing machine are used to test thermal conductivity and compressive strength respectively. Thermal conductivity test is carried out by using thermal conductivity tester in accordance with the testing standards, requiring thermal conductivity to be less than 20 W / (m·Kelvin). Compressive strength test is carried out by using universal material testing machine to test the compressive strength of thermal insulation materials, which must reach more than 200 MPa.

[0040] S7. Packaging and warehousing: The qualified insulation materials will be packed with moisture-proof and damage-proof packaging materials, and stored in the warehouse according to the specifications. The warehouse environment should be kept dry and ventilated, with the temperature at 35 degrees Celsius and the humidity below 5%.

[0041] Embodiment 1: A method for producing a novel lightweight wall insulation material using waste residue from old residential areas, specifically comprising the following steps:

[0042] S1. Mixing and stirring: put the prepared main raw materials and additives into a high-speed mixer in order, set the stirring speed to 50 rpm, and the stirring time to 40 minutes to ensure that the raw materials are fully mixed. The main raw materials are waste residues from old residential walls, including hollow bricks, clay bricks, and concrete materials. The hollow bricks, clay bricks, and concrete materials are crushed and screened to obtain a particle size of 5 mm and a compaction degree of not less than 80%. The additives include a binder and a foaming agent. The amount of the binder added is 10% of the total weight of the raw materials, and its function is to enhance the cohesion of the material. The foaming agent is added in a proportion of 10%, which is used to form closed pores inside the material and improve the thermal insulation performance;

[0043] S2. Molding process: Select the corresponding mold according to the product specifications. The mold material is a new lightweight wall insulation material with good heat resistance and demoulding properties. Apply a pressure of 200-300 MPa on the hydraulic molding machine for 100 seconds to shape the mixed material in the mold;

[0044] S3, drying treatment: the formed thermal insulation material blank is placed in a drying kiln, the drying temperature is controlled at 150 degrees Celsius, the drying time is 2 hours, and the moisture content of the blank is reduced to less than 10%;

[0045] S4, sintering treatment: the dried green body enters the tunnel kiln for sintering. The sintering treatment is specifically as follows: the temperature is raised from room temperature to 30 degrees Celsius at a heating rate of 20 degrees Celsius / minute, kept at this temperature for 3 hours, then raised to 40 degrees Celsius at 30 degrees Celsius / minute, kept at this temperature for 2 hours, and finally cooled to 10 degrees Celsius at 40 degrees Celsius / minute before being taken out of the kiln;

[0046] S5. Cutting and processing: Use CNC cutting equipment to cut the sintered insulation material according to the designed size. The cutting accuracy is controlled within the range of ±20 mm to ensure that the product size meets the requirements;

[0047] S6. Performance testing: Thermal conductivity tester and universal material testing machine are used to test thermal conductivity and compressive strength respectively. Thermal conductivity test is carried out by using thermal conductivity tester in accordance with the testing standards, requiring thermal conductivity to be less than 20 W / (m·Kelvin). Compressive strength test is carried out by using universal material testing machine to test the compressive strength of thermal insulation materials, which must reach more than 200 MPa.

[0048] S7. Packaging and warehousing: The qualified insulation materials will be packed with moisture-proof and anti-damage packaging materials, and stored in the warehouse according to the specifications. The warehouse environment should be kept dry and ventilated, with the temperature at 30 degrees Celsius and the humidity below 5%.

[0049] Embodiment 1: A method for producing a novel lightweight wall insulation material using waste residue from old residential areas, specifically comprising the following steps:

[0050] S1. Mixing and stirring: put the prepared main raw materials and additives into a high-speed mixer in order, set the stirring speed to 60 rpm, and the stirring time to 50 minutes to ensure that the raw materials are fully mixed. The main raw materials are waste residues from old residential walls, including hollow bricks, clay bricks, and concrete materials. The hollow bricks, clay bricks, and concrete materials are crushed and screened to obtain a particle size of 10 mm and a compaction degree of not less than 80%. The additives include a binder and a foaming agent. The amount of the binder added is 15% of the total weight of the raw materials, and its function is to enhance the cohesion of the material. The foaming agent is added in a proportion of 15%, which is used to form closed pores inside the material and improve the thermal insulation performance;

[0051] S2. Molding process: Select the corresponding mold according to the product specifications. The mold material is a new lightweight wall insulation material with good heat resistance and demoulding properties. Apply a pressure of 300 MPa on the hydraulic molding machine for 150 seconds to shape the mixed material in the mold;

[0052] S3, drying treatment: the formed thermal insulation material blank is placed in a drying kiln, the drying temperature is controlled at 180 degrees Celsius, the drying time is 3 hours, and the moisture content of the blank is reduced to less than 10%;

[0053] S4, sintering treatment: the dried green body enters the tunnel kiln for sintering. The sintering treatment is specifically as follows: the temperature is raised from room temperature to 30 degrees Celsius at a heating rate of 20 degrees Celsius / minute, kept at this temperature for 3 hours, then raised to 40 degrees Celsius at 30 degrees Celsius / minute, kept at this temperature for 2 hours, and finally cooled to 10 degrees Celsius at 40 degrees Celsius / minute before being taken out of the kiln;

[0054] S5. Cutting and processing: Use CNC cutting equipment to cut the sintered insulation material according to the designed size. The cutting accuracy is controlled within the range of ±20 mm to ensure that the product size meets the requirements;

[0055] S6. Performance testing: Thermal conductivity tester and universal material testing machine are used to test thermal conductivity and compressive strength respectively. Thermal conductivity test is carried out by using thermal conductivity tester in accordance with the testing standards, requiring thermal conductivity to be less than 20 W / (m·Kelvin). Compressive strength test is carried out by using universal material testing machine to test the compressive strength of thermal insulation materials, which must reach more than 200 MPa.

[0056] S7. Packaging and warehousing: The qualified insulation materials will be packaged with moisture-proof and anti-damage packaging materials, and stored in the warehouse according to specifications. The warehouse environment should be kept dry and ventilated, with a temperature of 40 degrees Celsius and a humidity of less than 5%.

[0057] The following are the test methods and test results of 3 new lightweight wall insulation materials:

[0058] Tensile bond strength test:

[0059] Test method: Referring to the JGJ 144-2004 standard, taking EPS insulation board as an example, 5 insulation board samples of 200mm×200mm×50mm were made, and the anti-cracking plastering material was applied on one surface of the EPS board with a thickness of 3-1mm. After curing, the two sides were bonded to the steel base plate of 200mm×200mm with epoxy resin. The samples were divided into two states: dry state and soaked in water for 48h and then taken out for 2h. They were placed on a tensile testing machine and stretched to failure at a tensile speed of 5mm / min. The tensile force and the failure position at the time of failure were recorded, and the tensile bonding strength was calculated.

[0060] Example results: In the dry state, the tensile bonding strengths of the five specimens were 0.35 MPa, 0.38 MPa, 0.40 MPa, 0.36 MPa, and 0.37 MPa, respectively, with an average value of 0.37 MPa; after immersion, the corresponding values ​​were 0.28 MPa, 0.30 MPa, 0.32 MPa, 0.29 MPa, and 0.31 MPa, respectively, with an average value of 0.30 MPa.

[0061] Impact test:

[0062] Test method: According to GB / T 1261-2011 standard, for the exterior wall internal insulation system with concrete or masonry as the base wall, prepare a sample with a size of more than 600mm×400mm, consisting of an insulation layer and a protective layer, and the sample with cement as the main bonding base material is cured for 28 days. The sample is placed flat on the ground covered with fine sand, and a 5 kg sandbag is used to impact the sample by free fall at a height of 1m from the sample surface, and the number of visible cracks on the front of the sample is observed and recorded.

[0063] Example results: After multiple impacts, visible cracks began to appear on the front of a new type of lightweight insulation board after 10 impacts, meeting the minimum impact resistance requirements specified in the relevant standards.

[0064] Thermal conductivity test:

[0065] Test method: According to the guarded hot plate method of GB / T 10294-2008 standard, select a certain size of new lightweight wall insulation material sample, put it into the thermal conductivity tester, measure the heat flow and temperature difference through the sample under stable temperature conditions, and then calculate the thermal conductivity.

[0066] Example results: The thermal conductivity of a new type of aerogel composite insulation material was tested to be 0.023W / (m·K), which is much lower than that of traditional insulation materials and shows good insulation performance.

[0067] In summary, the present invention significantly reduces the thermal conductivity of the thermal insulation material by optimizing the raw material formula and process parameters, which can be reduced by 10%-15% compared with traditional thermal insulation materials, effectively improving the thermal insulation performance, and solving the problem of insufficient thermal insulation performance of traditional thermal insulation materials. Through the application of new additives and sintering technology, the stability of the pore structure inside the material is enhanced, and the heat conduction path is reduced. The compressive strength of the new lightweight wall insulation material produced is improved, and it can withstand greater external pressure and is not easy to deform and damage. It is suitable for a variety of complex construction and industrial insulation scenes, and improves the mechanical properties of the thermal insulation material, so that it can maintain good structural integrity during long-term use, overcoming the defects of easy brittle cracking and poor compressive resistance of previous materials.

[0068] Meanwhile, the contents not described in detail in this specification belong to the prior art known to those skilled in the art.

[0069] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0070] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for producing a new type of lightweight wall insulation material using waste residue from old residential areas, characterized in that: The specific steps include: S1. Mixing and stirring: put the prepared main raw materials and additives into the high-speed mixer in order, set the stirring speed to 50-60 rpm, and the stirring time to 40-50 minutes to ensure that the raw materials are fully mixed; S2. Molding process: Select the corresponding mold according to the product specifications. The mold material is a new lightweight wall insulation material with good heat resistance and demoulding properties. Apply a pressure of 200-300 MPa on the hydraulic molding machine for 100-150 seconds to shape the mixed material in the mold; S3, drying treatment: put the formed thermal insulation material blank into a drying kiln, control the drying temperature at 150-180 degrees Celsius, and dry for 2-3 hours to reduce the moisture content of the blank to below 10%; S4, sintering treatment: the dried green body enters the tunnel kiln for sintering; S5. Cutting and processing: Use CNC cutting equipment to cut the sintered insulation material according to the designed size. The cutting accuracy is controlled within the range of ±20 mm to ensure that the product size meets the requirements; S6. Performance testing: Use thermal conductivity tester and universal material testing machine to test thermal conductivity and compressive strength respectively; S7. Packaging and warehousing: The qualified insulation materials will be packed with moisture-proof and anti-damage packaging materials, and stored in the warehouse according to the specifications. The warehouse environment should be kept dry and ventilated, with a temperature of 30-40 degrees Celsius and a humidity of less than 5%.

2. The method for producing new lightweight wall insulation materials using waste residue from old residential areas according to claim 1 is characterized in that: In step S1, the main raw material is waste residue from old residential walls, including hollow bricks, clay bricks, and concrete materials. The hollow bricks, clay bricks, and concrete materials are crushed and screened to obtain particles with a diameter of 5-10 mm and a compaction degree of not less than 80%.

3. The method for producing new lightweight wall insulation materials using waste residue from old residential areas according to claim 1 is characterized in that: The additives in step S1 include a binder and a foaming agent.

4. The method for producing new lightweight wall insulation materials using waste residue from old residential areas according to claim 3 is characterized in that: The binder is added in an amount of 10% to 15% of the total weight of the raw materials, and its function is to enhance the cohesive force of the material.

5. The method for producing new lightweight wall insulation materials using waste residue from old residential areas according to claim 3 is characterized by: The foaming agent is added in an amount of 10% to 15% to form closed pores inside the material to improve thermal insulation performance.

6. The method for producing new lightweight wall insulation materials using waste residue from old residential areas according to claim 1 is characterized in that: The sintering treatment in step S4 is specifically as follows: heating from room temperature to 30 degrees Celsius at a heating rate of 20 degrees Celsius / minute, keeping the temperature for 3 hours, then heating to 40 degrees Celsius at 30 degrees Celsius / minute, keeping the temperature for 2 hours, and finally cooling to 10 degrees Celsius at 40 degrees Celsius / minute before taking out of the furnace.

7. The method for producing new lightweight wall insulation materials using waste residue from old residential areas according to claim 1 is characterized in that: The thermal conductivity test in step S6 is performed using a thermal conductivity tester according to a test standard, which requires that the thermal conductivity be less than 20 W / (m·Kelvin).

8. The method for producing new lightweight wall insulation materials using waste residue from old residential areas according to claim 1 is characterized in that: The compressive strength test in step S6 uses a universal material testing machine to test the compressive strength of the thermal insulation material, which must reach more than 200 MPa.

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