Flexible folding heat preservation sandwich wall structure and manufacturing method thereof

Abstract

The invention discloses a flexible folding heat preservation sandwich wall structure and a manufacturing method thereof, and relates to the technical field of building wall structures. The composite wall board comprises a middle heat preservation layer in the middle and inner and outer wall boards on the two sides, the middle heat preservation layer is prepared from a multifunctional composite material formed by combining a polyethylene glycol-based flexible phase change material with a fireproof material and a reinforcing material, and the inner and outer wall boards are prepared from an ECC concrete material. Efficient temperature adjusting capacity is provided through the phase change characteristic of PEG, energy consumption is reduced, the polyurethane matrix endows the material with excellent flexibility and foldability, the folding requirement of an assembled house is met, the fire endurance of the material is remarkably improved through the flame retardant and the fireproof filler, the fireproof requirement of a building is met, the mechanical strength is improved through the light reinforcing material, and the service life of the material is prolonged. The explosion-proof performance is met, meanwhile, light weight of the material is kept, transportation and installation are convenient, the stable performance of the material can still be kept after the material is folded and unfolded for multiple times, and the material is suitable for fabricated buildings, temporary buildings and energy-saving buildings.

Description

Technical Field

[0001] The present invention relates to the technical field of building wall structures, and particularly to a flexible folding thermal insulation sandwich wall structure and a manufacturing method thereof. Background Art

[0002] Traditional building wall structures usually adopt single materials such as concrete, bricks, etc. These materials have certain limitations in terms of thermal insulation, fire protection, and flexibility. With the development of building technology, especially the rise of prefabricated buildings, the demand for multi-functional integration of walls is increasing day by day.

[0003] Phase change materials (PCMs) have significant temperature regulation capabilities in the field of building thermal insulation. They can absorb or release a large amount of heat through the phase change process, thereby effectively regulating the indoor temperature and reducing energy consumption. However, traditional phase change materials have the following problems in building applications: 1. Insufficient flexibility and foldability: Most traditional phase change materials are rigid materials and are difficult to meet the folding and unfolding requirements of walls in prefabricated buildings; 2. Poor fire resistance: Phase change materials are usually flammable and difficult to meet the building fire protection requirements; 3. Low mechanical strength: Phase change materials are prone to deformation in high or low temperature environments, resulting in poor structural stability. Engineered cementitious composites (ECCs) have high toughness, high crack resistance, and durability, but their thermal insulation performance is poor and it is difficult to meet the energy-saving and thermal insulation requirements of modern buildings alone. In addition, the rigid structure of ECC concrete limits its application in prefabricated buildings that require flexible folding.

[0004] Although the existing sandwich wall structures have improved in thermal insulation performance, they still have deficiencies in terms of fire protection, flexibility, and foldability. Therefore, we propose a flexible folding thermal insulation sandwich wall structure and a manufacturing method thereof to solve the problems mentioned above.

[0005] The above information disclosed in this background art is only used to increase the understanding of the background art of the present invention. Therefore, it may include prior art that is not known to those of ordinary skill in the art. Summary of the Invention

[0006] The purpose of the present invention is to provide a flexible folding thermal insulation sandwich wall structure and a manufacturing method thereof to solve the problems raised in the above background art.

[0007] To achieve the above purpose, the present invention provides the following technical solution: A flexible folding thermal insulation sandwich wall structure includes an intermediate thermal insulation layer in the middle and inner and outer layer wall panels on both sides. The intermediate thermal insulation layer is prepared from a multi-functional composite material formed by combining a polyethylene glycol-based flexible phase change material with a fireproof material and a reinforcing material, and the inner and outer layer wall panels are prepared from ECC concrete materials.

[0008] Preferably, the polyethylene glycol-based flexible phase change material achieves flexibility and foldability through the combination of polyethylene glycol and polyurethane.

[0009] Preferably, the fireproof material includes a flame retardant and a fireproof filler. The flame retardant is aluminum hydroxide, magnesium hydroxide, or an intumescent flame retardant, and the fireproof filler is ceramic fiber or vermiculite.

[0010] Preferably, the reinforcing material includes a lightweight reinforcing material and a thermal conductive filler. The lightweight reinforcing material is glass fiber or carbon fiber, and the thermal conductive filler is graphene or boron nitride.

[0011] The present invention also provides a manufacturing method for a flexible and foldable thermal insulation sandwich wall, which includes the following steps:

[0012] Step 1. Prepare the PEG-based flexible phase change material: Mix PEG and polyurethane prepolymer in proportion, add a crosslinking agent and a catalyst, heat to 60°C - 80°C, and pour into a mold for curing.

[0013] Step 2. Add the fireproof material: Add a flame retardant and a fireproof filler to the PEG-polyurethane mixture and stir evenly.

[0014] Step 3. Composite the reinforcing material: Add a lightweight reinforcing material and a thermal conductive filler to improve the mechanical strength and thermal conductivity.

[0015] Step 4. Molding and curing: Pour the final mixture into the mold of the sandwich wall insulation layer, and cure it by heating or at room temperature to form a multifunctional composite material.

[0016] Step 5. Assemble the sandwich wall: Place the prepared flexible phase change material plate in the middle insulation layer of the sandwich wall, cover it on the steel bars, pour concrete on both sides, and connect the plates with flexible connectors.

[0017] Preferably, in step 1, the mixing ratio of PEG to polyurethane prepolymer is that PEG accounts for 60% - 70% and polyurethane accounts for 30% - 40%.

[0018] Preferably, in step 2, the addition amount of the flame retardant is 10% - 20%, and the addition amount of the fireproof filler is 5% - 10%.

[0019] Preferably, in step 3, the addition amount of the lightweight reinforcing material is 5% - 10%, and the addition amount of the thermal conductive filler is 1% - 3%.

[0020] Preferably, in step 5, the flexible connector is a hinge or an elastic sealing strip.

[0021] Compared with the prior art, the beneficial effects of the present invention are:

[0022] The present invention provides efficient temperature regulation capabilities through the phase change characteristics of PEG, reducing energy consumption. The polyurethane matrix endows the material with excellent flexibility and foldability, meeting the folding requirements of prefabricated houses. Flame retardants and fireproof fillers significantly increase the fire resistance limit of the material, meeting the building fire protection requirements. Lightweight reinforcing materials improve mechanical strength, meeting explosion-proof performance while maintaining material lightweight, facilitating transportation and installation. The material can still maintain stable performance after being folded and unfolded multiple times, and is applicable to prefabricated buildings, temporary buildings, and energy-saving buildings.

[0023] The above summary is for the purpose of the specification only and is not intended to be limiting in any way. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features of the present invention will become apparent by reference to the drawings and the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 is a schematic structural diagram of the present invention;

[0025] Figure 2 is a schematic diagram of the preparation process of the present invention.

[0026] In the figure: 1, intermediate insulation layer; 2, inner and outer wall panels. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0027] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0028] Please refer to Figure 1 , a flexible folding thermal insulation sandwich wall structure, including an intermediate insulation layer 1 in the middle and inner and outer wall panels 2 on both sides. The intermediate insulation layer 1 is prepared from a multifunctional composite material formed by a polyethylene glycol (PEG)-based flexible phase change material combined with a fireproof material and a reinforcing material. The PEG-based flexible phase change material realizes flexibility and foldability through the combination of polyethylene glycol and polyurethane. The fireproof material includes a flame retardant and a fireproof filler. The flame retardant is aluminum hydroxide, magnesium hydroxide, or an intumescent flame retardant, and the fireproof filler is ceramic fiber or vermiculite. The reinforcing material includes a lightweight reinforcing material and a thermal conductive filler. The lightweight reinforcing material is glass fiber or carbon fiber, and the thermal conductive filler is graphene or boron nitride. The inner and outer wall panels 2 are prepared from ECC concrete materials.

[0029] A manufacturing method of a flexible folding thermal insulation sandwich wall includes the following steps:

[0030] Step 1. Preparation of PEG-based flexible phase change material: Mix PEG and polyurethane prepolymer in proportion, add a crosslinking agent and a catalyst, heat to 60°C - 80°C, and pour into a mold for curing;

[0031] The mixing ratio of PEG and polyurethane prepolymer is that PEG accounts for 60% - 70% and polyurethane accounts for 30% - 40%.

[0032] Step 2. Addition of fireproof materials: Add a flame retardant and a fireproof filler to the PEG-polyurethane mixture and stir evenly;

[0033] The addition amount of the flame retardant is 10% - 20%, and the addition amount of the fireproof filler is 5% - 10%.

[0034] Step 3. Composite of reinforcing materials: Add lightweight reinforcing materials and thermal conductive fillers to improve mechanical strength and thermal conductivity;

[0035] The addition amount of the lightweight reinforcing materials is 5% - 10%, and the addition amount of the thermal conductive fillers is 1% - 3%.

[0036] Step 4. Molding and curing: Pour the final mixture into the mold of the sandwich wall insulation layer, and cure it by heating or at room temperature to form a multifunctional composite material;

[0037] Step 5. Assembly of sandwich wall: Place the prepared flexible phase change material plate in the middle insulation layer of the sandwich wall, cover it on the steel bars, pour concrete on both sides, and connect the plates with flexible connectors.

[0038] The flexible connector is a hinge or an elastic sealing strip.

[0039] Example 1

[0040] Step 1. Preparation of PEG-based flexible phase change material: Mix PEG and polyurethane prepolymer in proportion, add a crosslinking agent and a catalyst, heat to 60°C - 80°C, and pour into a mold for curing; The mixing ratio of PEG and polyurethane prepolymer is that PEG accounts for 60% and polyurethane accounts for 40%.

[0041] Step 2. Addition of fireproof materials: Add a flame retardant and a fireproof filler to the PEG-polyurethane mixture and stir evenly; The addition amount of the flame retardant is 12%, and the addition amount of the fireproof filler is 10%.

[0042] Step 3. Composite of reinforcing materials: Add lightweight reinforcing materials and thermal conductive fillers to improve mechanical strength and thermal conductivity; The addition amount of the lightweight reinforcing materials is 5%, and the addition amount of the thermal conductive fillers is 3%.

[0043] Step 4. Molding and curing: Pour the final mixture into the mold of the sandwich wall insulation layer, and cure it by heating or at room temperature to form a multifunctional composite material;

[0044] Step 5. Assembly of the sandwich wall: Place the prepared flexible phase change material plates in the middle insulation layer of the sandwich wall, cover them on the steel bars, pour concrete on both sides, and connect the plates using flexible connectors. The flexible connectors are hinges or elastic sealing strips.

[0045] Example 2

[0046] Step 1. Preparation of PEG-based flexible phase change material: Mix PEG and polyurethane prepolymer in proportion, add a crosslinking agent and a catalyst, heat to 60°C - 80°C, and pour into a mold for curing; the mixing ratio of PEG and polyurethane prepolymer is 65% PEG and 35% polyurethane.

[0047] Step 2. Addition of fireproof materials: Add a flame retardant and a fireproof filler to the PEG-polyurethane mixture and stir evenly; the addition amount of the flame retardant is 15%, and the addition amount of the fireproof filler is 8%.

[0048] Step 3. Composite of reinforcing materials: Add lightweight reinforcing materials and thermal conductive fillers to improve mechanical strength and thermal conductivity; the addition amount of the lightweight reinforcing materials is 7%, and the addition amount of the thermal conductive fillers is 3%.

[0049] Step 4. Molding and curing: Pour the final mixture into the mold of the sandwich wall insulation layer, and cure it by heating or at room temperature to form a multifunctional composite material;

[0050] Step 5. Assembly of the sandwich wall: Place the prepared flexible phase change material plates in the middle insulation layer of the sandwich wall, cover them on the steel bars, pour concrete on both sides, and connect the plates using flexible connectors. The flexible connectors are hinges or elastic sealing strips.

[0051] Example 3

[0052] Step 1. Preparation of PEG-based flexible phase change material: Mix PEG and polyurethane prepolymer in proportion, add a crosslinking agent and a catalyst, heat to 60°C - 80°C, and pour into a mold for curing; the mixing ratio of PEG and polyurethane prepolymer is 70% PEG and 30% polyurethane.

[0053] Step 2. Addition of fireproof materials: Add a flame retardant and a fireproof filler to the PEG-polyurethane mixture and stir evenly; the addition amount of the flame retardant is 18%, and the addition amount of the fireproof filler is 7%.

[0054] Step 3. Composite of reinforcing materials: Add lightweight reinforcing materials and thermal conductive fillers to improve mechanical strength and thermal conductivity; the addition amount of the lightweight reinforcing materials is 8%, and the addition amount of the thermal conductive fillers is 2%.

[0055] Step 4. Molding and curing: Pour the final mixture into the mold of the sandwich wall insulation layer, and cure it by heating or at room temperature to form a multifunctional composite material;

[0056] Step 5. Sandwich wall assembly: Place the prepared flexible phase change material plate in the middle insulation layer of the sandwich wall, cover it on the steel bars, pour concrete on both sides, and connect the plates with flexible connectors. The flexible connectors are hinges or elastic sealing strips.

[0057] Example 4

[0058] Step 1. Preparation of PEG-based flexible phase change material: Mix PEG and polyurethane prepolymer in proportion, add a cross-linking agent and a catalyst, heat to 60°C - 80°C, and pour it into a mold for curing; the mixing ratio of PEG and polyurethane prepolymer is 60% for PEG and 40% for polyurethane.

[0059] Step 2. Adding fireproof materials: Add a flame retardant and a fireproof filler to the PEG-polyurethane mixture and stir evenly; the addition amount of the flame retardant is 20%, and the addition amount of the fireproof filler is 5%.

[0060] Step 3. Composite of reinforcing materials: Add lightweight reinforcing materials and heat-conducting fillers to improve mechanical strength and heat conduction performance; the addition amount of the lightweight reinforcing materials is 10%, and the addition amount of the heat-conducting fillers is 1%.

[0061] Step 4. Molding and curing: Pour the final mixture into the mold of the sandwich wall insulation layer, and cure it by heating or at room temperature to form a multifunctional composite material;

[0062] Step 5. Sandwich wall assembly: Place the prepared flexible phase change material plate in the middle insulation layer of the sandwich wall, cover it on the steel bars, pour concrete on both sides, and connect the plates with flexible connectors. The flexible connectors are hinges or elastic sealing strips.

[0063] I. Thermal insulation performance test

[0064] 1. Thermal conductivity test: According to ASTM C518 standard, use the heat flow meter method to measure the thermal conductivity (λ) of the sandwich wall. The test temperature range covers the PEG phase change temperature to simulate the actual use environment.

[0065] 2. Phase change latent heat and thermal cycle stability: Use a differential scanning calorimeter (DSC) to test the phase change latent heat of PEG, and cycle test (more than 1000 times) to verify the stability. Record the phase change latent heat and the latent heat attenuation rate after cycling.

[0066] 3. Dynamic hot box simulation test: Simulate extreme summer / winter climates (-20°C - 40°C) in a temperature and humidity controllable experimental chamber, and monitor the temperature difference between the two sides of the wall to calculate the temperature fluctuation amplitude.

[0067] The specimens prepared according to the solutions of Examples 1 - 4 were subjected to the above tests, and the results are shown in Table 1.

[0068] Table 1. Test Results of Thermal Insulation Performance

[0069] Item Thermal Conductivity (W / (m·K)) Latent Heat of Phase Change (J / g) Temperature Fluctuation Range (℃ / 24h) Example 1 0.14 153 1.8 Example 2 0.15 150 2.0 Example 3 0.13 156 1.9 Example 4 0.14 152 2.0

[0070] As can be seen from the above table, the thermal conductivity λ of the sandwich wall of the present invention does not exceed 0.15 W / (m·K), approaching the level of traditional thermal insulation materials (such as EPS foam), the phase change latent heat ≥ 150 J / g, and the indoor side temperature fluctuation range ≤ 2 °C / 24 h, having excellent thermal insulation performance.

[0071] II. Fire Resistance Performance Test

[0072] 1. Combustion Performance Grade Test: The non-combustibility test (Grade A) was carried out according to GB 8624 - 2012 "Classification of Combustion Performance of Building Materials".

[0073] 2. Fire Resistance Limit Test: The fire resistance test was carried out according to the GB / T 9978.1 standard, simulating the standard fire curve (ISO834), and recording the failure times of the wall integrity and heat insulation.

[0074] 3. Structural Stability at High Temperature: Heat it in a high-temperature furnace to 1000 °C and hold for 30 minutes, observing the cracking situation of the ECC layer and the leakage of PEG.

[0075] The specimens prepared according to the solutions of Examples 1 - 4 were subjected to the above tests, and the results are shown in Table 2.

[0076] Table 2. Test Results of Fire Resistance Performance

[0077] Item Combustion Performance Grade Fire Resistance Limit Structural Stability Example 1 A2 ≥ 2 hours No open flame, no dripping, surface crack width ≤ 0.2 mm Example 2 A2 ≥ 2 hours No open flame, no dripping, surface crack width ≤ 0.2 mm Example 3 A2 ≥ 2 hours No open flame, no dripping, surface crack width ≤ 0.2 mm Example 4 A2 ≥ 2 hours No open flame, no dripping, surface crack width ≤ 0.2 mm

[0078] As can be seen from the above table, the combustion performance grade of the sandwich wall of the present invention reaches A2 level (smoke density index ≤ 75, heat release rate ≤ 3 MJ / kg); the fire resistance limit ≥ 2 hours, meeting the requirements of the first-level fire separation; the structure is stable at high temperature, without open fire and dripping, and the surface crack width ≤ 0.2 mm, having excellent fire resistance performance.

[0079] III. Explosion Protection Performance Test

[0080] 1. Impact Resistance Test: Use the pendulum impact test (ASTM D256) or the drop hammer impact test to measure the energy absorbed by the wall.

[0081] 2. Explosion Pressure Wave Test: Simulate the shock wave in the explosion pressure chamber, with a peak pressure of 0.5 MPa and a duration of 10 ms, and record the wall failure mode.

[0082] 3. Fragment protection ability: Simulate the impact of explosive fragments by ejecting steel balls at high speed (speed 100 m / s), and evaluate the penetration depth of the wall.

[0083] Perform the above tests on the specimens prepared according to the solutions of Examples 1 - 4, and the results are shown in Table 3.

[0084] Table 3. Test results of explosion-proof performance

[0085]

[0086]

[0087] As can be seen from the above table, the sandwich wall of the present invention has an impact energy absorption of ≥50 kJ / m 2 , no through - penetration failure under 0.5 MPa, the penetration depth ≤ 50% of the wall thickness, and no spalling on the back, possessing excellent explosion - proof performance.

[0088] In the description of this specification, the description referring to terms such as "one embodiment", "some embodiments", "example", "specific example" or "some examples" means that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in a suitable manner in any one or more embodiments or examples. In addition, without contradiction, those skilled in the art can combine and combine the different embodiments or examples described in this specification and the features of different embodiments or examples.

[0089] Although the embodiments of the present invention have been shown and described above, it can be understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those of ordinary skill in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A flexible folding thermal insulation sandwich wall structure, comprising an intermediate thermal insulation layer (1) in the middle and inner and outer wall panels (2) on both sides, characterized in that: The middle thermal insulation layer (1) is prepared from a multifunctional composite material formed by a polyethylene glycol-based flexible phase change material combined with a fireproof material and a reinforcing material, and the inner and outer wall panels (2) are prepared from ECC concrete materials.

2. The flexible folding thermal insulation sandwich wall structure according to claim 1, characterized in that: The polyethylene glycol-based flexible phase change material achieves flexibility and foldability through the combination of polyethylene glycol and polyurethane.

3. A flexible folding thermal insulation sandwich wall structure according to claim 1, characterized in that: The fireproof material includes a flame retardant and a fireproof filler. The flame retardant is aluminum hydroxide, magnesium hydroxide or an intumescent flame retardant, and the fireproof filler is ceramic fiber or vermiculite.

4. A flexible folding thermal insulation sandwich wall structure according to claim 1, characterized in that: The reinforcing material includes a lightweight reinforcing material and a thermal conductive filler. The lightweight reinforcing material is glass fiber or carbon fiber, and the thermal conductive filler is graphene or boron nitride.

5. The manufacturing method of a flexible folding thermal insulation sandwich wall according to any one of claims 1-4, characterized in that, It includes the following steps: Step 1. Prepare the PEG-based flexible phase change material: Mix PEG and polyurethane prepolymer in proportion, add a crosslinking agent and a catalyst, heat to 60°C - 80°C, and pour into a mold for curing. Step 2. Add the fireproof material: Add a flame retardant and a fireproof filler to the PEG-polyurethane mixture and stir evenly. Step 3. Composite the reinforcing material: Add a lightweight reinforcing material and a thermal conductive filler to improve the mechanical strength and thermal conductivity. Step 4. Molding and curing: Pour the final mixture into the mold of the sandwich wall thermal insulation layer, heat or cure at room temperature to form a multifunctional composite material. Step 5. Assemble the sandwich wall: Place the prepared flexible phase change material plate in the middle thermal insulation layer of the sandwich wall, cover it on the steel bars, pour concrete on both sides, and connect the plates with flexible connectors.

6. The manufacturing method of a flexible folding thermal insulation sandwich wall according to claim 5, characterized in that: In the said Step 1, the mixing ratio of PEG and polyurethane prepolymer is that PEG accounts for 60% - 70% and polyurethane accounts for 30% - 40%.

7. A method for manufacturing a flexible folding thermal insulation sandwich wall according to claim 5, characterized in that: In the said Step 2, the addition amount of the flame retardant is 10% - 20%, and the addition amount of the fireproof filler is 5% - 10%.

8. A method for manufacturing a flexible folding thermal insulation sandwich wall according to claim 5, characterized in that: In the said Step 3, the addition amount of the lightweight reinforcing material is 5% - 10%, and the addition amount of the thermal conductive filler is 1% - 3%.

9. A method for manufacturing a flexible folding thermal insulation sandwich wall according to claim 5, characterized in that: In the said Step 5, the flexible connector is a hinge or an elastic sealing strip.

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