Aluminum foil composite expanded polystyrene insulation board and preparation method thereof

Abstract

The preparation method comprises the following steps: selecting an expanded polystyrene (EPS) thermal insulation layer, an aluminum foil reflecting layer material, an inorganic thermal insulation middle layer material and a thermal resistance transition layer material which meet the standard, and internally pasting protection; cleaning the surface of the aluminum foil reflecting layer by using isopropanol or ethanol, and slightly roughening the surface of the expanded polystyrene (EPS) heat insulating layer by using a grinding wheel or a brush; the prepared materials are stacked according to the sequence from outside to inside; after the composite board is assembled, edge structure forming machining is conducted on the four edges of the whole board; and placing the processed thermal insulation board in a ventilated and dry environment for natural curing for 24 hours, and then carrying out quality detection on the composite board. According to the preparation process, a compression molding and hot pressing integrated process is adopted, structural integration, high bonding strength and forming efficiency are achieved through multi-layer accurate positioning, warm-pressing compounding and edge shaping, and wide engineering application prospects are achieved.

Description

Technical Field

[0001] The invention relates to the technical field of building energy-saving materials, and in particular to an aluminum foil composite expanded polystyrene insulation board and a preparation method thereof. Background Art

[0002] Currently, widely used building insulation materials include expanded polystyrene (EPS) boards, extruded polystyrene (XPS) boards, rock wool boards, and polyurethane foam (PU) boards. Expanded polystyrene (EPS) insulation continues to be widely adopted in low- and medium-rise buildings, as well as in wall and roof insulation systems, due to its low density, low thermal conductivity, low price, and simple construction. However, despite its widespread use, EPS still has several significant limitations that affect its long-term performance and safety. These limitations include high emissivity (poor thermal radiation protection, reducing its effectiveness in preventing heat transfer), susceptibility to moisture absorption (reducing its insulation performance), and insufficient fire resistance (posing safety risks), making it difficult to meet the requirements of high-performance green buildings.

[0003] To address these issues, some research has attempted to improve the overall performance of EPS by combining it with other materials, such as cement-based panels, fiberglass cloth, and aluminum-coated films. However, these approaches often suffer from shortcomings such as unclear structural hierarchy, weak bonding, and limited functional integration. Consequently, a composite insulation board with systemic performance advantages suitable for industrial deployment has yet to be developed.

[0004] Therefore, there is an urgent need to develop a new type of aluminum foil composite expansion insulation board with reasonable structure, synergistic functions, strong thermal resistance, and excellent moisture-proof and fire-resistant properties, so as to overcome the shortcomings of traditional expanded polystyrene EPS insulation layer in heat reflection, waterproofness and fire resistance, and at the same time have good construction adaptability and industrial producibility, to meet the urgent demand for high-performance enclosure structure materials in the fields of green buildings, energy-saving renovations, etc. Summary of the Invention

[0005] The purpose of the present invention is to provide an aluminum foil composite expanded polystyrene insulation board and a preparation method thereof, so as to solve the technical problems of the existing EPS insulation board such as low thermal resistance, weak radiation protection ability and poor durability.

[0006] The above technical objectives of the present invention are achieved through the following technical solutions: An aluminum foil composite expanded polystyrene insulation board comprises an aluminum foil reflective layer, an inorganic heat-insulating intermediate layer material, a thermal resistance transition layer, an expanded polystyrene (EPS) heat-insulating layer, an inner protective layer, an adhesive layer, and an edge splicing structure.

[0007] The present invention also provides a method for preparing an aluminum foil composite expanded polystyrene insulation board, comprising the following steps: Step 1: Select the expanded polystyrene (EPS) insulation layer that meets the standards, the reflective layer material made of pure aluminum or aluminized polyester composite film and aluminum foil, the inorganic insulation intermediate layer material, the thermal resistance transition layer material, and the inner protective layer. Use a cutting machine or CNC cutting equipment to uniformly cut each layer of material into a cutting specification of 1200×600mm and number them; Step 2: Surface pretreatment: Use isopropyl alcohol or ethanol to remove oil and dust from the surface of the aluminum foil reflective layer. If necessary, perform plasma or flame surface treatment to enhance adhesion. The surface of the expanded polystyrene (EPS) insulation layer should be slightly roughened with a grinding wheel or brush to remove loose powder and enhance the mechanical bite force of the interface. Finally, let the board dry naturally. There should be no obvious moisture, oil stains, or impurities on the surface. Step 3: Molded integrated thermal composite assembly: The prepared materials are positioned and stacked in the structural order. The stacking order from outside to inside is: aluminum foil reflective layer, thermal resistance transition layer, inorganic insulation middle layer, expanded polystyrene (EPS) insulation layer, and inner protective layer. The entire structure is stacked layer by layer in a planar alignment manner, and adhesive is evenly applied between each interface to form a composite board. The coating amount is controlled at 200-300 g / m². Glue application can be done by scraping or rolling. After the interlayer lamination is completed, the entire composite board is placed in a heated mold and closed for mold pressing and hot lamination. When the hot pressing is completed, the mold is opened and the finished product is taken out and left to cool at room temperature for ≥4 hours to ensure that the adhesive layer is completely cured and the internal stress is released; Step 4: Edge forming and structural processing: After the composite board is assembled, the four sides of the whole board are processed for edge structural forming. Use a CNC slotting machine or hot pressing mold to process the edge splicing structure on the edge of the board according to the construction requirements; During the processing, the processing accuracy should be controlled within ±1mm, and the contact gap of the joints should be less than 1mm to ensure that the panels are tightly spliced ​​and tightly sealed during construction, reducing the risks of thermal bridges and moisture penetration; Step 5: Curing and performance testing: Place the processed insulation board in a ventilated and dry environment for natural curing for 24 hours to ensure that all adhesive layers are fully cured and the structure is stable; After curing is completed, the composite board needs to be quality tested. The test items include: thermal conductivity of the whole board (≤0.030W / m·K), surface emissivity (aluminum foil surface ≤0.07), adhesive layer peel strength (≥0.25 MPa), 72-hour water absorption (≤1.0%), flame retardancy (GB 8624 or UL-94 test should reach B1 or V1 level), etc., to ensure that the product meets the design specifications.

[0008] Further: in step 1, the aluminum foil material is industrial pure aluminum foil, preferably with a thickness of 0.03 to 0.08 mm and a surface emissivity of ≤0.07.

[0009] Further: In step one, the inorganic insulation middle layer material is silica aerogel felt or foam ceramic board with a thickness of 0.5-2 mm. If silica aerogel felt is used as the middle layer, it should be pre-cut 1-2 mm smaller than the expanded polystyrene EPS insulation layer to prevent expansion and extrusion during the hot pressing process.

[0010] Further: In step 1, the expanded polystyrene (EPS) insulation layer has a density of 15 to 25 kg / m³ and a thickness of 20 to 60 mm.

[0011] Furthermore: in step 1, the thermal resistance transition layer is an extruded polystyrene board containing ammonium polyphosphate (APP) or a phosphorus-based flame-retardant rigid polyurethane (PU) foam material with a thickness of 1 to 5 mm.

[0012] By adopting the above technical solution, the thermal buffering capacity between the aluminum foil and the expanded polystyrene (EPS) insulation layer is enhanced.

[0013] Furthermore: in step three, the adhesive is a flame retardant epoxy structural adhesive or a flame retardant thermoplastic polyurethane hot melt adhesive mixed with an inorganic flame retardant (such as aluminum hydroxide).

[0014] By adopting the above technical solution, the bonding strength and environmental adaptability of the adhesive can be enhanced.

[0015] Further: In step three, the composite panels are stacked in the following manner: first, the aluminum foil layer is laid flat on the bottom plate of the mold with the smooth side facing downwards, and is used as the outer decorative layer; then, the thermal resistance transition layer and the inorganic thermal insulation layer are laid in sequence, and fixed with adhesive; then, the expanded polystyrene EPS thermal insulation layer is attached thereto, and connected with adhesive; finally, an inner protective layer is laid on the back of the expanded polystyrene EPS thermal insulation layer, and the edges and corners of all layers are kept aligned, and clamps or limit grooves are used to assist in alignment when necessary.

[0016] Furthermore: In step three, the molding process parameters are recommended to be set as follows: the hot pressing temperature is controlled at 60-80°C, the applied pressure is 0.2-0.3 MPa, and the pressing time is 10-20 minutes.

[0017] Further: in step 4, the edge splicing structure is a tongue-and-groove structure, a tongue-and-groove structure or a step structure.

[0018] In summary, the present invention has the following beneficial effects: First, the present invention forms a partitioned composite structure by laminating an aluminum foil reflective layer and a thermal resistance transition layer on the outside of the expanded polystyrene (EPS) core layer, achieving dual blocking of infrared radiation and conductive heat. The synergistic cooperation between the aluminum foil layer, the thermal resistance layer, and the core layer not only enhances the board's ability to protect against external heat sources such as solar radiation and high-temperature heat flow, but also improves the stability of the interface structure, preventing problems such as interlayer delamination and thermal expansion deformation. Secondly, the present invention uses an aluminum foil reflective layer as the outer layer material, which has an extremely low water vapor transmission rate and can effectively block external moisture from entering the core layer. The intermediate thermal resistance transition layer, such as the XPS board itself, has a closed-cell structure and extremely low water absorption rate, which can form an additional moisture buffer barrier. The inner protective layer is located inside the core layer, effectively inhibiting the migration of indoor water vapor to the core layer. The multi-layer adhesive forms a dense structural interface during the composite process, improving the overall airtightness, preventing water seepage and condensation at the joints, and ensuring that the material maintains stable thermal performance in high humidity or rainy environments for a long time. Third, the expanded polystyrene (EPS) insulation layer used in the present invention as the main thermal insulator has the advantages of low density, low thermal conductivity, and high cost performance. The synergistic cooperation with the inner protective layer not only improves the core layer's compression and crack resistance, but also effectively ensures its long-term stability and construction adaptability in complex environments. The integration of multiple layers of adhesive in the composite structure forms a stable integrated structure between the functional layers, ensuring that delamination, shedding, and other failure behaviors will not occur in high temperature, humidity, or wind pressure environments. Fourthly, the present invention adopts an integrated hot pressing process of compression molding during the preparation process, and all structural layers are placed in a hot pressing mold with edge shaping grooves in sequence, and a certain temperature and pressure are applied for hot pressing and curing, completing multi-layer composite, edge molding and adhesive layer lamination at one time, which can significantly improve the interlayer bonding strength, composite interface density and overall dimensional accuracy, and effectively suppress assembly dislocation, thermal bridges and local deformation. Through the synergistic combination and composite reinforcement effect of each structural layer, not only the multiple protection capabilities of the insulation board against heat conduction, thermal radiation, moisture and flame are significantly improved, but also a complete and stable plate structure is formed, avoiding engineering problems such as loose structure, interface aging, and installation offset. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 1 is an overall schematic diagram of the thermal insulation composite material of the present invention; Figure 2 It is a schematic diagram of the structure of each layer of material of the heat insulation board of the present invention; Figure 3 This is a performance comparison table of thermal insulation composite panels according to embodiments of the present invention.

[0020] 1. Aluminum foil reflective layer; 2. Inorganic thermal insulation intermediate layer material; 3. Thermal resistance transition layer; 4. Expanded polystyrene (EPS) thermal insulation layer; 5. Inner protective layer; 6. Adhesive layer; 7. Edge splicing structure. DETAILED DESCRIPTION

[0021] The present invention will be further described in detail below with reference to the accompanying drawings.

[0022] In the description of the present invention, it should be understood that the terms "up", "down", "left", "right", "front", "back", "inside", "outside", etc., indicating directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as a limitation on the present invention.

[0023] Example 1, with reference to Figure 1-3 , an aluminum foil composite expanded polystyrene insulation board, including an aluminum foil reflective layer 1, an inorganic insulation intermediate layer material 2, a thermal resistance transition layer 3, an expanded polystyrene EPS insulation layer 4, an inner protective layer 5, an adhesive layer 6 and an edge splicing structure 7.

[0024] A method for preparing an aluminum foil composite expanded polystyrene insulation board comprises the following steps: Step 1: Prepare and cut raw materials: Use ordinary expanded polystyrene (EPS) insulation with a density of 20 kg / m³ and a thickness of 30 mm as the core layer. The aluminum foil reflective layer uses industrial-grade pure aluminum foil with a thickness of 0.05 mm and a surface emissivity of 0.06. The thermal resistance transition layer uses extruded polystyrene board containing ammonium polyphosphate (APP) with a thickness of 3 mm and a thermal conductivity of 0.028 W / m·K. The inorganic insulation intermediate layer material uses silica aerogel felt with a thickness of 1 mm. The inner protective layer is a phosphorus-nitrogen-modified flame-retardant polyethylene terephthalate (PET) film with a thickness of 0.2 mm. The adhesive is an inorganic flame-retardant epoxy structural adhesive mixed with aluminum hydroxide. Use a cutting machine or CNC cutting equipment to cut each layer of material into a uniform specification of 1200×600mm and number them. The aerogel felt should be cut 2 mm smaller than the expanded polystyrene EPS insulation layer to prevent expansion and extrusion during the hot pressing process.

[0025] Step 2: Surface pretreatment: Use isopropyl alcohol to remove oil and dust from the surface of the aluminum foil reflective layer. If necessary, perform plasma or flame surface treatment to enhance adhesion. The surface of the expanded polystyrene (EPS) insulation layer should be slightly roughened with a grinding wheel or brush to remove loose powder and improve the mechanical bite force of the interface. Finally, let the board dry naturally. There should be no obvious moisture, oil stains, or impurities on the surface. Step 3: Molded Integrated Thermal Composite Assembly: The prepared materials are positioned and stacked in order to form a composite panel. The stacking order from outside to inside is: aluminum foil reflective layer, thermal resistance transition layer, inorganic insulation intermediate layer, expanded polystyrene (EPS) insulation layer, and inner protective layer. The entire structure is stacked layer by layer in a planar alignment manner, and adhesive is evenly applied between each interface. Use flame-retardant hot-melt polyurethane adhesive or modified epoxy resin adhesive, with a coating amount of 200-300 g / m². Glue application can be done by scraping or rolling. When positioning each structural layer, first lay the aluminum foil layer flat on the mold base with the smooth side facing down, which will serve as the exterior decorative layer. Then, lay the thermal resistance transition layer and the inorganic insulation layer in sequence and secure them with adhesive. Then, attach the expanded polystyrene (EPS) insulation layer on top of it and connect them with adhesive. Finally, lay the inner protective layer on the back of the expanded polystyrene (EPS) insulation layer. Keep the edges and corners of all layers aligned, and use fixtures or limit grooves to assist in alignment if necessary. After the interlayer overlap is completed, the entire composite board is placed in a heated mold and closed for compression hot compounding. The recommended compression process parameters are as follows: the hot pressing temperature is controlled at 70°C, the applied pressure is 0.3 MPa, and the pressing time is 20 minutes. When the hot pressing is completed, open the mold to take out the finished product, and let it cool at room temperature for ≥4 hours to ensure that the adhesive layer is completely cured and the internal stress is released.

[0026] Step 4: Edge forming and structural processing: After the composite board is assembled, the edge splicing structure is set on the four sides of the whole board. A CNC grooving machine or a hot pressing mold is used to process the tongue-and-groove structure, tongue-and-groove structure or step-lap structure on the edge of the board. The specific structure type is selected according to the construction requirements. During the processing, the processing accuracy should be controlled within ±1mm, and the contact gap of the joint should be less than 1mm to ensure that the boards are tightly spliced ​​and tightly sealed during construction to reduce the risk of thermal bridges and moisture penetration.

[0027] Step 5: Curing and performance testing: Place the processed insulation board in a ventilated and dry environment for natural curing for 24 hours to ensure that all adhesive layers are fully cured and the structure is stable; After curing is completed, the composite board needs to be quality tested. The test items include: thermal conductivity of the whole board (≤0.030W / m·K), surface emissivity (aluminum foil surface ≤0.07), adhesive layer peel strength (≥0.25 MPa), 72-hour water absorption (≤1.0%), flame retardancy (GB 8624 or UL-94 test should reach B1 or V1 level), etc., to ensure that the product meets the design specifications.

[0028] Example 2 Different from Example 1, Example 2 does not include aluminum foil and related materials, and the remaining material layers and steps are the same.

[0029] Example 3 Different from Example 1, Example 3 does not include an inorganic thermal insulation layer and related materials, and the remaining material layers and steps are the same.

[0030] Example 4 Different from Example 1, Example 4 does not include an inner protective layer and its related materials, and the remaining material layers and steps are the same.

[0031] Performance results comparison Comparison of the performance test results of Example 2 and Example 1 shows that aluminum foil is a key layer for improving the thermal resistance and moisture resistance of the composite material panel. The aluminum foil reflective layer itself is a non-combustible material with excellent heat reflection and physical isolation functions. It can effectively block the transmission of heat radiation in the initial stage of the flame and prevent the open flame from directly contacting the underlying polymer core material. At the same time, the aluminum foil reflective layer, as the outer layer material, has an extremely low water vapor permeability, which can effectively prevent external moisture from entering the core layer. By comparing the performance test results of Example 3 with those of Example 1, it can be seen that the inorganic thermal insulation layer further enhances the thermal inertia of the board under high temperature conditions, thereby improving the thermal stability and fire resistance of the entire board. By comparing the performance test results of Example 4 with those of Example 1, it can be seen that the coordinated cooperation of the inner protective layer can not only improve the compression and crack resistance of the core layer, but also the inner protective layer is located on the inner side of the core layer, which effectively inhibits the migration of indoor water vapor to the core layer, and effectively ensures its long-term stability and construction adaptability in complex environments.

[0032] 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 creative modifications to this embodiment as needed. However, as long as they are within the scope of the claims of the present invention, they are protected by patent law.

Claims

1. An aluminum foil composite expanded polystyrene insulation board, characterized by: It comprises an aluminum foil reflective layer (1), an inorganic heat-insulating intermediate layer material (2), a thermal resistance transition layer (3), an expanded polystyrene (EPS) heat-insulating layer (4), an inner protective layer (5), an adhesive layer (6), and an edge splicing structure (7).

2. The method for preparing an aluminum foil composite expanded polystyrene insulation board according to claim 1, characterized in that: The following steps are involved: Step 1: Select the expanded polystyrene (EPS) insulation layer that meets the standards, the reflective layer material made of pure aluminum or aluminized polyester composite film and aluminum foil, the inorganic insulation intermediate layer material, the thermal resistance transition layer material, and the inner protective layer. Use a cutting machine or CNC cutting equipment to uniformly cut each layer of material into a cutting specification of 1200×600mm and number them; Step 2: Surface pretreatment: Use isopropyl alcohol or ethanol to remove oil and dust from the surface of the aluminum foil reflective layer. If necessary, perform plasma or flame surface treatment to enhance adhesion. The surface of the expanded polystyrene (EPS) insulation layer should be slightly roughened with a grinding wheel or brush to remove loose powder and enhance the mechanical bite force of the interface. Finally, let the board dry naturally. There should be no obvious moisture, oil stains, or impurities on the surface. Step 3: Molded integrated thermal composite assembly: The prepared materials are positioned and stacked in the structural order. The stacking order from outside to inside is: aluminum foil reflective layer, thermal resistance transition layer, inorganic insulation middle layer, expanded polystyrene (EPS) insulation layer, and inner protective layer. The entire structure is stacked layer by layer in a planar alignment manner, and adhesive is evenly applied between each interface to form a composite board. The coating amount is controlled at 200-300g / m². The glue can be applied by scraping or rolling. After the interlayer lamination is completed, the entire composite board is placed in a heated mold and closed for mold pressing and hot lamination. When the hot pressing is completed, the mold is opened and the finished product is taken out and left to cool at room temperature for ≥4 hours to ensure that the adhesive layer is completely cured and the internal stress is released; Step 4: Edge forming and structural processing: After the composite board is assembled, the four sides of the whole board are processed for edge structural forming. Use a CNC slotting machine or hot pressing mold to process the edge splicing structure on the edge of the board according to the construction requirements; During the processing, the processing accuracy should be controlled within ±1 mm, and the contact gap of the joints should be less than 1 mm to ensure that the panels are tightly spliced ​​and tightly sealed during construction, thereby reducing the risks of thermal bridges and moisture penetration. Step 5: Curing and performance testing: Place the processed insulation board in a ventilated and dry environment for natural curing for 24 hours to ensure that all adhesive layers are fully cured and the structure is stable; After curing is completed, the composite board needs to be quality tested. The test items include: thermal conductivity of the whole board (≤0.030 W / m·K), surface emissivity (aluminum foil surface ≤0.07), adhesive layer peel strength (≥0.25 MPa), 72-hour water absorption (≤1.0%), flame retardancy (GB 8624 or UL-94 test should reach B1 or V1 level), etc., to ensure that the product meets the design specifications.

3. The method for preparing an aluminum foil composite expanded polystyrene insulation board according to claim 2, characterized in that: In step 1, the aluminum foil material is industrial pure aluminum foil, preferably with a thickness of 0.03 to 0.08 mm and a surface emissivity of ≤0.

07.

4. The method for preparing an aluminum foil composite expanded polystyrene insulation board according to claim 2, wherein: In step one, the inorganic insulation middle layer material is silica aerogel felt or foam ceramic board with a thickness of 0.5-2 mm. If silica aerogel felt is used as the middle layer, it should be pre-cut 1-2 mm smaller than the expanded polystyrene EPS insulation layer to prevent expansion and extrusion during the hot pressing process.

5. The method for preparing an aluminum foil composite expanded polystyrene insulation board according to claim 2, characterized in that: In step 1, the expanded polystyrene (EPS) insulation layer has a density of 15 to 25 kg / m³ and a thickness of 20 to 60 mm.

6. The method for preparing an aluminum foil composite expanded polystyrene insulation board according to claim 2, characterized in that: In step 1, the thermal resistance transition layer is an extruded polystyrene board containing ammonium polyphosphate (APP) or a phosphorus-based flame-retardant rigid polyurethane (PU) foam material with a thickness of 1 to 5 mm.

7. The method for preparing an aluminum foil composite expanded polystyrene insulation board according to claim 2, characterized in that: In step three, the adhesive is a flame retardant epoxy structural adhesive or a flame retardant thermoplastic polyurethane hot melt adhesive mixed with an inorganic flame retardant (such as aluminum hydroxide).

8. The aluminum foil composite expanded polystyrene thermal insulation board and the preparation method thereof according to claim 2, characterized in that: In step three, the composite panels are stacked in the following way: first, the aluminum foil layer is laid flat on the mold bottom plate with the smooth side facing down, which is used as the outer decorative layer; then the thermal resistance transition layer and the inorganic insulation layer are laid in sequence and fixed with adhesive; then the expanded polystyrene (EPS) insulation layer is attached thereon and connected with adhesive; finally, the inner protective layer is laid on the back of the expanded polystyrene (EPS) insulation layer, and the edges and corners of all layers are kept aligned. If necessary, clamps or limit grooves are used to assist in alignment.

9. The aluminum foil composite expanded polystyrene thermal insulation board and the preparation method thereof according to claim 2, characterized in that: In step three, the molding process parameters are recommended to be set as follows: the hot pressing temperature is controlled at 60-80°C, the applied pressure is 0.2-0.3 MPa, and the pressing time is 10-20 minutes.

10. The aluminum foil composite expanded polystyrene thermal insulation board and preparation method according to claim 2, characterized in that: In step 4, the edge splicing structure is a tongue-and-groove structure, a tongue-and-groove structure, or a step structure.

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