External wall insulation board with integrated structure and production method thereof

Abstract

The invention discloses an integrated structure external wall insulation board and a production method thereof, the integrated structure external wall insulation board comprises a base material board, one side face of the base material board is provided with a lower mortar layer, and the lower mortar layer is internally provided with lower layer gridding cloth; a heat preservation groove is formed in the other side face of the base material plate, a core material mortar layer is arranged in the heat preservation groove, a heat preservation core material is laid in the heat preservation groove, an upper mortar layer is laid on the upper portion of the heat preservation core material, and upper-layer gridding cloth is arranged in the upper mortar layer. When the external wall insulation board with the integrated structure is manufactured, the manufacturing steps are simple, existing insulation board forming equipment can be used for participating in production, the equipment can be continuously used when new productivity and old productivity are converted, the utilization rate of the equipment is improved, and the rejection rate of the equipment is reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of exterior wall insulation boards, and in particular relates to an exterior wall insulation board with an integrated structure and a production method thereof. Background Art

[0002] In existing buildings, in order to improve their thermal insulation, insulation boards are usually installed on the outside of the exterior wall by hanging after the exterior wall is formed. The exterior wall insulation board can improve the thermal insulation performance of the wall. In order to meet the national requirements for the fire protection performance of buildings, fireproof materials are usually added inside the insulation board to expand its fire protection function.

[0003] The technical problems currently encountered are: 1. The existing fireproof panels are installed secondary after the wall is formed, and their construction is relatively complicated. After long-term use, in severe weather such as strong winds, the insulation panels are easily detached from the wall, causing a major safety hazard; 2. The general structure of the existing insulation panels is to set extruded panels, and set mesh cloth and high-strength mortar on the sides of the extruded panels. However, during installation, the main thermal insulation function is achieved only by the extruded panels, and its effectiveness is limited; 3. Technical personnel in this field have tried to fix STP panels directly on the exterior wall, but when fixing, it is necessary to punch holes in the insulation panels. This punching action destroys the integrity and sealing of the STP panels, resulting in the loss or weakening of their thermal insulation performance.

[0004] In view of the practical problems currently existing in insulation boards, the applicant, as a research and development and design unit of building materials, is very necessary to improve the existing insulation board structure and production process, and design an integrated structural exterior wall insulation board with a reasonable structure and easy production. Summary of the Invention

[0005] In order to overcome the shortcomings of the existing technology, the present invention provides an integrated structural exterior wall insulation board and a production method thereof. Its structural design is novel. With the help of existing molding equipment, by changing the insulation board structure, it can achieve high-strength and good thermal insulation performance board molding.

[0006] In order to achieve the above technical objectives, the present invention adopts the following scheme: An integrated structural exterior wall insulation board comprises a substrate board, a lower mortar layer being provided on one side of the substrate board, a lower mesh cloth being provided in the lower mortar layer; an insulation groove being provided on the other side of the substrate board, a core material mortar layer being provided in the insulation groove, an insulation core material being laid flat in the insulation groove, an upper mortar layer being laid on the upper part of the insulation core material, and an upper mesh cloth being provided inside the upper mortar layer.

[0007] A marking area is provided on the outer surface of the structural exterior wall insulation board, and the marking area corresponds to the ribs between the insulation grooves.

[0008] The upper mortar layer comprises a filling mortar layer, a reinforcing mesh cloth is laid on the filling mortar layer, and a sealing mortar layer is arranged on the reinforcing mesh cloth.

[0009] The outer side of the integrated structure exterior wall insulation board is covered with an outer mortar layer, and the integrated structure exterior wall insulation board is covered by the outer mortar layer.

[0010] The integrated structure exterior wall insulation board is provided with a plurality of through holes, and the through holes are arranged on the ribs or on the square insulation core material with an area of less than 40 square centimeters.

[0011] The insulation tank is paved with an insulation tank mesh cloth, and a core material mortar layer is sprayed on the insulation tank mesh cloth. The insulation core material is laid flat on the core material mortar layer to make the insulation core material have a higher bonding strength.

[0012] The insulation core material is composed of a sealing bag and an insulation board. The outer side of the sealing bag is a glass fiber woven layer, and the inner side is an aluminum foil layer or a thermosetting adhesive film layer. When the inner side is an aluminum foil layer, thermosetting adhesive needs to be sprayed on the aluminum foil layer.

[0013] The outer side of the insulation board is provided with a rough surface or a concave-convex surface. This design can increase the contact area between the outer side of the insulation board and the aluminum foil layer or the thermosetting adhesive layer.

[0014] A molding process for an integrated structural exterior wall insulation board specifically includes the following production steps: Step (1) using a Class A fireproof board as a substrate, laying a mesh cloth on one side thereof and spraying or laying a mortar layer, and then leaving it to stand for 1 to 4 days after laying; Step (2) a plurality of insulation grooves are processed at intervals on the other side of the Class A fireproof board, ribs are formed in the interval area, and the groove depth is 2 to 3 cm thick. After the grooves are formed, impurities in the grooves are cleaned, and a mesh cloth is laid in the insulation grooves. After the mesh cloth is laid, an adhesive layer is sprayed or laid, and an insulation core material is laid in the insulation grooves; Step (3) laying or spraying mortar on one side of the Class A fireproof board with the insulation core material, then laying several layers of mesh cloth on the mortar, laying or spraying mortar on top of the mesh cloth, and leaving it to stand for 1 to 4 days after laying; Step (4) marking the rib area on the integrated structural exterior wall insulation board, which serves as a reference for subsequent drilling and installation; Step (5) trimming the edges and drilling holes in the integrated structural exterior wall insulation board; Step (6) stack the panels vertically, spray mortar on all four sides of the insulation board to form a surface mortar layer, and cover the entire periphery of the integrated structure exterior wall insulation board. After spraying, leave the panels to stand for 1 to 4 days for curing.

[0015] When the thermal insulation core material is produced, a punching device is used to punch a rough surface or a concave-convex surface on the thermal insulation board, and the surface is reserved for later use; Open a sealed bag with one or both ends open, spray thermosetting glue inside the bag, place the insulation board inside the sealed bag, and then put the bag into a vacuum machine to evacuate the bag so that the insulation board is vacuum-wrapped. Place in a thermosetting machine for thermosetting at a temperature of 150 to 200 degrees Celsius for 0.5 to 2 minutes. After thermosetting, the edges of the sealed bag are sheared or folded to obtain a heat-insulating core material with a vacuum structure.

[0016] The beneficial effects of the present invention are as follows: the present invention discloses an insulation structure of an integrated structure exterior wall insulation board, which can integrate a vacuum board as an insulation core material with an existing insulation board structure, and can fully reflect the insulation and sealing properties of the insulation core material of the vacuum structure. During installation and fixation, the integrated structure exterior wall insulation board can be directly used as a template, and does not need to be disassembled a second time when the exterior wall is formed. It can be directly fixed inside the wall, and while ensuring the insulation properties of the wall, it can effectively prevent the insulation board from falling off. The integrated structure exterior wall insulation board has simple production steps, and existing polystyrene insulation board and extruded board forming equipment can be used in production. The equipment can be continuously used during the conversion from old to new production capacity, thereby increasing the utilization rate of the equipment and reducing the equipment scrap rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is a schematic diagram of the product's appearance and structure; Figure 2 This is a schematic diagram of the layered structure of the product of the present invention; Figure 3 Schematic diagram of the thermal insulation core material laying structure; Figure 4 This is a schematic diagram of the structure of the product of the present invention when it is not covered with outer covering; Figure 5 This is a schematic diagram of the thermal insulation core material packaging structure; Figure 6 Schematic diagram of the outer structure of the insulation board; Figure 7 This is a schematic diagram of the insulation core material covering structure; Figure 8 This is a schematic diagram of the construction structure of the product of the present invention; In the accompanying drawings: In the figure: 1. Board body, 10. Surface mortar layer, 11. Through hole, 12. Marking area, 2. Lower mortar layer, 21. Lower mesh cloth, 3. Class A fireproof insulation board, 30. Insulation groove, 31. Core mortar layer, 32. Insulation groove mesh cloth, 33. Ribs, 4. Insulation core material, 40. Small piece of insulation core material, 41. Sealing bag, 411. Glass fiber woven layer, 412. Thermosetting adhesive layer, 42. Insulation board, 421. Concave and convex surface, 43. Sealing edge, 5. Upper mortar layer, 51. Filling mortar layer, 52. Reinforced mesh cloth I, 53. Reinforced mesh cloth II, 54. Sealing mortar layer, 6. Steel cage, 7. Inner wall formwork, 8. Tie bar. DETAILED DESCRIPTION

[0018] The present invention is described in detail below through specific embodiments. Those skilled in the art will readily appreciate the other advantages and benefits of the present invention from the disclosure herein. However, it should be noted that the following specific embodiments do not constitute a technical limitation on the present invention. The scope of protection of this patent application shall be determined by the claims.

[0019] Example 1: An integrated structural exterior wall insulation board includes a board body 1, which is composed of a base material board as a basic structure. In this embodiment, the base material board adopts an A-class fireproof insulation board 3, and a lower mortar layer 2 is provided on one side of the A-class fireproof insulation board 3, and a lower mesh cloth 21 is provided in the lower mortar layer 2; an insulation groove 30 is processed and provided on the other side of the A-class fireproof insulation board 3, and ribs 33 are provided between each adjacent two insulation grooves 30 and between the insulation grooves 30 and the outer edge, and the width of the ribs is greater than 20 mm; in this embodiment, the overall thickness of the integrated structural exterior wall insulation board is 6 cm, and the thickness of the A-class fireproof insulation board 3 is 5.4 cm, wherein the groove depth is 2.5 to 2.7 cm in depth on the periphery.

[0020] After the insulation groove 30 is grooved, before the insulation core material 4 is laid, a core material mortar layer 31 is set in the insulation groove 30. The insulation core material 4 is laid flatly in the insulation groove 30. In order to further improve the bonding strength of the insulation core material 4 in the insulation groove 30, before spraying the core material mortar layer 31 in the insulation groove 30, a layer of insulation groove mesh cloth 32 is first laid in the insulation groove 30, and then a layer of core material mortar layer 31 is sprayed on the insulation groove mesh cloth 32, so that the core material mortar layer 31 soaks the insulation groove mesh cloth 32, and finally the insulation core material 4 is laid flatly on the core material mortar layer 31 to make the insulation core material 4 have a higher bonding strength.

[0021] After the insulation core material 4 is attached, an upper mortar layer 5 is laid on top of the insulation core material 4, with an upper layer of mesh cloth disposed within the upper mortar layer. More specifically, in this embodiment, the upper mortar layer 5 includes a filling mortar layer 51. This filling mortar layer 51 is first laid on top of the insulation core material 4, effectively sealing and filling the perimeter of the insulation core material 4, directly covering the insulation core material 4. After covering, two layers of reinforcing mesh cloth are laid on the filling mortar layer 51: reinforcing mesh cloth I 52 and reinforcing mesh cloth II 53. A sealing mortar layer 54 is then laid or sprayed on top of reinforcing mesh cloth II 53. This design improves the sealing effect and sealing stability of the insulation core material 4.

[0022] On the basis of the above structure, an outer surface of the integrated structure exterior wall insulation board is further covered with an outer mortar layer 10 , and the integrated structure exterior wall insulation board is entirely covered by the outer mortar layer 10 .

[0023] To facilitate construction, the integrated exterior wall insulation board is further provided with a number of through-holes 11, which are located on the ribs 33. Since the processing of the through-holes 11 is the last step after the product is formed, to avoid deviations when the heating personnel drill the holes, a marking area 12 is provided on the outer surface of the structural exterior wall insulation board. The marking area 12 corresponds to the ribs 33 between the insulation grooves 30. When the through-holes 11 are processed, the through-holes 11 are placed on the ribs 33 to avoid damaging the integrity of the insulation core material 4.

[0024] Furthermore, those skilled in the art can also provide through-holes 11 in the thermal insulation core material 4. However, to minimize the area of thermal insulation core material 4 damaged, the thermal insulation core material 4 requiring through-holes 11 is preferably provided in a square structure of less than 40 square centimeters. This reduces the damaged area of the thermal insulation core material 4 and reduces thermal insulation performance to a certain extent.

[0025] In this embodiment, Figure 5 、 6 As shown in Figures 7 and 8, the insulation core material 4 is composed of a sealing bag 41 and an insulation board 42. The outer side of the sealing bag 41 is a glass fiber woven layer 411, and the inner side is an aluminum foil layer, which is sprayed with thermosetting adhesive 412. The outer surface of the insulation board 42 is provided with a rough surface or a concave-convex surface 421. In this embodiment, the insulation board 42 adopts a concave-convex surface 421 design, which can increase the contact area between the outer side of the insulation board and the aluminum foil layer or thermosetting adhesive layer.

[0026] Those skilled in the art may also replace the thermosetting adhesive 412 with a PET film or a PE film coated on the aluminum foil layer, which can also be thermoset and formed under high heat.

[0027] Example 2: A molding process for an integrated structural exterior wall insulation board specifically includes the following production steps: Step (1) using a Class A fireproof insulation board 3 of Class A fireproof insulation structure as a base material, with a thickness of 5.4 cm, cut into a square structure, laying a lower layer of mesh cloth 21 on one side thereof and spraying or laying a lower mortar layer 2, the thickness of the lower mortar layer 2 being 3 mm, and standing and curing for 3 days after laying; Step (2) a plurality of insulation grooves 30 are processed at intervals on the other side of the Class A fireproof insulation board 3 of the Class A fireproof insulation structure, ribs 33 are formed in the interval area, and the groove depth is 2.7 cm thick. After the grooves are formed, the impurities in the insulation grooves 30 are cleaned, and the insulation groove mesh cloth 32 is laid in the insulation grooves 30. After the insulation groove mesh cloth 32 is laid, the bonding layer is sprayed or laid. In this embodiment, the core material mortar layer 31 is used as the bonding layer. Those skilled in the art can also use an adhesive instead, which is used to bond the insulation core material 4 in the insulation groove to improve the firmness of the insulation core material 4 after bonding; Furthermore, when the thermal insulation core material 4 is manufactured, a rough surface or a concave-convex surface 421 is first punched on the thermal insulation board 42 by a punching device, and then reserved for use; a sealing bag 41 with a single or double opening is opened, and a thermosetting adhesive 412 is sprayed inside the sealing bag 41, and then the thermal insulation board 42 is placed in the sealing bag 41, which is then placed in a vacuum machine for evacuation, so that the sealing bag 41 vacuum-coats the thermal insulation board 42; The vacuumed insulation board 42 is placed in a thermosetting machine for thermosetting at a temperature of 160 degrees Celsius for 1 minute. After thermosetting, the excess material around the sealing edge 43 of the sealing bag 41 is sheared or folded to obtain a vacuum structured insulation core material. Step (3) paving or spraying a mortar layer 5 on one side of the bonding insulation core material 4 of the Class A fireproof insulation board 3 of the Class A fireproof insulation structure, wherein the upper mortar layer 5 is a multi-layer structure, which includes, from bottom to top, a filling mortar layer 51, a reinforcing mesh cloth I 52, a reinforcing mesh cloth II 53, and a sealing mortar layer 54. When the multi-layer structure is formed, it is formed in a disordered manner layer by layer; after paving, it is left to stand for curing for 3 days; Step (4) Mark the rib 33 area on the integrated structure exterior wall insulation board. The mark serves as a reference for subsequent drilling and installation to prevent the through hole 11 from being processed on the insulation core material 4, thereby reducing the sealing, insulation or fire resistance. Step (5) edge trimming, which can be divided and processed according to the actual assembly size on the wall, and then the through hole 11 is processed on the integrated structure exterior wall insulation board; Step (6) vertically stacking and spraying mortar on the four sides of the insulation board to form a surface mortar layer 10 to cover the outer periphery of the integrated structure exterior wall insulation board as a whole. After spraying, let it stand for 3 days to increase the strength of the insulation board and the sealing of the covering.

[0028] Example 3: When the integrated structure exterior wall insulation board is used in construction conditions, it is used as an exterior wall insulation board, such as Figure 8 As shown, the inner wall formwork 7 and the integrated structural exterior wall insulation board of the outer wall are pulled by the tie rod 8. The tie rod 8 is pulled through the through hole 11. After the pulling is fixed, commercial concrete is poured into the steel cage 6 area. After the wall is fixed, the inner wall formwork 7 is removed, and the integrated structural exterior wall insulation board on the outer wall is fixed to the wall as a whole. This structure can ensure that the integrated structural exterior wall insulation board will not fall off during long-term use.

[0029] The overall thickness of the integrated structural exterior wall insulation board disclosed in the present invention only needs to be about 5cm. While meeting the 83% energy-saving requirement of our province, it also improves the housing acquisition rate of ordinary people, reduces the common area, and reduces the volume ratio. Because the product is a wrapped type, the built-in insulation core material 4 is a vacuum insulation structure with a thermal conductivity coefficient as low as 0.005 to 0.008, which has better thermal insulation. The fire resistance of this product is Class A, which can reduce the thickness of the exterior wall thin plaster. The product size is fully detailed in the drawings before it is delivered to the construction site, and zero cutting can be achieved at the construction site, which improves construction efficiency.

Claims

1. Integrated structural exterior wall insulation board and its production method, characterized by: It includes a substrate board, a lower mortar layer is provided on one side of the substrate board, a lower mesh cloth is provided in the lower mortar layer; an insulation groove is provided on the other side of the substrate board, a core material mortar layer is provided in the insulation groove, an insulation core material is laid flat in the insulation groove, an upper mortar layer is laid on the upper part of the insulation core material, and an upper mesh cloth is provided inside the upper mortar layer; an insulation groove mesh cloth is laid in the insulation groove, and a core material mortar layer is sprayed on the insulation groove mesh cloth; a marking area is provided on the outer surface of the structural exterior wall insulation board, and the marking area corresponds to the ribs between the insulation grooves.

2. The integrated structural exterior wall insulation board according to claim 1, characterized in that: The upper mortar layer comprises a filling mortar layer, a reinforcing mesh cloth is laid on the filling mortar layer, and a sealing mortar layer is arranged on the reinforcing mesh cloth.

3. The integrated structural exterior wall insulation board according to claim 1, characterized in that: The outer side of the integrated structure exterior wall insulation board is covered with an outer mortar layer, and the integrated structure exterior wall insulation board is covered by the outer mortar layer.

4. The integrated structural exterior wall insulation board according to claim 1, characterized in that: The integrated structure exterior wall insulation board is provided with a plurality of through holes, and the through holes are arranged on the ribs or on the square insulation core material with an area of less than 40 square centimeters.

5. The integrated structural exterior wall insulation board according to claim 1, characterized in that: The insulation core material is composed of a sealing bag and an insulation board. The outer side of the sealing bag is a glass fiber woven layer, and the inner side is an aluminum foil layer or a thermosetting adhesive film layer. When the inner side is an aluminum foil layer, thermosetting adhesive needs to be sprayed on the aluminum foil layer.

6. The integrated structural exterior wall insulation board according to claim 1, characterized in that: The outer surface of the heat insulation board is provided with a rough surface or a concave-convex surface.

7. A molding process for an integrated structural exterior wall insulation board, characterized by: It specifically includes the following production steps: Step (1) using a Class A fireproof board as a substrate, laying a mesh cloth on one side thereof and spraying or laying a mortar layer, and then leaving it to stand for 1 to 4 days after laying; Step (2) a plurality of insulation grooves are processed at intervals on the other side of the Class A fireproof board, ribs are formed in the interval area, and the groove depth is 2 to 3 cm thick. After the grooves are formed, impurities in the grooves are cleaned, and a mesh cloth is laid in the insulation grooves. After the mesh cloth is laid, an adhesive layer is sprayed or laid, and an insulation core material is laid in the insulation grooves; Step (3) laying or spraying mortar on one side of the Class A fireproof board with the insulation core material, then laying several layers of mesh cloth on the mortar, laying or spraying mortar on top of the mesh cloth, and leaving it to stand for 1 to 4 days after laying; Step (4) marking the rib area on the integrated structural exterior wall insulation board, which serves as a reference for subsequent drilling and installation; Step (5) trimming the edges and drilling holes in the integrated structural exterior wall insulation board; Step (6) stack the panels vertically, spray mortar on all four sides of the insulation board to form a surface mortar layer, and cover the entire periphery of the integrated structure exterior wall insulation board. After spraying, leave the panels to stand for 1 to 4 days for curing.

8. The forming process of the integrated structural exterior wall insulation board according to claim 7, characterized in that: When the thermal insulation core material is produced, a punching device is used to punch a rough surface or a concave-convex surface on the thermal insulation board, and the surface is reserved for later use; Open a sealed bag with one or both ends open, spray thermosetting glue inside the bag, place the insulation board inside the sealed bag, and then put the bag into a vacuum machine to evacuate the bag so that the insulation board is vacuum-wrapped. Place in a thermosetting machine for thermosetting at a temperature of 150 to 200 degrees Celsius for 0.5 to 2 minutes. After thermosetting, the edges of the sealed bag are sheared or folded to obtain a heat-insulating core material with a vacuum structure.

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