Manufacturing method of efficient and ultrathin autoclaved aerated concrete composite thermal insulation wallboard

Abstract

The invention discloses a manufacturing method of an efficient and ultrathin autoclaved aerated concrete composite thermal insulation wallboard, a lightweight concrete composite thermal insulation wallboard comprises a base layer board, and an FRP mesh cage and a thermal insulation board which are arranged in the base layer board, and the thermal insulation board is also located in the FRP mesh cage; the heat preservation plate is a vacuum heat insulation layer, and the vacuum heat insulation layer is a hollow and vacuum heat preservation plate formed by bonding glass fiber cloth with a plurality of vacuum heat preservation and heat preservation plates through curing of unsaturated resin or vinyl resin. The unsaturated polyester resin is reinforced by the glass fiber cloth and is compounded on the outer side of the vacuum heat preservation and insulation plate, so that the heat preservation plate can be completely fixed in the glass fiber cloth reinforced protection bag. And unsaturated resin or vinyl resin is used as thermosetting resin, and can resist high temperature of over 1000 DEG C without melting after being cured, so that the vacuum layer of the vacuum heat-insulation heat-preservation board compounded in the autoclaved aerated concrete wallboard is prevented from being damaged to cause loss of heat-preservation performance.

Description

Technical Field

[0001] The present invention relates to the technical field of building wall panels, and more specifically to a manufacturing method for an efficient and ultra-thin autoclaved aerated concrete composite thermal insulation wall panel. Background Art

[0002] With the improvement of building energy-saving requirements, the thermal insulation layer is getting thicker and thicker. This brings increasing difficulties to the production and installation of wall panels and is also uneconomical. The excessive thickness of the wall panel also leads to a reduction in usable area and an increase in shared area, resulting in a waste of social resources. How to reduce the thickness of the wall panel while meeting the building energy-saving requirements is a direction for the next step in the manufacture of building wall panels.

[0003] The vacuum insulation panel for building exterior wall thermal insulation is an excellent thermal insulation material. With the gradual maturity of technology, it has been well applied in building thermal insulation. Its thermal conductivity is extremely low, only 0.002, which is 1 / 20 of the EPS foam board and 1 / 12 of the polyurethane thermal insulation board. A 20-mm-thick vacuum insulation panel can achieve the same thermal insulation effect as a 240-mm-thick polyurethane panel. The production process of the vacuum insulation panel is to vacuum-seal the thermal insulation core board in an aluminum foil non-woven bag, and the seal uses a thermosetting adhesive. However, the temperature of the hot melt adhesive is only 70 - 150 degrees Celsius. In a high-temperature environment, such as during the production process of autoclaved aerated concrete, the hot melt adhesive will melt, thus destroying the vacuum insulation layer and losing its thermal insulation performance.

[0004] Therefore, how to provide a manufacturing method for an autoclaved aerated concrete composite thermal insulation wall panel that can seal the vacuum insulation panel, composite it with lightweight concrete, be unaffected by high temperatures, not damage the vacuum, and not reduce the thermal insulation effect, so as to be able to significantly reduce the thickness of the wall panel and make the production, installation, and use of the wall panel simple, efficient, and ultra-thin is one of the technical problems urgently to be solved in this field. Summary of the Invention

[0005] In view of this, the present invention provides a manufacturing method for an efficient and ultra-thin autoclaved aerated concrete composite thermal insulation wall panel. The purpose is to solve the above deficiencies.

[0006] To solve the above technical problems, the present invention adopts the following technical solutions:

[0007] An efficient and ultra-thin autoclaved aerated concrete composite thermal insulation wall panel and its manufacturing method. The autoclaved aerated concrete composite thermal insulation wall panel includes a base plate, an FRP cage and a thermal insulation board arranged in the base plate, and the thermal insulation board is also located inside the FRP cage; the thermal insulation board is a hollow vacuum adiabatic thermal insulation layer, and the vacuum adiabatic thermal insulation layer is a thermal insulation board with a hollow and vacuum inside, which is composed of a glass fiber cloth bonded with one or more vacuum adiabatic thermal insulation boards through an unsaturated resin, and the glass fiber cloth is bonded to the vacuum adiabatic thermal insulation board without gaps; the manufacturing method of the lightweight concrete composite thermal insulation wall panel includes the following steps:

[0008] Step 1) Prepare the FRP cage according to the wall panel size and structural requirements for standby;

[0009] Step 2) Use a vacuum adiabatic thermal insulation board and a glass fiber cloth to form a hollow vacuum adiabatic thermal insulation layer through an unsaturated resin;

[0010] Step 3) Use a connector to penetrate the reserved hole of the vacuum adiabatic thermal insulation layer to fix the prefabricated fiber cloth-reinforced vacuum adiabatic thermal insulation layer in the FRP cage, and note that the vacuum adiabatic thermal insulation layer should be parallel to the FRP cage; fix the FRP cage and the fiber cloth-reinforced protective vacuum adiabatic thermal insulation layer on the steel bar frame by passing steel fibers through the FRP cage and fixing them;

[0011] Step 4) Mix and stir the prepared autoclaved aerated concrete slurry, dry materials and additives, then pour them into a mold, and then put the FRP cage made in Step 3 into the mold containing the slurry. After placing, enter the pre-curing room for static curing. After the strength of the concrete wall panel blank reaches a certain strength, pull out the steel bars to obtain the lightweight concrete composite thermal insulation wall panel blank;

[0012] Step 5) Push the mold to the turning crane, after turning, cut and group the six sides, and then push it into the autoclave;

[0013] Step 6) According to the autoclave curing requirements, after 8-10 hours, pull out the wall panel to complete the production.

[0014] Preferably, the manufacturing method of the vacuum adiabatic thermal insulation layer includes the following steps:

[0015] Step 2.1) Lay out the lines according to the size of the vacuum adiabatic thermal insulation layer, place the lower glass fiber cloth on the flat plate, apply unsaturated resin on the surface of the lower glass fiber cloth, and then arrange the lower sides of one or more vacuum adiabatic thermal insulation boards on the lower glass fiber cloth according to the requirements;

[0016] Step 2.2) Apply unsaturated resin on the upper side of each vacuum adiabatic thermal insulation board to perform secondary sealing on the opening of each vacuum adiabatic thermal insulation board;

[0017] Step 2.3) Uniformly apply unsaturated resin on one side of the upper glass fiber cloth close to the vacuum adiabatic insulation board, and cover the upper side of the insulation board, so as to completely wrap the vacuum adiabatic insulation board, forming a vacuum adiabatic insulation layer reinforced by high-temperature resistant fiber cloth.

[0018] Preferably, holes are reserved at the joints of adjacent vacuum adiabatic insulation boards for passing through FRP connecting bars, so as to fix the vacuum adiabatic insulation layer and form connecting columns to enhance the integrity of the wall panel.

[0019] Preferably, a vacuum adiabatic insulation layer is also formed and covered at the holes reserved at the joints of adjacent vacuum adiabatic insulation boards.

[0020] Preferably, the unsaturated resin can be replaced by vinyl resin.

[0021] Preferably, the vacuum adiabatic insulation board can be selected from STP or microfiber vacuum adiabatic boards.

[0022] Preferably, the vacuum adiabatic insulation board is one or more of STP, aerogel board, glass wool board, melamine cotton board, rock wool board or aluminum silicate cotton board.

[0023] The present invention has achieved the following technical effects compared with the prior art:

[0024] The present invention can compound an excellent hollow fiberglass product - a glass fiber cloth reinforced protective bag by using unsaturated resin and glass fiber cloth. The composite is on the outer side of the vacuum adiabatic insulation board, which can completely fix the vacuum adiabatic insulation board in the glass fiber cloth reinforced protective bag. Moreover, since the unsaturated resin is a thermosetting resin, it can withstand high temperatures above 1000 °C without melting after curing, thus ensuring that the vacuum formed by the vacuum adiabatic insulation board is not damaged and the insulation performance is not lost. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 is a schematic structural diagram of an efficient autoclaved aerated concrete composite insulation wall panel of the present invention;

[0026] Figure 2 is a schematic structural diagram of a glass fiber cloth reinforced protective vacuum adiabatic insulation layer of an efficient autoclaved aerated concrete composite insulation wall panel of the present invention;

[0027] In the figure: 1, base plate; 11, strengthening column; 2, concrete layer plate; 3, vacuum adiabatic insulation layer; 31, glass fiber cloth layer; 32, unsaturated resin layer; 33, vacuum adiabatic insulation board layer; 4, FRP connecting bar. DETAILED DESCRIPTION OF THE INVENTION

[0028] Next, in conjunction with the accompanying drawings in the embodiments of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all 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.

[0029] Embodiment 1

[0030] A method for manufacturing an efficient autoclaved aerated concrete composite thermal insulation wall panel. The autoclaved aerated concrete composite thermal insulation wall panel includes a base plate 1, an FRP cage 2 disposed within the base plate 1, and a thermal insulation plate, and the thermal insulation plate is also located inside the FRP cage 2; the thermal insulation plate is a hollow vacuum adiabatic thermal insulation layer 3, and the vacuum adiabatic thermal insulation layer 3 is an internally hollow and vacuum thermal insulation layer formed by bonding one or more vacuum adiabatic thermal insulation boards 33 with a glass fiber cloth 31 through an unsaturated resin 32; the method for manufacturing the autoclaved aerated concrete composite thermal insulation wall panel includes the following steps:

[0031] Step 1) Prepare the FRP cage 2 according to the wall panel size and structural requirements.

[0032] Step 2) Use the glass fiber cloth 31 to bond multiple vacuum adiabatic thermal insulation boards 33 through the unsaturated resin 32 to form a fiber cloth-reinforced protective vacuum adiabatic thermal insulation layer 3 with a hollow interior.

[0033] Among them, the preparation method of the fiber cloth-reinforced protective vacuum adiabatic thermal insulation layer 3 includes the following steps:

[0034] Step 2.1) Lay out the lines according to the size of the vacuum adiabatic thermal insulation layer 3, place the lower glass fiber cloth 31 on a flat plate, apply the unsaturated resin 32 on the surface of the lower glass fiber cloth 31, and then arrange the lower sides of multiple vacuum adiabatic thermal insulation boards 33 on the lower glass fiber cloth 31 as required.

[0035] Step 2.2) Apply the unsaturated resin 32 at the vacuum bonding joints of each vacuum adiabatic thermal insulation board 33 to seal the openings of each vacuum adiabatic thermal insulation board 33.

[0036] Step 2.3) Apply the unsaturated resin 32 evenly on the side of the upper glass fiber cloth 31 close to the vacuum adiabatic thermal insulation board 33, and cover the upper side of the vacuum adiabatic thermal insulation board 33, so as to completely wrap the vacuum adiabatic thermal insulation board 33 to form a fiber cloth-reinforced protective vacuum adiabatic thermal insulation layer 3.

[0037] Step 3) Use a connector to penetrate the reserved holes of the vacuum insulation layer 3 and fix the prefabricated fiber cloth reinforced vacuum insulation layer 3 in the FRP mesh cage 2, making sure that the vacuum insulation layer 3 is parallel to the FRP mesh cage 2; Use steel fibers to penetrate the FRP mesh cage 2 and fix it, so that the FRP mesh cage 2 and vacuum insulation layer 3 are assembled and fixed on the steel drill frame;

[0038] Step 4) The prepared autoclaved aerated concrete slurry, dry materials and additives are mixed and stirred and poured into a mold, and then the FRP mesh cage 2 prepared in step 3) is placed in the mold containing the slurry. After placement, the cage is placed in a pre-curing room for static curing. After the strength of the concrete wall panel blank reaches a certain strength, the drill is removed to obtain a lightweight concrete composite insulation wall panel blank;

[0039] Step 5) Push the mold to the turning carriage, turn it over, cut it into six sides and put it into the autoclave;

[0040] Step 6) According to the requirements of autoclaving and curing, after 8-10 hours, the wall panels are pulled out to complete the production.

[0041] As a preferred or optional method of this embodiment, holes are reserved at the junctions of two adjacent vacuum insulation panels 33 for passing FRP connecting ribs, thereby enhancing the integrity of the wall panels.

[0042] As a preferred or optional manner of this embodiment, a vacuum insulation layer 3 with fiber cloth reinforced protection is also formed at the hole reserved at the junction of two adjacent vacuum insulation panels 33 .

[0043] In some embodiments, the unsaturated resin 32 may be replaced with a vinyl resin.

[0044] Example 2

[0045] A method for manufacturing a highly efficient, ultra-thin, autoclaved aerated concrete composite insulation wall panel. The lightweight concrete composite insulation wall panel comprises a base panel 1, an FRP mesh cage 2 disposed within the base panel 1, and an insulation board, the insulation board also being located within the FRP mesh cage 2. The insulation board comprises a hollow vacuum insulation layer 3. The vacuum insulation board layer 3 comprises a glass fiber cloth 31 bonded to a vacuum insulation board 33 at its sealing portion via an unsaturated resin 32 to ensure that the vacuum of the insulation board is not destroyed when exposed to high temperatures. The method for manufacturing the lightweight concrete composite insulation wall panel comprises the following steps:

[0046] Step 1) Prepare FRP mesh cage 2 according to the wall panel size and structural requirements;

[0047] Step 2) Select aluminum foil covered with fiberglass cloth to make the vacuum insulation panel 33; Use the fiberglass cloth 31 to bond one or more vacuum insulation panels 33 through the unsaturated resin 32 to form a vacuum insulation layer 3 with a hollow interior; The preparation method of the vacuum insulation layer 3 includes the following steps:

[0048] Step 2.1) Lay out the lines according to the size of the vacuum insulation layer 3, and arrange the lower sides of one or more vacuum insulation panels 33 on the lower inorganic or organic fixing thin plates as required;

[0049] Step 2.2) Apply the unsaturated resin 32 to the vacuum bonding joints of each vacuum insulation panel 33, and use the resin to cover the fiberglass cloth and paste it at the sealing joints, so as to seal the openings of each vacuum insulation panel 33 for secondary sealing reinforcement;

[0050] Step 2.3) Reserve holes at the contact points of the arranged vacuum insulation panels 33 for the fixing tie bars or connectors to pass through, and after curing, form a vacuum insulation layer 3 reinforced by fiberglass cloth;

[0051] Step 3) Fix the prefabricated vacuum insulation layer 3 in the FRP cage 2, and fix it by passing steel fibers through the FRP cage 2, so as to assemble and fix the FRP cage 2 and the vacuum insulation layer 3 on the steel bar frame, and put them together into the mold for preparing the concrete wall panel;

[0052] Step 4) Mix and stir the prepared autoclaved aerated concrete slurry, dry materials and additives, and then pour them into the mold for preparing the autoclaved aerated concrete wall panel in the above step 3); After pouring, carry out static curing. After the strength of the concrete wall panel blank reaches a certain strength, pull out the steel bars to obtain the lightweight concrete composite insulation wall panel;

[0053] Step 5) Push the mold to the turning crane, after turning, cut and group the six sides, and then push it into the autoclave;

[0054] Step 6) According to the autoclave curing requirements, after 8 - 10h, pull out the wall panel to complete the production.

[0055] As a preferred or optional method of this embodiment, holes are reserved at the joints of adjacent two vacuum insulation panels 33 for passing through the FRP connecting bars, so as to enhance the integrity of the wall panel. As a preferred or optional method of this embodiment, there is also a fiberglass cloth reinforced protective vacuum insulation layer 3 at the holes reserved at the joints of adjacent two vacuum insulation panels 33.

[0056] In some examples, the sealing joints of the vacuum insulation panels are directly fixed on the thin plates after being smeared with fiberglass cloth reinforced by unsaturated resin to form the insulation layer.

[0057] In some instances, each piece of vacuum insulation panel is made into an individual that is resistant to high temperatures and airtight, and then the insulation panel is laminated onto a fiberglass cloth-reinforced flat plate or an inorganic or organic thin plate.

[0058] In some embodiments, the FRP cage 2 includes two FRP mesh sheets, a plurality of FRP connecting sheets, and a plurality of FRP short ribs, and the plurality of FRP connecting sheets are fixedly connected to the upper and lower ends of the two FRP mesh sheets; the plurality of FRP short ribs are all fixedly connected between the two FRP mesh sheets.

[0059] In some embodiments, each FRP short rib can be perpendicular to between the two FRP mesh sheets; or, obliquely intersect between the two FRP mesh sheets.

[0060] In some other embodiments, the two FRP mesh sheets, the plurality of FRP connecting sheets, and the plurality of FRP short ribs are integrally formed.

[0061] In some other embodiments, the vacuum insulation panel 33 is one or more of STP, aerogel panel, glass wool board, melamine cotton board, rock wool board, or aluminum silicate cotton board.

[0062] The present invention uses unsaturated resin and fiberglass cloth to reinforce the vacuum insulation panel, and can composite an excellent hollow fiberglass product - a fiberglass cloth protective bag. The fiberglass cloth protective bag is a fiberglass product and has strong rigidity; it is laminated on the outside of the vacuum insulation panel, and can completely fix the vacuum insulation panel in the fiberglass cloth protective bag, or, at each sealed (open) place, directly use one or more pieces of vacuum insulation panel reinforced with fiberglass cloth to fix on the overall inorganic or organic thin plate. Using unsaturated resin or vinyl resin as a thermosetting resin, it can withstand high temperatures above 1000 degrees without melting after curing, thereby ensuring that the vacuum formed by the fiberglass cloth-reinforced protective vacuum insulation panel is not damaged, and it will not lose its heat insulation performance due to this.

[0063] The above is only a preferred embodiment of the present invention, and does not impose any limitation on the technical scope of the present invention. Therefore, any minor modification, equivalent change, and modification made to the above embodiments according to the technical essence of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. A manufacturing method of an efficient and ultra-thin autoclaved aerated concrete composite thermal insulation wall panel. The lightweight concrete composite thermal insulation wall panel includes a base plate (1), an FRP cage (2) arranged in the base plate (1), and a thermal insulation board, and the thermal insulation board is also located inside the FRP cage (2); it is characterized in that, The insulation board is a hollow vacuum insulation layer (3), and the vacuum insulation layer (3) is a hollow and vacuum insulation board composed of glass fiber cloth (31) bonded to one or more vacuum insulation boards (33) through unsaturated resin (32), and the glass fiber cloth (31) and the vacuum insulation board (33) are bonded together without gaps. The manufacturing method of the lightweight concrete composite insulation wallboard comprises the following steps: Step 1) making an FRP mesh cage (2) in accordance with the wall panel size and structural requirements; Step 2) using a vacuum insulation board (33) and a glass fiber cloth (31) through an unsaturated resin (32) to form a vacuum insulation layer (3) with a hollow interior; Step 3) Use a connector to penetrate the reserved holes of the vacuum thermal insulation layer (3) and fix the prefabricated fiber cloth reinforced vacuum thermal insulation layer (3) in the FRP mesh cage (2), and pay attention to making the vacuum thermal insulation layer (3) parallel to the FRP mesh cage (2); pass the steel fiber through the FRP mesh cage (2) and fix it, so that the FRP mesh cage (2) and the fiber cloth reinforced protective vacuum thermal insulation layer (3) are assembled and fixed on the steel drill frame; Step 4) The prepared autoclaved aerated concrete slurry, dry materials and additives are mixed and stirred and then poured into a mold, and then the FRP mesh cage (2) prepared in step 3 is placed in the mold containing the slurry. After placement, the cage is placed in a pre-curing room for static curing. After the strength of the concrete wall panel blank reaches a certain strength, the drill is pulled out to obtain a lightweight concrete composite insulation wall panel blank; Step 5) Push the mold to the turning carriage, turn it over, cut it into six sides and put it into the autoclave; Step 6) According to the requirements of autoclaving and curing, after 8-10 hours, the wall panels are pulled out to complete the production.

2. The manufacturing method of an efficient and ultra-thin autoclaved aerated concrete composite thermal insulation wall panel according to claim 1, characterized in that, The method for preparing the vacuum thermal insulation layer (3) comprises the following steps: Step 2.1) Lay out the vacuum insulation layer (3) in accordance with its dimensions, place the lower glass fiber cloth (31) on a flat plate, apply unsaturated resin (32) to the surface of the lower glass fiber cloth (31), and then arrange the lower side surfaces of one or more vacuum insulation panels (33) on the lower glass fiber cloth (31) as required; Step 2.2) applying unsaturated resin (32) to the upper side of each vacuum insulation panel (33), thereby performing secondary sealing on the opening of each vacuum insulation panel (33); Step 2.3) Evenly apply unsaturated resin (32) to one side of the upper glass fiber cloth (31) close to the vacuum insulation board (33), covering the upper side of the insulation board (33), thereby completely covering the vacuum insulation board (33). After curing, a vacuum insulation layer (3) with enhanced protection of high-temperature resistant fiber cloth is formed.

3. The manufacturing method of an efficient and ultra-thin autoclaved aerated concrete composite thermal insulation wall panel according to claim 2, characterized in that, Holes are reserved at the junctions of two adjacent vacuum insulation panels (33) for passing FRP connecting ribs to fix the vacuum insulation layer (3) and form connecting columns to enhance the integrity of the wall panels.

4. The manufacturing method of the high-efficiency and ultra-thin autoclaved aerated concrete composite thermal insulation wall panel according to claim 3, wherein The holes reserved at the junction of two adjacent vacuum insulation panels (33) are also covered with a vacuum insulation layer (3).

5. The manufacturing method of an efficient and ultra-thin autoclaved aerated concrete composite thermal insulation wall panel according to any one of claims 1 or 2, characterized in that The unsaturated resin (32) can be replaced by vinyl resin.

6. The manufacturing method of an efficient and ultra-thin autoclaved aerated concrete composite thermal insulation wall panel according to claim 1, characterized in that The vacuum insulation panel (33) is one or more of STP, aerogel panel, rock wool board, glass wool board, melamine cotton board or aluminum silicate cotton board.

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