Autoclaved aerated concrete composite thermal insulation wallboard and manufacturing process thereof

Abstract

The invention belongs to the technical field of concrete prefabricated parts, and relates to an autoclaved aerated concrete composite thermal insulation wallboard and a manufacturing process thereof. The autoclaved aerated concrete composite thermal insulation wallboard is of a three-layer composite structure and comprises autoclaved aerated concrete layers on the two sides and a phenolic aldehyde board arranged between the autoclaved aerated concrete layers on the two sides. The manufacturing process comprises the following steps: carrying out high-temperature steam curing on the phenolic aldehyde plate in advance through a still kettle, then obliquely inserting and fixing the phenolic aldehyde plate by using a reinforcing mesh (the area of the reinforcing mesh is larger than that of the phenolic aldehyde plate), sinking into a mold filled with slurry for pre-curing, cutting after the composite thermal insulation wallboard is preliminarily formed, punching two sides of the wallboard, and then putting into the still kettle for autoclaved curing, thereby obtaining the composite thermal insulation wallboard. According to the manufacturing process, the phenolic aldehyde board is effectively prevented from being separated from the autoclaved aerated concrete layer, cracks are effectively prevented from occurring at the edge intersection position of the autoclaved aerated concrete and the phenolic aldehyde board, the percent of pass of the wallboard is increased, the service life of the wallboard is prolonged, and the autoclaved aerated concrete composite wallboard has wide market prospects.

Description

Technical Field

[0001] The present invention relates to the technical field of precast concrete components, and more specifically, it relates to an autoclaved aerated concrete composite thermal insulation wall panel and its manufacturing process. Background Art

[0002] Autoclaved aerated concrete composite thermal insulation wall panels have excellent properties such as light weight, heat insulation, sound insulation and noise reduction, and are widely used in the field of building wall materials. The wall panel realizes the integration of building thermal insulation by compounding autoclaved aerated concrete with the core material, meeting the requirements of contemporary carbon neutral, low-carbon and green buildings. However, phenolic board core materials are prone to shrinkage and gas release during the high-temperature steam curing process of the wall panel, resulting in voids between the autoclaved aerated concrete and the core material and cracks at the junction of the autoclaved aerated concrete and the edge of the phenolic board core material.

[0003] Currently, as disclosed in Chinese patent document CN202227501U, an autoclaved aerated composite thermal insulation board is composed of an outer layer, an inner layer and an adhesive material layer that bonds the outer layer and the inner layer together. The outer layer is an autoclaved aerated concrete board with low density and no steel mesh inside, the inner layer is a thermal insulation material, the specification size of the autoclaved aerated concrete board is 600*1000*(70 - 90) mm, the specification size of the thermal insulation material is 600*1000*10 mm, and the thickness dimension of the autoclaved aerated concrete board is between 80 - 100 mm. This solution reduces the bulk density and the heat transfer efficiency, meeting the needs of using it as a single material to externally attach to beams, columns and shear walls for thermal insulation and fire prevention in production applications. This autoclaved aerated composite thermal insulation board is mainly aimed at solving the thermal insulation problems of beams, columns and shear walls. Even with the adhesive material layer bonding the outer layer and the inner layer, it is still unable to well avoid the shrinkage deformation of the inner thermal insulation core material and the cracking of the board during the high-temperature steam curing process of the board.

[0004] Based on the above statements, the present invention provides an autoclaved aerated concrete composite thermal insulation wall panel and its manufacturing process. Summary of the Invention

[0005] In order to solve the problems of shrinkage deformation of the phenolic board core material and cracking of the board during the high-temperature steam curing process of the existing composite thermal insulation wall panel, the present invention provides an autoclaved aerated concrete composite thermal insulation wall panel and its manufacturing process.

[0006] In the first aspect, the present invention provides an autoclaved aerated concrete composite thermal insulation wall panel, adopting the following technical solution: An autoclaved aerated concrete composite thermal insulation wall panel, having a three-layer composite structure, comprising autoclaved aerated concrete layers on both sides and a phenolic board arranged in the middle of the autoclaved aerated concrete layers on both sides; The phenolic board comprises raw materials in the following parts by weight: 100-200 parts of silicon boron modified phenolic resin, 20-40 parts of ceramic fiber, 4-8 parts of toughening agent, 5-12 parts of foaming agent, and 1-5 parts of surfactant.

[0007] Preferably, the preparation method of the silicon boron modified phenolic resin comprises the following steps: Mix cardanol, formaldehyde solution and 4-vinylphenylboronic acid evenly, carry out condensation reflux stirring reaction at 60-70 °C for 0.5-2 h, then raise the temperature to 75-88 °C, carry out condensation reflux stirring reaction for 1-3 h, dropwise add organosiloxane using a constant pressure funnel, finish dropping within 5 min, continue to raise the temperature to 90-105 °C, carry out condensation reflux stirring reaction for 3-5 h to obtain the silicon boron modified phenolic resin.

[0008] Preferably, the mass ratio of cardanol, formaldehyde solution, 4-vinylphenylboronic acid, and organosiloxane is 30:(10-17):(5-10):(2-6); the mass fraction of the formaldehyde solution is 35%-38%.

[0009] Preferably, the organosiloxane is obtained by mixing γ-glycidoxypropyltrimethoxysilane and glycidoxypropylcyclotetrasiloxane in a mass ratio of (2-4):1.

[0010] Preferably, the toughening agent is one or more of polyvinyl alcohol, polyamide, and styrene-butadiene rubber.

[0011] Preferably, the foaming agent is one or more of cyclopentane, n-hexane, and petroleum ether.

[0012] Preferably, the surfactant is one or more of Tween, Span, and polyvinylpyrrolidone.

[0013] Preferably, the preparation method of the phenolic board comprises the following steps: Uniformly mix the silicon boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent, and surfactant, carry out airtight curing, cure at 90-100 °C for 1-2 h, 120-130 °C for 1-2 h, 150-160 °C for 1-2 h, 180-190 °C for 1-2 h, and after curing, dry at 50-60 °C for 24-28 h to obtain the phenolic board.

[0014] In the second aspect, the present invention provides a manufacturing process for an autoclaved aerated concrete composite thermal insulation wall panel, adopting the following technical solution: A manufacturing process for an autoclaved aerated concrete composite thermal insulation wall panel comprises the following steps: First, put the phenolic board into an autoclave for pre-high-temperature steam curing. Then, fix the phenolic board in the middle of two steel mesh sheets. When pouring the autoclaved aerated concrete slurry, put the slurry into the mold and then implant the steel mesh sheet with the phenolic board into the mold. After pre-curing, cut it and drill holes on both sides of the board. Finally, put it into the autoclave for autoclave curing to form an autoclaved aerated concrete composite thermal insulation wall panel with exhaust holes.

[0015] Preferably, the conditions for pre-high-temperature steam curing of the phenolic board are: temperature 170 - 200 °C, air pressure 1.1 - 1.5 MPa, and time 5 - 10 h.

[0016] Preferably, the temperature for pre-curing is 40 - 60 °C and the time is 2 - 4 h; the temperature for autoclave curing is 170 °C - 200 °C, air pressure 1.1 - 1.5 MPa, and time 6 - 8 h.

[0017] Preferably, the holes on both sides of the board are equidistant, and the distance is 10 - 30 cm; the area of the steel mesh sheet is larger than the area of the phenolic board.

[0018] The present invention has positive and beneficial effects: (1) The autoclaved aerated concrete composite thermal insulation wall panel of the present invention has a three-layer composite structure. The raw materials of the phenolic board therein include silicon-boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent, and surfactant. Each component interacts with each other to form a phenolic board with excellent performance; the silicon-boron modified phenolic resin is obtained by reacting cardanol, formaldehyde solution, 4-vinylphenylboronic acid, and organosiloxane. The double cross-linking network of organosiloxane and borate ester improves the thermal stability of the phenolic board, promotes the phenolic board not to deform easily during autoclaving, effectively improves the defect that the phenolic board is prone to shrinkage and deformation during high-temperature steam curing in the board, and further greatly reduces the occurrence of board cracking; at the same time, the rigidity and toughness of the phenolic board are also significantly improved, increasing the compressive and bending strength of the phenolic board, and making the bearing capacity of the wall panel better after being combined with autoclaved aerated concrete.

[0019] (2) The present invention selects the phenolic board of γ-glycidoxypropyltrimethoxysilane and glycidoxypropylcyclotetrasiloxane to synergistically increase the cross-linking density and form a flexible chain, which not only improves the impact resistance of the phenolic board, but also helps to improve the interfacial performance of the phenolic board. The phenolic board after high-temperature steam curing has high interfacial molecular activity. When combined with autoclaved aerated concrete, the interfacial bonding force is effectively enhanced, greatly reducing the phenomenon of cracks on the wall surface caused by poor interfacial bonding.

[0020] (3) In the production process of the autoclaved aerated concrete composite thermal insulation wallboard of the present invention, the phenolic board is pre-steam-cured at a high temperature to release the internal gas, causing the board to slightly shrink, thus avoiding the gas generated when directly using the phenolic board for steam curing in the autoclaved aerated concrete board, which may cause the wallboard to crack along the edge of the phenolic board, and also avoiding the formation of gaps due to the deformation of the phenolic board inside the steam aerated concrete; the exhaust holes on the thermal insulation wallboard further prevent the residual gas from expanding and causing cracking of the concrete interface. In addition, the size of the steel mesh exceeds the outer edge of the phenolic board. By utilizing the anchoring effect between the mesh and the concrete, the interfacial bonding performance between the phenolic board and the concrete is improved, effectively preventing the edge cracks caused by stress concentration during the steam curing process. Description of the Drawings

[0021] Figure 1 It is a display diagram of the autoclaved aerated concrete composite thermal insulation wallboard obtained in Example 1. Detailed Embodiments

[0022] Here, in order to more clearly explain the overall concept of the present invention, the overall solution of the present invention will be described in detail by way of examples below; in the following description, a large number of specific details are given to provide a more thorough understanding of the present invention; however, it is obvious to those skilled in the art that the present invention can be implemented without one or more of these details; in other examples, in order to avoid confusion with the present invention, some well-known technical features in the art are not described.

[0023] Unless otherwise specified, each raw material component in the following examples can be obtained through commercial channels, the experimental instruments used are all conventional laboratory experimental instruments, and the performance testing methods are known testing methods in the art.

[0024] Preparation Examples 1-6 provide a phenolic board and its preparation method.

[0025] Preparation Example 1: A phenolic board, comprising the following raw materials in parts by weight: 100 parts of silicon-boron modified phenolic resin, 20 parts of ceramic fiber, 4 parts of toughening agent, 5 parts of foaming agent, 1 part of surfactant; Among them, the preparation method of the silicon-boron modified phenolic resin includes the following steps: After mixing 30 g of cardanol, 10 g of formaldehyde solution (mass fraction 35%) and 5 g of 4-vinylphenylboronic acid evenly, carry out a condensation reflux stirring reaction at 60 °C for 0.5 h, then raise the temperature to 75 °C, and carry out a condensation reflux stirring reaction for 1 h. Dropwise add 2 g of organosiloxane (obtained by mixing γ-glycidoxypropyltrimethoxysilane and glycidoxypropylcyclotetrasiloxane in a mass ratio of 2:1) using a constant pressure funnel, finish the dropping within 5 min, continue to raise the temperature to 90 °C, and carry out a condensation reflux stirring reaction for 3 h to obtain the silicon-boron modified phenolic resin; The toughening agent is polyvinyl alcohol; the foaming agent is cyclopentane; the surfactant is polyvinylpyrrolidone; A preparation method of a phenolic board, comprising the following steps:

[0026] Weigh the raw materials by weight, uniformly mix the silicon-boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent, and surfactant, seal and cure, cure at 90 °C for 1 h, 120 °C for 1 h, 150 °C for 1 h, 180 °C for 1 h, and after the curing is completed, dry at 50 °C for 24 h to obtain the phenolic board.

[0027] Preparation Example 2: A phenolic board, comprising the following raw materials by weight: 150 parts of silicon-boron modified phenolic resin, 30 parts of ceramic fiber, 6 parts of toughening agent, 10 parts of foaming agent, 2.5 parts of surfactant; Among them, the preparation method of the silicon-boron modified phenolic resin comprises the following steps: After uniformly mixing 30 g of cardanol, 14 g of formaldehyde solution (mass fraction 37%) and 8 g of 4-vinylphenylboronic acid, carry out a condensation reflux stirring reaction at 65 °C for 1.5 h, then raise the temperature to 80 °C, and carry out a condensation reflux stirring reaction for 2 h. Dropwise add 4 g of organosiloxane (obtained by mixing γ-glycidoxypropyltrimethoxysilane and glycidoxypropylcyclotetrasiloxane in a mass ratio of 3:1) using a constant pressure funnel, finish the dropwise addition within 5 min, continue to raise the temperature to 100 °C, and carry out a condensation reflux stirring reaction for 4 h to obtain the silicon-boron modified phenolic resin; The toughening agent is polyvinyl alcohol; the foaming agent is n-hexane; the surfactant is Tween; A preparation method of a phenolic board, comprising the following steps:

[0028] Weigh the raw materials by weight, uniformly mix the silicon-boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent, and surfactant, seal and cure, cure at 95 °C for 1.5 h, 125 °C for 1.5 h, 155 °C for 1.5 h, 185 °C for 1.5 h, and after the curing is completed, dry at 55 °C for 26 h to obtain the phenolic board.

[0029] Preparation Example 3: A phenolic board, comprising the following raw materials by weight: 200 parts of silicon-boron modified phenolic resin, 40 parts of ceramic fiber, 8 parts of toughening agent, 12 parts of foaming agent, 5 parts of surfactant; Among them, the preparation method of the silicon-boron modified phenolic resin comprises the following steps: After uniformly mixing 30 g of cardanol, 17 g of formaldehyde solution (mass fraction 38%) and 10 g of 4-vinylphenylboronic acid, carry out a condensation reflux stirring reaction at 70 °C for 2 h. Subsequently, raise the temperature to 88 °C and carry out a condensation reflux stirring reaction for 3 h. Use a constant pressure funnel to dropwise add 6 g of organosiloxane (obtained by mixing γ-glycidoxypropyltrimethoxysilane and glycidoxypropylcyclotetrasiloxane in a mass ratio of 4:1), complete the dropping within 5 min, continue to raise the temperature to 105 °C, and carry out a condensation reflux stirring reaction for 5 h to obtain a silicon-boron modified phenolic resin; The toughening agent is styrene-butadiene rubber; the foaming agent is petroleum ether; the surfactant is span; A preparation method of a phenolic board, comprising the following steps:

[0030] Weigh the raw materials by weight parts, uniformly mix the silicon-boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent, and surfactant, carry out airtight curing, cure at 100 °C for 2 h, 130 °C for 2 h, 160 °C for 2 h, 190 °C for 2 h, and after the curing is completed, dry at 60 °C for 28 h to obtain a phenolic board.

[0031] Preparation Example 4: For Preparation Example 4, the difference from Preparation Example 1 is only that an equal mass of boric acid is used to replace 4-vinylphenylboronic acid, specifically as follows: A phenolic board, comprising the following raw materials by weight parts: 100 parts of silicon-boron modified phenolic resin, 20 parts of ceramic fiber, 4 parts of toughening agent, 5 parts of foaming agent, 1 part of surfactant; Among them, the preparation method of the silicon-boron modified phenolic resin comprises the following steps: After uniformly mixing 30 g of cardanol, 10 g of formaldehyde solution (mass fraction 35%) and 5 g of boric acid, carry out a condensation reflux stirring reaction at 60 °C for 0.5 h. Subsequently, raise the temperature to 75 °C and carry out a condensation reflux stirring reaction for 1 h. Use a constant pressure funnel to dropwise add 2 g of organosiloxane (obtained by mixing γ-glycidoxypropyltrimethoxysilane and glycidoxypropylcyclotetrasiloxane in a mass ratio of 2:1), complete the dropping within 5 min, continue to raise the temperature to 90 °C, and carry out a condensation reflux stirring reaction for 3 h to obtain a silicon-boron modified phenolic resin; The toughening agent is polyvinyl alcohol; the foaming agent is cyclopentane; the surfactant is polyvinylpyrrolidone; A preparation method of a phenolic board, comprising the following steps:

[0032] Weigh the raw materials by weight parts, uniformly mix the silicon-boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent, and surfactant, carry out airtight curing, cure at 90 °C for 1 h, 120 °C for 1 h, 150 °C for 1 h, 180 °C for 1 h, and after the curing is completed, dry at 50 °C for 24 h to obtain a phenolic board.

[0033] Preparation Example 5: Preparation Example 5 is different from Preparation Example 1 only in that the organosiloxane is only γ-glycidoxypropyltrimethoxysilane, and the details are as follows: A phenolic board comprises the following raw materials in parts by weight: 100 parts of a silicon-boron modified phenolic resin, 20 parts of ceramic fiber, 4 parts of toughening agent, 5 parts of foaming agent, and 1 part of surfactant; Among them, the preparation method of the silicon-boron modified phenolic resin comprises the following steps: After mixing 30 g of cardanol, 10 g of formaldehyde solution (mass fraction 35%) and 5 g of 4-vinylphenylboronic acid evenly, carry out a condensation reflux stirring reaction at 60 °C for 0.5 h, then raise the temperature to 75 °C, carry out a condensation reflux stirring reaction for 1 h, use a constant pressure funnel to dropwise add 2 g of organosiloxane (γ-glycidoxypropyltrimethoxysilane), finish the dropping within 5 min, continue to raise the temperature to 90 °C, and carry out a condensation reflux stirring reaction for 3 h to obtain the silicon-boron modified phenolic resin; The toughening agent is polyvinyl alcohol; the foaming agent is cyclopentane; the surfactant is polyvinylpyrrolidone; A preparation method of a phenolic board comprises the following steps:

[0034] Weigh the raw materials according to parts by weight, uniformly mix the silicon-boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent, and surfactant, carry out closed curing, cure at 90 °C for 1 h, 120 °C for 1 h, 150 °C for 1 h, 180 °C for 1 h, and after the curing is completed, dry at 50 °C for 24 h to obtain the phenolic board.

[0035] Preparation Example 6: Preparation Example 6 is different from Preparation Example 1 only in that the organosiloxane is only glycidoxypropylcyclotetrasiloxane, and the details are as follows: A phenolic board comprises the following raw materials in parts by weight: 100 parts of a silicon-boron modified phenolic resin, 20 parts of ceramic fiber, 4 parts of toughening agent, 5 parts of foaming agent, and 1 part of surfactant; Among them, the preparation method of the silicon-boron modified phenolic resin comprises the following steps: After mixing 30 g of cardanol, 10 g of formaldehyde solution (mass fraction 35%) and 5 g of 4-vinylphenylboronic acid evenly, carry out a condensation reflux stirring reaction at 60 °C for 0.5 h, then raise the temperature to 75 °C, carry out a condensation reflux stirring reaction for 1 h, use a constant pressure funnel to dropwise add 2 g of organosiloxane (glycidoxypropylcyclotetrasiloxane), finish the dropping within 5 min, continue to raise the temperature to 90 °C, and carry out a condensation reflux stirring reaction for 3 h to obtain the silicon-boron modified phenolic resin; The toughening agent is polyvinyl alcohol; the foaming agent is cyclopentane; the surfactant is polyvinylpyrrolidone; A preparation method of a phenolic board comprises the following steps:

[0036] Weigh the raw materials by weight parts, uniformly mix the silicon-boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent and surfactant, and cure them in a closed state. Cure at 90 °C for 1 h, 120 °C for 1 h, 150 °C for 1 h, and 180 °C for 1 h. After curing, dry at 50 °C for 24 h to obtain a phenolic board.

[0037] Examples 1-6 provide an autoclaved aerated concrete composite thermal insulation wall panel and its manufacturing process.

[0038] Example 1:

[0039] An autoclaved aerated concrete composite thermal insulation wall panel has a three-layer composite structure, including autoclaved aerated concrete layers on both sides and a phenolic board (prepared from Preparation Example 1) disposed in the middle of the autoclaved aerated concrete layers on both sides; A manufacturing process of an autoclaved aerated concrete composite thermal insulation wall panel includes the following steps: First, load the phenolic board into an autoclave for pre-high-temperature steam curing, and cure at a temperature of 170 °C and a pressure of 1.1 MPa for 5 h; then fix the phenolic board in the middle of two steel wire mesh sheets (the area is larger than the area of the phenolic board). When pouring the autoclaved aerated concrete slurry, put the slurry into the mold and then implant the steel wire mesh sheet with the phenolic board into the mold. After pre-curing in a pre-curing room at a temperature of 40 °C for 2 h, cut and drill equally spaced holes on both sides of the board, with a spacing of 10 cm. Finally, enter the autoclave for autoclave curing, and cure at a temperature of 170 °C and a pressure of 1.4 MPa for 8 h to form an autoclaved aerated concrete composite thermal insulation wall panel with exhaust holes.

[0040] Example 2:

[0041] An autoclaved aerated concrete composite thermal insulation wall panel has a three-layer composite structure, including autoclaved aerated concrete layers on both sides and a phenolic board (prepared from Preparation Example 2) disposed in the middle of the autoclaved aerated concrete layers on both sides; A manufacturing process of an autoclaved aerated concrete composite thermal insulation wall panel includes the following steps: First, load the phenolic board into an autoclave for pre-high-temperature steam curing, and cure at a temperature of 180 °C and a pressure of 1.4 MPa for 8 h; then fix the phenolic board in the middle of two steel wire mesh sheets (the area is larger than the area of the phenolic board). When pouring the autoclaved aerated concrete slurry, put the slurry into the mold and then implant the steel wire mesh sheet with the phenolic board into the mold. After pre-curing in a pre-curing room at a temperature of 50 °C for 3 h, cut and drill equally spaced holes on both sides of the board, with a spacing of 20 cm. Finally, enter the autoclave for autoclave curing, and cure at a temperature of 180 °C and a pressure of 1.1 MPa for 7 h to form an autoclaved aerated concrete composite thermal insulation wall panel with exhaust holes.

[0042] Example 3:

[0043] An autoclaved aerated concrete composite thermal insulation wall panel, which has a three-layer composite structure and includes autoclaved aerated concrete layers on both sides and a phenolic board (prepared from Preparation Example 3) disposed in the middle of the autoclaved aerated concrete layers on both sides; A manufacturing process for an autoclaved aerated concrete composite thermal insulation wall panel, comprising the following steps: First, load the phenolic board into an autoclave for pre-high-temperature steam curing for 10 h under the conditions of a temperature of 200°C and a pressure of 1.5 MPa; then fix the phenolic board in the middle of two wire meshes (the area of which is larger than the area of the phenolic board). When pouring the autoclaved aerated concrete slurry, after putting the slurry into the mold, implant the wire mesh with the phenolic board into the mold. After pre-curing in a pre-curing room at a temperature of 60°C for 4 h, perform cutting and punch equally spaced holes on both sides of the board, with a spacing of 30 cm. Finally, enter the autoclave for autoclave curing for 6 h under the conditions of a temperature of 200°C and a pressure of 1.5 MPa to form an autoclaved aerated concrete composite thermal insulation wall panel with exhaust holes.

[0044] Example 4:

[0045] Example 4 is different from Example 1 only in that the phenolic board is prepared from Preparation Example 4, which is specifically as follows: An autoclaved aerated concrete composite thermal insulation wall panel, which has a three-layer composite structure and includes autoclaved aerated concrete layers on both sides and a phenolic board (prepared from Preparation Example 4) disposed in the middle of the autoclaved aerated concrete layers on both sides; A manufacturing process for an autoclaved aerated concrete composite thermal insulation wall panel, comprising the following steps: First, load the phenolic board into an autoclave for pre-high-temperature steam curing for 5 h under the conditions of a temperature of 170°C and a pressure of 1.1 MPa; then fix the phenolic board in the middle of two wire meshes (the area of which is larger than the area of the phenolic board). When pouring the autoclaved aerated concrete slurry, after putting the slurry into the mold, implant the wire mesh with the phenolic board into the mold. After pre-curing in a pre-curing room at a temperature of 40°C for 2 h, perform cutting and punch equally spaced holes on both sides of the board, with a spacing of 10 cm. Finally, enter the autoclave for autoclave curing for 8 h under the conditions of a temperature of 170°C and a pressure of 1.4 MPa to form an autoclaved aerated concrete composite thermal insulation wall panel with exhaust holes.

[0046] Example 5:

[0047] Example 5 is different from Example 1 only in that the phenolic board is prepared from Preparation Example 5, which is specifically as follows: An autoclaved aerated concrete composite thermal insulation wall panel, having a three-layer composite structure, includes autoclaved aerated concrete layers on both sides and a phenolic board (prepared by Preparation Example 5) disposed between the autoclaved aerated concrete layers on both sides; A manufacturing process of an autoclaved aerated concrete composite thermal insulation wall panel includes the following steps: First, load the phenolic board into an autoclave for pre-high-temperature steam curing, and cure it for 5 h under the conditions of a temperature of 170 °C and a pressure of 1.1 MPa; then fix the phenolic board in the middle of two steel mesh sheets (the area of which is larger than the area of the phenolic board), and when casting the autoclaved aerated concrete slurry, put the slurry into a mold and then implant the steel mesh sheet with the phenolic board into the mold. After pre-curing in a pre-curing room at a temperature of 40 °C for 2 h, perform cutting and punch equally spaced holes on both sides of the board, with a spacing of 10 cm. Finally, enter the autoclave for autoclave curing, and cure it for 8 h under the conditions of a temperature of 170 °C and a pressure of 1.4 MPa to form an autoclaved aerated concrete composite thermal insulation wall panel with exhaust holes.

[0048] Example 6:

[0049] The difference between Example 6 and Example 1 is only that the phenolic board is prepared by Preparation Example 6, and the details are as follows: An autoclaved aerated concrete composite thermal insulation wall panel, having a three-layer composite structure, includes autoclaved aerated concrete layers on both sides and a phenolic board (prepared by Preparation Example 6) disposed between the autoclaved aerated concrete layers on both sides; A manufacturing process of an autoclaved aerated concrete composite thermal insulation wall panel includes the following steps: First, load the phenolic board into an autoclave for pre-high-temperature steam curing, and cure it for 5 h under the conditions of a temperature of 170 °C and a pressure of 1.1 MPa; then fix the phenolic board in the middle of two steel mesh sheets (the area of which is larger than the area of the phenolic board), and when casting the autoclaved aerated concrete slurry, put the slurry into a mold and then implant the steel mesh sheet with the phenolic board into the mold. After pre-curing in a pre-curing room at a temperature of 40 °C for 2 h, perform cutting and punch equally spaced holes on both sides of the board, with a spacing of 10 cm. Finally, enter the autoclave for autoclave curing, and cure it for 8 h under the conditions of a temperature of 170 °C and a pressure of 1.4 MPa to form an autoclaved aerated concrete composite thermal insulation wall panel with exhaust holes.

[0050] Comparative Example 1: The difference between Comparative Example 1 and Example 1 is only that the phenolic board (commercially available from Langfang Zeke Chemical Building Materials Co., Ltd.) is as follows: An autoclaved aerated concrete composite thermal insulation wall panel, having a three-layer composite structure, includes autoclaved aerated concrete layers on both sides and a phenolic board disposed between the autoclaved aerated concrete layers on both sides; A manufacturing process for autoclaved aerated concrete composite thermal insulation wall panels, comprising the following steps: First, place the phenolic board into the autoclave for pre-high-temperature steam curing for 5 h under the conditions of a temperature of 170°C and a pressure of 1.1 MPa. Then, fix the phenolic board in the middle of two steel mesh sheets (the area of which is larger than that of the phenolic board). When pouring the autoclaved aerated concrete slurry, put the slurry into the mold and then implant the steel mesh sheet with the phenolic board into the mold. After pre-curing for 2 h in a pre-curing room at a temperature of 40°C, perform cutting and drill equally spaced holes on both sides of the board with a spacing of 10 cm. Finally, enter the autoclave for autoclave curing for 8 h under the conditions of a temperature of 170°C and a pressure of 1.4 MPa to form an autoclaved aerated concrete composite thermal insulation wall panel with exhaust holes.

[0051] Comparative Example 2: Comparative Example 2 is different from Example 1 only in that the phenolic board is not subjected to pre-high-temperature steam curing, specifically as follows: An autoclaved aerated concrete composite thermal insulation wall panel has a three-layer composite structure, including autoclaved aerated concrete layers on both sides and a phenolic board (prepared from Preparation Example 1) disposed in the middle of the autoclaved aerated concrete layers on both sides; A manufacturing process for autoclaved aerated concrete composite thermal insulation wall panels, comprising the following steps: First, fix the phenolic board in the middle of two steel mesh sheets (the area of which is larger than that of the phenolic board). When pouring the autoclaved aerated concrete slurry, put the slurry into the mold and then implant the steel mesh sheet with the phenolic board into the mold. After pre-curing for 2 h in a pre-curing room at a temperature of 40°C, perform cutting and drill equally spaced holes on both sides of the board with a spacing of 10 cm. Finally, enter the autoclave for autoclave curing for 8 h under the conditions of a temperature of 170°C and a pressure of 1.4 MPa to form an autoclaved aerated concrete composite thermal insulation wall panel with exhaust holes.

[0052] Comparative Example 3: Comparative Example 3 is different from Example 1 only in that the area of the selected steel mesh sheet is equal to the area of the phenolic board, specifically as follows: An autoclaved aerated concrete composite thermal insulation wall panel has a three-layer composite structure, including autoclaved aerated concrete layers on both sides and a phenolic board (prepared from Preparation Example 1) disposed in the middle of the autoclaved aerated concrete layers on both sides; A manufacturing process for autoclaved aerated concrete composite thermal insulation wall panels, comprising the following steps: First, load the phenolic aldehyde board into an autoclave for pre-high-temperature steam curing for 5 hours under the conditions of a temperature of 170°C and a pressure of 1.1 MPa. Then, fix the phenolic aldehyde board in the middle of two steel mesh sheets (the area is equal to the area of the phenolic aldehyde board). When pouring the autoclaved aerated concrete slurry, after putting the slurry into the mold, implant the steel mesh sheet with the phenolic aldehyde board into the mold. After pre-curing for 2 hours in a pre-curing room at a temperature of 40°C, cut it and make equally spaced holes on both sides of the board with a spacing of 10 cm. Finally, enter the autoclave for autoclave curing for 8 hours under the conditions of a temperature of 170°C and a pressure of 1.4 MPa to form an autoclaved aerated concrete composite thermal insulation wall board with exhaust holes.

[0053] According to GB / T 15762-2020 "Autoclaved Aerated Concrete Boards", test the performance of the autoclaved aerated concrete composite thermal insulation wall boards prepared in Examples 1-6 and Comparative Examples 1-3, and observe whether there are cracks on the board surface and whether the phenolic aldehyde board shrinks. The test results are shown in Table 1.

[0054] Table 1: 。

[0055] As shown in Table 1, the product quality of the autoclaved aerated concrete composite thermal insulation wall boards obtained in Examples 1-6 of the present invention is better than that of Comparative Examples 1-3, which fully shows that by preparing high-performance phenolic aldehyde boards, pre-high-temperature steam curing the phenolic aldehyde boards, and selecting steel mesh sheets with an area larger than that of the phenolic aldehyde board, the combination of the phenolic aldehyde board and autoclaved aerated concrete can be strengthened, avoiding the adverse phenomena of phenolic aldehyde board shrinkage and cracks on the board surface, increasing the qualified rate of wall board production, and having a broad market prospect.

[0056] Comparing Example 1 with Example 4 shows that using 4-vinylphenylboronic acid instead of boric acid is more conducive to the formation of the internal cross-linking network of the phenolic aldehyde board. Comparing Example 1 with Examples 5 and 6 shows that the organosiloxane is selected as a mixture of γ-glycidoxypropyltrimethoxysilane and glycidoxypropylcyclotetrasiloxane, and the two coordinate and synergistically enhance the cross-linking density of the phenolic aldehyde board. Therefore, combining Example 1 with Examples 4-6 can more prominently show that the special silicon-boron modified phenolic resin is used in the raw materials of the phenolic aldehyde board of the present invention, which is beneficial to improving the thermal stability of the phenolic aldehyde board and further improving the comprehensive mechanical properties of the wall board.

[0057] This specific embodiment is only an interpretation of the present invention, and it is not a limitation of the present invention. Those skilled in the art can make modifications without creative contributions to this embodiment according to needs after reading this specification, but as long as it is within the scope of the claims of the present invention, it is protected by the patent law.

Claims

1. An autoclaved aerated concrete composite thermal insulation wall panel, characterized in that, It has a three-layer composite structure, including autoclaved aerated concrete layers on both sides and a phenolic board arranged in the middle of the autoclaved aerated concrete layers on both sides; The phenolic board includes the following raw materials in parts by weight: 100-200 parts of silicon-boron modified phenolic resin, 20-40 parts of ceramic fiber, 4-8 parts of toughening agent, 5-12 parts of foaming agent, and 1-5 parts of surfactant.

2. The autoclaved aerated concrete composite thermal insulation wall panel according to claim 1, characterized in that, The preparation method of the silicon-boron modified phenolic resin includes the following steps: After uniformly mixing cardanol, formaldehyde solution and 4-vinylphenylboronic acid, carry out condensation reflux stirring reaction at 60-70 °C for 0.5-2 h, then raise the temperature to 75-88 °C, carry out condensation reflux stirring reaction for 1-3 h, use a constant pressure funnel to dropwise add organosiloxane, finish dropping within 5 min, continue to raise the temperature to 90-105 °C, carry out condensation reflux stirring reaction for 3-5 h to obtain silicon-boron modified phenolic resin.

3. The autoclaved aerated concrete composite thermal insulation wall panel according to claim 2, wherein, The mass ratio of cardanol, formaldehyde solution, 4-vinylphenylboronic acid, and organosiloxane is 30:(10-17):(5-10):(2-6); the mass fraction of the formaldehyde solution is 35%-38%.

4. The autoclaved aerated concrete composite thermal insulation wall panel according to claim 2, wherein The organosiloxane is obtained by mixing γ-glycidoxypropyltrimethoxysilane and glycidoxypropylcyclotetrasiloxane with a mass ratio of (2-4):

1.

5. The autoclaved aerated concrete composite thermal insulation wall panel according to claim 1, characterized in that, The toughening agent is one or more of polyvinyl alcohol, polyamide, and styrene-butadiene rubber; the foaming agent is one or more of cyclopentane, n-hexane, and petroleum ether; the surfactant is one or more of Tween, Span, and polyvinylpyrrolidone.

6. The autoclaved aerated concrete composite thermal insulation wall panel according to claim 1, wherein, The preparation method of the phenolic board includes the following steps: Uniformly mix the silicon-boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent, and surfactant, carry out airtight curing, cure at 90-100 °C for 1-2 h, 120-130 °C for 1-2 h, 150-160 °C for 1-2 h, 180-190 °C for 1-2 h, and after curing, dry at 50-60 °C for 24-28 h to obtain the phenolic board.

7. The manufacturing process of the autoclaved aerated concrete composite thermal insulation wallboard according to any one of claims 1-6, characterized in that, It includes the following steps: First, put the phenolic board into an autoclave for pre-high-temperature steam curing, then fix the phenolic board in the middle of the mesh with two steel mesh sheets. When pouring the autoclaved aerated concrete slurry, put the slurry into the mold and then implant the steel mesh sheet with the phenolic board into the mold. After pre-curing, carry out cutting and drill holes on both sides of the board, and finally enter the autoclave for autoclave curing to form an autoclaved aerated concrete composite thermal insulation wall panel with exhaust holes.

8. The manufacturing process of the autoclaved aerated concrete composite thermal insulation wall panel according to claim 7, characterized in that, The conditions for pre-high-temperature steam curing of the phenolic board are: temperature 170-200 °C, air pressure 1.1-1.5 MPa, and time 5-10 h.

9. The manufacturing process of the autoclaved aerated concrete composite thermal insulation wall panel according to claim 7, characterized in that, The pre-curing temperature is 40-60 °C and the time is 2-4 h; the temperature of autoclave curing is 170-200 °C, the air pressure is 1.1-1.5 MPa, and the time is 6-8 h.

10. The manufacturing process of the autoclaved aerated concrete composite thermal insulation wall panel according to claim 7, characterized in that, The holes on both sides of the board are equally spaced, and the spacing is 10-30 cm; the area of the steel mesh sheet is larger than the area of the phenolic board.

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