Autoclaved aerated concrete composite thermal insulation wallboard and its manufacturing process

Abstract

The present invention belongs to the technical field of prefabricated concrete parts and relates to an autoclaved aerated concrete composite insulation wall panel and its manufacturing process. The autoclaved aerated concrete composite insulation wall panel of the present invention has a three-layer composite structure, comprising autoclaved aerated concrete layers on both sides and a phenolic board arranged between the autoclaved aerated concrete layers on both sides; its manufacturing process is to pre-heat the phenolic board in an autoclave, then fix the phenolic board with a steel mesh obliquely inserted (the area of ​​the steel mesh is larger than that of the phenolic board) and sink it into a mold filled with slurry for pre-curing. After the composite insulation wall panel is initially formed, it is cut, holes are punched on both sides of the board, and then it is put into an autoclave for autoclaving and curing to form an autoclaved aerated concrete composite wall panel with exhaust holes. This manufacturing process effectively prevents the phenolic board from separating from the autoclaved aerated concrete layer, and the occurrence of cracks at the junction of the autoclaved aerated concrete and the phenolic board, thereby improving the qualified rate of the wall panel and the service life of the wall panel, and has broad market prospects.

Description

Technical Field

[0001] The present invention relates to the technical field of prefabricated concrete parts, and more particularly to an autoclaved aerated concrete composite thermal insulation wallboard and a manufacturing process thereof. Background Art

[0002] Autoclaved aerated concrete composite insulation wall panels are widely used in building wall materials due to their lightweight, thermal insulation, and soundproofing properties. By combining autoclaved aerated concrete with a core material, these panels achieve integrated building insulation, meeting the demands of today's carbon-neutral, low-carbon, and green buildings.

[0003] However, the phenolic board core material is prone to shrinkage and release gas during the high-temperature steam curing process of the wall panel, resulting in gaps between the autoclaved aerated concrete and the core material and cracks at the junction of the autoclaved aerated concrete and the phenolic board core material.

[0004] At present, as disclosed in Chinese patent document CN202227501U, an autoclaved aerated composite insulation board is a composite board consisting of an outer layer, an inner layer, and an adhesive material layer bonding the outer layer and the inner layer together. The outer layer is an autoclaved aerated concrete board with a low-density, non-reinforced mesh built in, and the inner layer is a thermal insulation material. The specifications and dimensions of the autoclaved aerated concrete board are 600*1000*(70-90) mm, the specifications and dimensions of the thermal insulation material are 600*1000*10 mm, and the thickness of the autoclaved aerated concrete board is between 80-100 mm. This solution reduces the bulk density and the heat transfer efficiency, and meets the needs of using a single material to attach beams, columns, and shear walls in production applications to provide insulation and fire protection. The autoclaved aerated composite insulation board is mainly used to solve the insulation problem of beams, columns and shear walls. Even if the outer layer and the inner layer are bonded by an adhesive material layer, it is still impossible to effectively prevent the inner layer insulation core material from shrinking, deforming and cracking during the high-temperature steaming process of the board.

[0005] Based on the above statements, the present invention provides an autoclaved aerated concrete composite thermal insulation wall panel and a manufacturing process thereof. Summary of the Invention

[0006] In order to solve the problem of shrinkage, deformation and cracking of the phenolic board core material in the existing composite insulation wallboard during the high-temperature steam curing process of the board, the present invention provides an autoclaved aerated concrete composite insulation wallboard and a manufacturing process thereof.

[0007] In a first aspect, the present invention provides an autoclaved aerated concrete composite insulation wall panel, which adopts the following technical solution:

[0008] An autoclaved aerated concrete composite thermal insulation wallboard, having a three-layer composite structure, comprising autoclaved aerated concrete layers on both sides and a phenolic board arranged between the autoclaved aerated concrete layers on both sides;

[0009] The phenolic board comprises 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.

[0010] Preferably, the preparation method of the silicon-boron modified phenolic resin comprises the following steps:

[0011] After uniformly mixing cardanol, formaldehyde solution and 4-vinylphenylboronic acid, the mixture was stirred at 60-70°C for 0.5-2h under condensation reflux, and then heated to 75-88°C, stirred at condensation reflux for 1-3h, and the organosiloxane was added dropwise using a constant pressure funnel within 5 minutes. The mixture was then heated to 90-105°C, stirred at condensation reflux for 3-5h to obtain a silicon-boron modified phenolic resin.

[0012] Preferably, the mass ratio of the cardanol, formaldehyde solution, 4-vinylphenylboronic acid, and organosiloxane is 30:(10-17):(5-10):(2-6); and the mass fraction of the formaldehyde solution is 35%-38%.

[0013] Preferably, the organosiloxane is obtained by mixing γ-glycidyloxypropyltrimethoxysilane and glycidyloxypropylcyclotetrasiloxane in a mass ratio of (2-4):1.

[0014] Preferably, the toughening agent is one or more of polyvinyl alcohol, polyamide, and styrene-butadiene rubber.

[0015] Preferably, the foaming agent is one or more of cyclopentane, n-hexane, and petroleum ether.

[0016] Preferably, the surfactant is one or more of Tween, Span, and polyvinyl pyrrolidone.

[0017] Preferably, the method for preparing the phenolic board comprises the following steps:

[0018] The silicon boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent and surfactant are uniformly mixed and sealed for curing at 90-100°C for 1-2h, 120-130°C for 1-2h, 150-160°C for 1-2h and 180-190°C for 1-2h. After curing, the phenolic board is dried at 50-60°C for 24-28h to obtain the phenolic board.

[0019] In a second aspect, the present invention provides a process for manufacturing an autoclaved aerated concrete composite thermal insulation wall panel, which adopts the following technical solution:

[0020] A process for producing an autoclaved aerated concrete composite thermal insulation wallboard comprises the following steps:

[0021] First, the phenolic board is placed in an autoclave for pre-high-temperature steam curing, and then two steel meshes are used to fix the phenolic board in the middle of the mesh. When pouring autoclaved aerated concrete slurry, the slurry is put into the mold and then the steel mesh with the phenolic board is implanted into the mold. After pre-curing, it is cut and holes are punched on both sides of the board. Finally, it is placed in the autoclave for autoclaving curing to form an autoclaved aerated concrete composite insulation wall panel with exhaust holes.

[0022] Preferably, the phenolic board is pre-cured at high temperature under the following conditions: temperature of 170-200° C., air pressure of 1.1-1.5 MPa, and time of 5-10 h.

[0023] Preferably, the pre-curing temperature is 40-60° C. and the time is 2-4 h; the autoclave curing temperature is 170-200° C., the air pressure is 1.1-1.5 MPa, and the time is 6-8 h.

[0024] Preferably, the holes on both sides of the plate are spaced equally apart, with a spacing of 10-30 cm; and the area of ​​the steel mesh is larger than that of the phenolic board.

[0025] The present invention has positive and beneficial effects:

[0026] (1) The autoclaved aerated concrete composite insulation wallboard of the present invention has a three-layer composite structure, wherein the raw materials of the phenolic board include silicon boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent, and surfactant, and the components interact 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-vinylphenylboric acid, and organosiloxane, and the double cross-linked network of organosiloxane and borate improves the thermal stability of the phenolic board, making the phenolic board less likely to deform during the autoclaving process, effectively improving the defect of the phenolic board that is easy to shrink and deform during high-temperature steam curing in the board, thereby greatly reducing the occurrence of board cracking; at the same time, the rigidity and toughness of the phenolic board are also significantly improved, so that the compressive and flexural strengths of the phenolic board are improved, and the bearing capacity of the wallboard after being composited with autoclaved aerated concrete is better.

[0027] (2) The present invention uses γ-glycidyloxypropyltrimethoxysilane and glycidyloxypropylcyclotetrasiloxane to synergistically enhance the phenolic board, 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 interface performance of the phenolic board. The phenolic board that has been steamed at high temperature has high interface molecular activity. When compounded with autoclaved aerated concrete, the interface bonding force is effectively enhanced, which greatly reduces the phenomenon of cracks on the wall caused by poor interface bonding.

[0028] (3) In the process of manufacturing the autoclaved aerated concrete composite insulation wallboard, the phenolic board is pre-cured at high temperature to release the internal gas, causing the board to shrink. This avoids the gas generated when the phenolic board is directly used in the autoclaved aerated concrete board to be steam-cured, causing the wallboard to crack along the edge of the phenolic board. It also avoids the phenolic board from deforming inside the steam aerated concrete and forming gaps. The exhaust holes on the insulation wallboard further prevent the expansion of residual gas and cracking of the concrete interface. In addition, the size of the steel mesh exceeds the outer edge of the phenolic board. The anchoring effect of the mesh and the concrete is used to improve the interface bonding performance between the phenolic board and the concrete, effectively preventing edge cracks caused by stress concentration during the steam curing process. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 This is a display diagram of the autoclaved aerated concrete composite thermal insulation wallboard prepared in Example 1. DETAILED DESCRIPTION

[0030] In order to more clearly illustrate the overall concept of the present invention, the overall scheme of the present invention is described in detail below in the form of embodiments; 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 technical features known in the art are not described.

[0031] Unless otherwise specified, all raw material components in the following examples can be purchased from commercial sources, the experimental instruments used are conventional laboratory instruments, and the performance testing methods are known in the art.

[0032] Preparation Example 1-6 provides a phenolic board and a preparation method thereof.

[0033] Preparation Example 1:

[0034] A phenolic board comprises 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, and 1 part of surfactant;

[0035] The preparation method of silicon-boron modified phenolic resin comprises the following steps:

[0036] 30 g of cardanol, 10 g of formaldehyde solution (mass fraction 35%) and 5 g of 4-vinylphenylboronic acid were uniformly mixed, and the mixture was stirred and reacted at 60°C under condensation reflux for 0.5 h. The mixture was then heated to 75°C and stirred and reacted under condensation reflux for 1 h. 2 g of organosiloxane (prepared by mixing γ-glycidyloxypropyltrimethoxysilane and glycidyloxypropylcyclotetrasiloxane in a mass ratio of 2:1) was added dropwise using a constant pressure funnel. The addition was completed within 5 min, and the mixture was heated to 90°C and stirred and reacted under condensation reflux for 3 h to obtain a boron-silicon-modified phenolic resin.

[0037] The toughening agent is polyvinyl alcohol; the foaming agent is cyclopentane; the surfactant is polyvinyl pyrrolidone;

[0038] A method for preparing a phenolic board comprises the following steps:

[0039] The raw materials were weighed by weight, and the silicon boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent and surfactant were uniformly mixed, and cured in a sealed manner at 90°C for 1 hour, 120°C for 1 hour, 150°C for 1 hour, and 180°C for 1 hour. After the curing was completed, the phenolic board was dried at 50°C for 24 hours to obtain the phenolic board.

[0040] Preparation Example 2:

[0041] A phenolic board comprises the following raw materials in parts 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, and 2.5 parts of surfactant;

[0042] The preparation method of silicon-boron modified phenolic resin comprises the following steps:

[0043] 30 g of cardanol, 14 g of formaldehyde solution (mass fraction 37%) and 8 g of 4-vinylphenylboronic acid were uniformly mixed, and the mixture was stirred under condensation reflux at 65°C for 1.5 h. The mixture was then heated to 80°C and stirred under condensation reflux for 2 h. 4 g of organosiloxane (prepared by mixing γ-glycidyloxypropyltrimethoxysilane and glycidyloxypropylcyclotetrasiloxane in a mass ratio of 3:1) was added dropwise using a constant pressure funnel. The addition was completed within 5 min, and the mixture was heated to 100°C and stirred under condensation reflux for 4 h to obtain a boron-silicon-modified phenolic resin.

[0044] The toughening agent is polyvinyl alcohol; the foaming agent is n-hexane; the surfactant is Tween;

[0045] A method for preparing a phenolic board comprises the following steps:

[0046] The raw materials were weighed by weight, and the silicon boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent and surfactant were uniformly mixed, and cured in a sealed manner at 95°C for 1.5h, 125°C for 1.5h, 155°C for 1.5h, and 185°C for 1.5h. After curing, the phenolic board was dried at 55°C for 26h to obtain the phenolic board.

[0047] Preparation Example 3:

[0048] A phenolic board comprises the following raw materials in parts 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, and 5 parts of surfactant;

[0049] The preparation method of silicon-boron modified phenolic resin comprises the following steps:

[0050] 30 g of cardanol, 17 g of formaldehyde solution (mass fraction 38%) and 10 g of 4-vinylphenylboronic acid were uniformly mixed, and the mixture was stirred and refluxed at 70°C for 2 h. The mixture was then heated to 88°C and stirred and refluxed for 3 h. 6 g of organosiloxane (prepared by mixing γ-glycidyloxypropyltrimethoxysilane and glycidyloxypropylcyclotetrasiloxane in a mass ratio of 4:1) was added dropwise using a constant pressure funnel. The addition was completed within 5 min, and the mixture was heated to 105°C and stirred and refluxed for 5 h to obtain a silicon-boron modified phenolic resin.

[0051] The toughening agent is styrene-butadiene rubber; the foaming agent is petroleum ether; the surfactant is Span;

[0052] A method for preparing a phenolic board comprises the following steps:

[0053] The raw materials were weighed by weight, and the silicon boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent and surfactant were uniformly mixed, and cured in a sealed manner at 100°C for 2h, 130°C for 2h, 160°C for 2h, and 190°C for 2h. After the curing was completed, the phenolic board was dried at 60°C for 28h to obtain the phenolic board.

[0054] Preparation Example 4:

[0055] Preparation Example 4 is the same as Preparation Example 1 except that an equal amount of boric acid is used to replace 4-vinylphenylboronic acid, as follows:

[0056] A phenolic board comprises 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, and 1 part of surfactant;

[0057] The preparation method of silicon-boron modified phenolic resin comprises the following steps:

[0058] 30 g of cardanol, 10 g of formaldehyde solution (mass fraction 35%) and 5 g of boric acid were uniformly mixed, and the mixture was stirred and reacted at 60°C under condensation reflux for 0.5 h. The mixture was then heated to 75°C and stirred and reacted under condensation reflux for 1 h. 2 g of organosiloxane (prepared by mixing γ-glycidyloxypropyltrimethoxysilane and glycidyloxypropylcyclotetrasiloxane in a mass ratio of 2:1) was added dropwise using a constant pressure funnel. The addition was completed within 5 min, and the mixture was heated to 90°C and stirred and reacted under condensation reflux for 3 h to obtain a silicon-boron modified phenolic resin.

[0059] The toughening agent is polyvinyl alcohol; the foaming agent is cyclopentane; the surfactant is polyvinyl pyrrolidone;

[0060] A method for preparing a phenolic board comprises the following steps:

[0061] The raw materials were weighed by weight, and the silicon boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent and surfactant were uniformly mixed, and cured in a sealed manner at 90°C for 1 hour, 120°C for 1 hour, 150°C for 1 hour, and 180°C for 1 hour. After the curing was completed, the phenolic board was dried at 50°C for 24 hours to obtain the phenolic board.

[0062] Preparation Example 5:

[0063] Preparation Example 5 is different from Preparation Example 1 only in that only γ-glycidyloxypropyltrimethoxysilane is used as the organosiloxane, specifically as follows:

[0064] A phenolic board comprises 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, and 1 part of surfactant;

[0065] The preparation method of silicon-boron modified phenolic resin comprises the following steps:

[0066] 30 g of cardanol, 10 g of formaldehyde solution (mass fraction 35%) and 5 g of 4-vinylphenylboronic acid were mixed uniformly, and the mixture was stirred and refluxed at 60°C for 0.5 h. The mixture was then heated to 75°C and stirred and refluxed for 1 h. 2 g of organosiloxane (γ-glycidyloxypropyltrimethoxysilane) was added dropwise using a constant pressure funnel within 5 min. The mixture was then heated to 90°C and stirred and refluxed for 3 h to obtain a boron-silicon-modified phenolic resin.

[0067] The toughening agent is polyvinyl alcohol; the foaming agent is cyclopentane; the surfactant is polyvinyl pyrrolidone;

[0068] A method for preparing a phenolic board comprises the following steps:

[0069] The raw materials were weighed by weight, and the silicon boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent and surfactant were uniformly mixed, and cured in a sealed manner at 90°C for 1 hour, 120°C for 1 hour, 150°C for 1 hour, and 180°C for 1 hour. After the curing was completed, the phenolic board was dried at 50°C for 24 hours to obtain the phenolic board.

[0070] Preparation Example 6:

[0071] Preparation Example 6 is different from Preparation Example 1 only in that only glycidyloxypropylcyclotetrasiloxane is used as the organosiloxane, specifically as follows:

[0072] A phenolic board comprises 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, and 1 part of surfactant;

[0073] The preparation method of silicon-boron modified phenolic resin comprises the following steps:

[0074] 30 g of cardanol, 10 g of formaldehyde solution (mass fraction 35%) and 5 g of 4-vinylphenylboronic acid were mixed uniformly, and the mixture was stirred and reacted at 60°C under condensation reflux for 0.5 h. The mixture was then heated to 75°C and stirred and reacted under condensation reflux for 1 h. 2 g of organosiloxane (glycidyloxypropylcyclotetrasiloxane) was added dropwise using a constant pressure funnel within 5 min. The mixture was then heated to 90°C and stirred and reacted under condensation reflux for 3 h to obtain a boron-silicon-modified phenolic resin.

[0075] The toughening agent is polyvinyl alcohol; the foaming agent is cyclopentane; the surfactant is polyvinyl pyrrolidone;

[0076] A method for preparing a phenolic board comprises the following steps:

[0077] The raw materials were weighed by weight, and the silicon boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent and surfactant were uniformly mixed, and cured in a sealed manner at 90°C for 1 hour, 120°C for 1 hour, 150°C for 1 hour, and 180°C for 1 hour. After the curing was completed, the phenolic board was dried at 50°C for 24 hours to obtain the phenolic board.

[0078] Examples 1-6 provide an autoclaved aerated concrete composite thermal insulation wallboard and a manufacturing process thereof.

[0079] Example 1:

[0080] An autoclaved aerated concrete composite insulation wallboard having a three-layer composite structure, comprising autoclaved aerated concrete layers on both sides and a phenolic board (prepared in Preparation Example 1) disposed between the autoclaved aerated concrete layers on both sides;

[0081] A process for producing an autoclaved aerated concrete composite thermal insulation wallboard comprises the following steps:

[0082] First, the phenolic board is placed in an autoclave for pre-high-temperature steam curing at a temperature of 170°C and an air pressure of 1.1MPa for 5 hours; then, two steel meshes (with an area larger than that of the phenolic board) are used to fix the phenolic board in the middle of the meshes. When pouring autoclaved aerated concrete slurry, the slurry is put into the mold and then the steel mesh with the phenolic board is implanted into the mold. After pre-curing in a pre-curing room at a temperature of 40°C for 2 hours, it is cut and holes are punched on both sides of the board at equal intervals of 10cm. Finally, it is placed in an autoclave for autoclave curing at a temperature of 170°C and an air pressure of 1.4MPa for 8 hours to form an autoclaved aerated concrete composite insulation wall panel with exhaust holes.

[0083] Example 2:

[0084] An autoclaved aerated concrete composite insulation wallboard having a three-layer composite structure, comprising autoclaved aerated concrete layers on both sides and a phenolic board (prepared in Preparation Example 2) disposed between the autoclaved aerated concrete layers on both sides;

[0085] A process for producing an autoclaved aerated concrete composite thermal insulation wallboard comprises the following steps:

[0086] First, the phenolic board is placed in an autoclave for pre-high-temperature steam curing, and steam-cured for 8 hours at a temperature of 180°C and an air pressure of 1.4MPa; then, two steel meshes (with an area larger than that of the phenolic board) are used to fix the phenolic board in the middle of the meshes. When pouring autoclaved aerated concrete slurry, the slurry is put into the mold and then the steel mesh with the phenolic board is implanted into the mold. After pre-curing for 3 hours in a pre-curing room at a temperature of 50°C, it is cut and holes are punched on both sides of the board at equal intervals of 20cm. Finally, it is placed in an autoclave for autoclave curing, and autoclaved and cured for 7 hours at a temperature of 180°C and an air pressure of 1.1MPa to form an autoclaved aerated concrete composite insulation wall panel with exhaust holes.

[0087] Example 3:

[0088] An autoclaved aerated concrete composite insulation wallboard having a three-layer composite structure, comprising autoclaved aerated concrete layers on both sides and a phenolic board (prepared in Preparation Example 3) disposed between the autoclaved aerated concrete layers on both sides;

[0089] A process for producing an autoclaved aerated concrete composite thermal insulation wallboard comprises the following steps:

[0090] First, the phenolic board is placed in an autoclave for pre-high-temperature steam curing, and is steam-cured for 10 hours at a temperature of 200°C and a pressure of 1.5MPa; then, two steel meshes (with an area larger than that of the phenolic board) are used to fix the phenolic board in the middle of the meshes. When pouring autoclaved aerated concrete slurry, the slurry is put into the mold and then the steel mesh with the phenolic board is implanted into the mold. After pre-curing for 4 hours in a pre-curing room at a temperature of 60°C, it is cut and holes are punched on both sides of the board at equal intervals of 30cm. Finally, it is placed in an autoclave for autoclave curing, and is autoclaved and cured for 6 hours at a temperature of 200°C and an air pressure of 1.5MPa to form an autoclaved aerated concrete composite insulation wall panel with exhaust holes.

[0091] Example 4:

[0092] Example 4 is different from Example 1 only in that the phenolic board is prepared by Preparation Example 4, specifically as follows:

[0093] An autoclaved aerated concrete composite insulation wallboard having a three-layer composite structure, comprising autoclaved aerated concrete layers on both sides and a phenolic board (prepared in Preparation Example 4) disposed between the autoclaved aerated concrete layers on both sides;

[0094] A process for producing an autoclaved aerated concrete composite thermal insulation wallboard comprises the following steps:

[0095] First, the phenolic board is placed in an autoclave for pre-high-temperature steam curing at a temperature of 170°C and an air pressure of 1.1MPa for 5 hours; then, two steel meshes (with an area larger than that of the phenolic board) are used to fix the phenolic board in the middle of the meshes. When pouring autoclaved aerated concrete slurry, the slurry is put into the mold and then the steel mesh with the phenolic board is implanted into the mold. After pre-curing in a pre-curing room at a temperature of 40°C for 2 hours, it is cut and holes are punched on both sides of the board at equal intervals of 10cm. Finally, it is placed in an autoclave for autoclave curing at a temperature of 170°C and an air pressure of 1.4MPa for 8 hours to form an autoclaved aerated concrete composite insulation wall panel with exhaust holes.

[0096] Example 5:

[0097] Example 5 is different from Example 1 only in that the phenolic board is prepared according to Preparation Example 5, specifically as follows:

[0098] An autoclaved aerated concrete composite insulation wallboard having a three-layer composite structure, comprising autoclaved aerated concrete layers on both sides and a phenolic board (prepared in Preparation Example 5) disposed between the autoclaved aerated concrete layers on both sides;

[0099] A process for producing an autoclaved aerated concrete composite thermal insulation wallboard comprises the following steps:

[0100] First, the phenolic board is placed in an autoclave for pre-high-temperature steam curing at a temperature of 170°C and an air pressure of 1.1MPa for 5 hours; then, two steel meshes (with an area larger than that of the phenolic board) are used to fix the phenolic board in the middle of the meshes. When pouring autoclaved aerated concrete slurry, the slurry is put into the mold and then the steel mesh with the phenolic board is implanted into the mold. After pre-curing in a pre-curing room at a temperature of 40°C for 2 hours, it is cut and holes are punched on both sides of the board at equal intervals of 10cm. Finally, it is placed in an autoclave for autoclave curing at a temperature of 170°C and an air pressure of 1.4MPa for 8 hours to form an autoclaved aerated concrete composite insulation wall panel with exhaust holes.

[0101] Example 6:

[0102] Example 6 is different from Example 1 only in that the phenolic board is prepared according to Preparation Example 6, specifically as follows:

[0103] An autoclaved aerated concrete composite insulation wallboard having a three-layer composite structure, comprising autoclaved aerated concrete layers on both sides and a phenolic board (prepared in Preparation Example 6) disposed between the autoclaved aerated concrete layers on both sides;

[0104] A process for producing an autoclaved aerated concrete composite thermal insulation wallboard comprises the following steps:

[0105] First, the phenolic board is placed in an autoclave for pre-high-temperature steam curing at a temperature of 170°C and an air pressure of 1.1MPa for 5 hours; then, two steel meshes (with an area larger than that of the phenolic board) are used to fix the phenolic board in the middle of the meshes. When pouring autoclaved aerated concrete slurry, the slurry is put into the mold and then the steel mesh with the phenolic board is implanted into the mold. After pre-curing in a pre-curing room at a temperature of 40°C for 2 hours, it is cut and holes are punched on both sides of the board at equal intervals of 10cm. Finally, it is placed in an autoclave for autoclave curing at a temperature of 170°C and an air pressure of 1.4MPa for 8 hours to form an autoclaved aerated concrete composite insulation wall panel with exhaust holes.

[0106] Comparative Example 1:

[0107] Comparative Example 1 is different from Example 1 only in that the phenolic board (commercially available, Langfang Zeke Chemical Building Materials Co., Ltd.) is used as follows:

[0108] An autoclaved aerated concrete composite thermal insulation wallboard, having a three-layer composite structure, comprising autoclaved aerated concrete layers on both sides and a phenolic board arranged between the autoclaved aerated concrete layers on both sides;

[0109] A process for producing an autoclaved aerated concrete composite thermal insulation wallboard comprises the following steps:

[0110] First, the phenolic board is placed in an autoclave for pre-high-temperature steam curing at a temperature of 170°C and an air pressure of 1.1MPa for 5 hours; then, two steel meshes (with an area larger than that of the phenolic board) are used to fix the phenolic board in the middle of the meshes. When pouring autoclaved aerated concrete slurry, the slurry is put into the mold and then the steel mesh with the phenolic board is implanted into the mold. After pre-curing in a pre-curing room at a temperature of 40°C for 2 hours, it is cut and holes are punched on both sides of the board at equal intervals of 10cm. Finally, it is placed in an autoclave for autoclave curing at a temperature of 170°C and an air pressure of 1.4MPa for 8 hours to form an autoclaved aerated concrete composite insulation wall panel with exhaust holes.

[0111] Comparative Example 2:

[0112] Comparative Example 2 is different from Example 1 only in that the phenolic board is not pre-cured at high temperature, specifically as follows:

[0113] An autoclaved aerated concrete composite insulation wallboard having a three-layer composite structure, comprising autoclaved aerated concrete layers on both sides and a phenolic board (prepared in Preparation Example 1) disposed between the autoclaved aerated concrete layers on both sides;

[0114] A process for producing an autoclaved aerated concrete composite thermal insulation wallboard comprises the following steps:

[0115] First, use two steel meshes (the area is larger than that of the phenolic board) to fix the phenolic board in the middle of the mesh. When pouring autoclaved aerated concrete slurry, put the slurry into the mold and then implant the steel mesh with the phenolic board into the mold. After pre-curing for 2 hours in a pre-curing room at a temperature of 40°C, cut and punch holes at equal intervals of 10 cm on both sides of the board. Finally, put it into the autoclave for autoclaving and curing. Under the conditions of temperature of 170°C and air pressure of 1.4MPa, autoclave curing is carried out for 8 hours to form an autoclaved aerated concrete composite insulation wall panel with exhaust holes.

[0116] Comparative Example 3:

[0117] Comparative Example 3 is different from Example 1 only in that the area of ​​the steel mesh selected is equal to the area of ​​the phenolic board, as follows:

[0118] An autoclaved aerated concrete composite insulation wallboard having a three-layer composite structure, comprising autoclaved aerated concrete layers on both sides and a phenolic board (prepared in Preparation Example 1) disposed between the autoclaved aerated concrete layers on both sides;

[0119] A process for producing an autoclaved aerated concrete composite thermal insulation wallboard comprises the following steps:

[0120] First, the phenolic board is placed in an autoclave for pre-high-temperature steam curing at a temperature of 170°C and an air pressure of 1.1MPa for 5 hours; then, two steel meshes (area equal to the area of ​​the phenolic board) are used to fix the phenolic board in the middle of the meshes. When pouring autoclaved aerated concrete slurry, the slurry is put into the mold and then the steel mesh with the phenolic board is implanted into the mold. After pre-curing in a pre-curing room at a temperature of 40°C for 2 hours, it is cut and holes are punched on both sides of the board at equal intervals of 10cm. Finally, it is placed in an autoclave for autoclave curing at a temperature of 170°C and an air pressure of 1.4MPa for 8 hours to form an autoclaved aerated concrete composite insulation wall panel with exhaust holes.

[0121] According to GB / T 15762-2020 "Autoclaved Aerated Concrete Board", the performance of the autoclaved aerated concrete composite insulation wall panels prepared in Examples 1-6 and Comparative Examples 1-3 was tested, and the board surface was observed to see whether there were cracks and whether the phenolic board shrank. The test results are shown in Table 1.

[0122] Table 1:

[0123] .

[0124] As shown in Table 1, the product quality of the autoclaved aerated concrete composite thermal insulation wallboards obtained in Examples 1-6 of the present invention is superior to that of Comparative Examples 1-3. This fully demonstrates that by preparing high-performance phenolic boards, pre-curing the phenolic boards at high temperatures, and selecting a steel mesh with an area larger than that of the phenolic boards, the bonding between the phenolic boards and the autoclaved aerated concrete can be strengthened, the undesirable phenomena of shrinkage of the phenolic boards and cracks on the board surfaces can be avoided, the qualified rate of wallboard production can be increased, and the present invention has broad market prospects.

[0125] Compared with Example 4, Example 1 illustrates that the use of 4-vinylbenzeneboric acid is more conducive to the formation of the internal cross-linked network of the phenolic board than boric acid; compared with Examples 5 and 6, Example 1 illustrates that the organic siloxane is a mixture of γ-glycidyloxypropyltrimethoxysilane and glycidyloxypropylcyclotetrasiloxane, and the two coordinate and enhance the synergy, further improving the cross-linking density of the phenolic board; thus, combining Example 1 with Examples 4-6, it can be more highlighted that the use of a special silicon-boron modified phenolic resin in the raw materials of the phenolic board of the present invention is beneficial to improving the thermal stability of the phenolic board, thereby improving the comprehensive mechanical properties of the wallboard.

[0126] This specific embodiment is merely an explanation of the present invention and is not intended to limit the present invention. After reading this specification, those skilled in the art may make non-creative modifications to this embodiment as needed. However, as long as such modifications are within the scope of the claims of the present invention, they are protected by patent law.

Claims

1. An autoclaved aerated concrete composite thermal insulation wallboard, characterized in that: It has a three-layer composite structure, including autoclaved aerated concrete layers on both sides and a phenolic board arranged between the autoclaved aerated concrete layers on both sides; The phenolic board comprises 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; The preparation method of the silicon-boron modified phenolic resin comprises the following steps: After the cardanol, formaldehyde solution and 4-vinylphenylboronic acid are uniformly mixed, the mixture is stirred under condensation reflux at 60-70°C for 0.5-2h, then the temperature is raised to 75-88°C, the mixture is stirred under condensation reflux for 1-3h, and the organosiloxane is added dropwise using a constant pressure funnel within 5 minutes. The temperature is further raised to 90-105°C, the mixture is stirred under condensation reflux for 3-5h to obtain a silicon-boron modified phenolic resin; The organosiloxane is obtained by mixing γ-glycidyloxypropyltrimethoxysilane and glycidyloxypropylcyclotetrasiloxane in a mass ratio of (2-4):

1.

2. The autoclaved aerated concrete composite thermal insulation wallboard according to claim 1, characterized in that: The mass ratio of the 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%.

3. The autoclaved aerated concrete composite thermal insulation wallboard 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; and the surfactant is one or more of Tween, Span, and polyvinyl pyrrolidone.

4. The autoclaved aerated concrete composite thermal insulation wallboard according to claim 1, characterized in that: The preparation method of the phenolic board comprises the following steps: The silicon boron modified phenolic resin, ceramic fiber, toughening agent, foaming agent and surfactant are uniformly mixed and sealed for curing at 90-100°C for 1-2h, 120-130°C for 1-2h, 150-160°C for 1-2h and 180-190°C for 1-2h. After curing, the phenolic board is dried at 50-60°C for 24-28h to obtain the phenolic board.

5. A process for producing the autoclaved aerated concrete composite thermal insulation wallboard according to any one of claims 1 to 4, characterized in that: The following steps are involved: First, the phenolic board is placed in an autoclave for pre-high-temperature steam curing, and then two steel meshes are used to fix the phenolic board in the middle of the mesh. When pouring autoclaved aerated concrete slurry, the slurry is put into the mold and then the steel mesh with the phenolic board is implanted into the mold. After pre-curing, it is cut and holes are punched on both sides of the board. Finally, it is placed in the autoclave for autoclaving curing to form an autoclaved aerated concrete composite insulation wall panel with exhaust holes.

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

7. The process for producing the autoclaved aerated concrete composite thermal insulation wallboard according to claim 5, characterized in that: The pre-curing temperature is 40-60° C. and the time is 2-4 hours; the autoclave curing temperature is 170-200° C., the air pressure is 1.1-1.5 MPa, and the time is 6-8 hours.

8. The process for producing the autoclaved aerated concrete composite thermal insulation wallboard according to claim 6, characterized in that: The holes on both sides of the plate are spaced equally apart, with a spacing of 10-30 cm; the area of ​​the steel mesh is larger than that of the phenolic board.

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