Polystyrene insulation board and preparation method thereof

Abstract

The invention relates to the field of foam forming boards, and particularly discloses a polystyrene insulation board and a preparation method thereof. The polystyrene insulation board comprises the following raw materials: foamable beads A1, foamable beads A2, foamable beads B, foamable beads C and foamable beads D of which the particle sizes are continuously graded, and also comprises an insulation material, the foamable beads A1 and the foamable beads A2 comprise high impact polystyrene and styrene, the thermal insulation material comprises a water glass solution and an inorganic filler, wherein the inorganic filler comprises calcined kaolin, wollastonite and mica; the preparation method comprises the following steps: granulating, foaming to prepare a board, preparing a thermal insulation material and carrying out thermal insulation treatment. The polystyrene insulation board has good thermal insulation performance, fire resistance and structural stability, the heat conductivity coefficient is not higher than 0.0432 W / (m.K), the tensile strength is not lower than 0.32 MPa, and the combustion heat value is not higher than 3.1 MJ / kg.

Description

Technical Field

[0001] The present application relates to the technical field of foamed molded boards, and in particular to a polystyrene insulation board and a preparation method thereof. Background Art

[0002] Polystyrene (EPS) boasts advantages such as low cost, thermal insulation, waterproofing, strong corrosion resistance, and excellent dielectric properties. It is widely used as packaging material for fragile items such as machinery, equipment, and instruments, as well as in food packaging boxes and bags. It can also be used as sheet material in the construction industry. One such material is polystyrene insulation board. Since its introduction, its excellent thermal insulation properties and lightweight design have rapidly made it a popular choice for building insulation, becoming an indispensable material in numerous construction projects. With the booming construction industry, the application of EPS insulation board has continued to expand, encompassing various building types, including residential, commercial, and industrial plants, making a significant contribution to building energy conservation and insulation. It effectively reduces heat exchange between internal and external surfaces, lowering energy consumption and improving indoor comfort, thus playing a positive role in promoting building energy conservation. Furthermore, with the acceleration of urbanization and the improvement of people's living standards, the performance requirements for building insulation materials are becoming increasingly stringent. Not only are they expected to provide excellent thermal insulation, but they also impose higher standards for fire resistance and strength.

[0003] In the past, when solving the performance problems of polystyrene insulation boards, the industry conventionally adopted a variety of methods. In order to improve the fire resistance, thermal insulation materials are usually added to the polystyrene material, which can enhance the fire resistance of the board to a certain extent. In addition, researchers have proposed using the negative pressure infiltration method to prepare a fireproof layer on the polystyrene foam board, which can ensure the structural strength and integrity of the polystyrene foam board. In terms of balancing the thermal conductivity and mechanical strength of the board, the common practice is to adjust the particle size ratio of the foamed particles and try to find a suitable ratio to take into account the performance of both. At the same time, in order to improve the bonding force between the foamed particles, the particles are also modified. However, most of these methods are based on a single performance improvement and lack systematic and comprehensive considerations. Therefore, how to achieve comprehensive optimization of the performance of polystyrene insulation boards is still a more difficult problem. Summary of the Invention

[0004] In order to solve the above technical problems, the present application provides a polystyrene insulation board and a preparation method thereof.

[0005] In a first aspect, the present application provides a polystyrene insulation board, the raw materials used comprising foamable beads A1, foamable beads A2, foamable beads B, foamable beads C, and foamable beads D having continuously graded particle sizes and a weight ratio of (20-25):(20-25):20:(25-30):(15-20), and also comprising insulation material; wherein the particle size of foamable beads A1 is 0.1-1.0 mm, the particle size of foamable beads A2 is 1.1-2.0 mm, and the particle size of foamable beads B is 2.1-3. 0mm, the particle size of foamable beads C is 3.1-4.0mm, and the particle size of foamable beads D is 4.1-5.0mm; the raw materials used for foamable beads A1 and foamable beads A2 include high-impact polystyrene and styrene in a weight ratio of (2-2.5): (30-35), and foamable beads B, foamable beads C and foamable beads D are all polystyrene beads; the thermal insulation material includes a water glass solution and an inorganic filler in a weight ratio of (170-175):20, and the inorganic filler includes calcined kaolin, wollastonite and mica.

[0006] By adopting the above-mentioned technical scheme, the present application uses high-impact polystyrene and styrene to prepare small-particle beads, and mixes them with other large-particle polystyrene beads according to continuous grading to prepare boards, taking into account the mechanical strength and thermal insulation effect of the insulation board. At the same time, calcined kaolin, wollastonite and mica are compounded as inorganic fillers and blended with water glass solution to prepare insulation materials. After processing with polystyrene boards, polystyrene insulation boards with good structural strength and integrity can be obtained, with a thermal conductivity coefficient of not higher than 0.0432W / (m·K), a tensile strength of not less than 0.32MPa, and a combustion calorific value of not more than 3.1MJ / kg, and good thermal insulation performance, fire resistance and structural stability.

[0007] Preferably, the weight ratio of the expandable beads A1, expandable beads A2, expandable beads B, expandable beads C and expandable beads D is 22:23:20:26:19.

[0008] By adopting the above technical solution, the present application further optimizes the weight ratio of foamable beads A1, foamable beads A2, foamable beads B, foamable beads C and foamable beads D. At this time, the ratio of the number of continuously graded beads in the system reaches the optimal level, which can greatly improve the structural stability without affecting the thermal insulation performance and fire resistance of the polystyrene insulation board, thereby increasing the tensile strength by nearly 10%.

[0009] Preferably, the weight ratio of the calcined kaolin, wollastonite and mica is (5-8):(5-10):(5-7).

[0010] By adopting the above technical solution, the present application controls the weight ratio of calcined kaolin, wollastonite and mica in the inorganic filler, balances the degree of improvement of the mechanical strength and thermal insulation effect of the three, and the three can maximize the synergistic effect and fully improve the comprehensive performance of the polystyrene insulation board.

[0011] Preferably, the water glass solution is further modified, specifically by blending water glass solution, alkaline silica sol and silicone acrylic emulsion in a weight ratio of 20:(10-12):(2-3), and reacting to obtain a modified water glass solution.

[0012] By adopting the above-mentioned technical solution, the present application utilizes alkaline silica sol and silicone acrylic emulsion to modify the water glass solution, fully utilizing the good compatibility between the alkaline silica sol and silicone acrylic emulsion and the water glass solution, and greatly improving the mechanical strength of the final cured film of the thermal insulation material, which can be more firmly filled in the gaps of the polystyrene board, thereby simultaneously optimizing the mechanical strength and thermal insulation effect of the polystyrene insulation board.

[0013] Preferably, the weight ratio of the water glass solution, alkaline silica sol and silicone acrylic emulsion is 20:11:2.7.

[0014] By adopting the above technical solution, the present application strictly controls the weight ratio of water glass solution, alkaline silica sol and silicone acrylic emulsion, so that the modified water glass solution can achieve the optimal improvement in the mechanical strength and thermal insulation effect of the polystyrene insulation board. At this time, the thermal conductivity is as low as 0.0396W / (m·K) and the tensile strength can reach 0.38MPa.

[0015] Preferably, the mica is further modified, specifically by blending a modifier and mica in a weight ratio of (4.5-5):100, sand-milling, adding ethanol for Soxhlet extraction, drying, and ball-milling to obtain modified mica, wherein the modifier is prepared from n-butyl acrylate, sodium p-styrenesulfonate, and vinyltriethoxysilane.

[0016] By adopting the above technical scheme, the present application modifies the mica. First, n-butyl acrylate, sodium p-styrene sulfonate and vinyl triethoxysilane are reacted to obtain a modifier, which is then blended with mica and sand-milled. After a series of treatments, modified mica with a lower particle size is obtained, and its specific surface area increases by 55-60%, and D50 decreases by 5.9-6.1μm, thereby improving its suspension ability in the thermal insulation material, enabling it to be stably dispersed in the liquid phase for a longer period of time. The steric hindrance effect caused by the stretching of the macromolecular chain of the modifier causes the mica particles to repel each other, prevent stacking, and effectively alleviate the agglomeration phenomenon. In addition, the molecular chains of the modifier bonded to the surface of the powder form a good compatibility effect between the mica and other substances in the system, so that the components in the thermal insulation material can be more fully and evenly filled in the gaps of the polystyrene board, thereby greatly optimizing the thermal insulation effect of the polystyrene insulation board.

[0017] In the second aspect, the present application provides a method for preparing a polystyrene insulation board, comprising the following steps: S1, granulation: obtaining foamable beads A1 and foamable beads A2; S2, foaming and board making: blending the foamable beads A1, foamable beads A2, foamable beads B, foamable beads C and foamable beads D, foaming, curing, punching and forming, and drying under the conditions of a system pressure of 7-8 Pa and a temperature of 160-180°C to obtain a polystyrene board; S3, preparing insulation material; S4, insulation treatment: blending the polystyrene board obtained in step S2 and the insulation material obtained in step S3 under negative pressure conditions, and drying to obtain a polystyrene insulation board.

[0018] Preferably, in step S4, the volume mass ratio of the polystyrene board obtained in step S2 and the thermal insulation material obtained in step S3 is controlled to be 1m 3 :(70-80)kg.

[0019] Preferably, in step S4, the system pressure is -80 cmHg to -70 cmHg.

[0020] By adopting the above technical solution, the present application firstly uses high-impact polystyrene and styrene to blend, and then adds a variety of additives such as dispersants, lubricants, cross-linking agents, foaming agents and initiators. After a series of treatments such as heat preservation reaction, continuously graded foamable beads with particle sizes of 0.1-1.0 mm and 1.1-2.0 mm are obtained, and are respectively recorded as foamable beads A1 and foamable beads A2. Subsequently, the present application combines the foamable beads A1 and foamable beads A2 with the continuously graded particles of The foamable beads B with a particle size of 2.1-3.0 mm, the foamable beads C with a particle size of 3.1-4.0 mm and the foamable beads D with a particle size of 4.1-5.0 mm are blended, foamed under a certain pressure and temperature, cured, formed into plates, and dried in the shade to obtain polystyrene plates with a size of 2 m × 1 m × 50 mm, which are then used. Then, water glass solution, inorganic fillers (calcined kaolin, wollastonite and mica) and surfactants are blended to obtain a thermal insulation material. Finally, the thermal insulation material is prepared according to a volume-to-mass ratio of 1 m 3 :(70-80)kg The polystyrene board and the thermal insulation material are combined by negative pressure infiltration and dried to obtain a polystyrene insulation board with good thermal insulation performance, fire resistance and structural stability.

[0021] In a specific embodiment of the present application, the dispersant is calcium phosphate and hydroxyethyl cellulose, the lubricant is polyethylene wax, the initiator is sodium bisulfite and benzoyl peroxide, the crosslinking agent is divinylbenzene, the foaming agent is pentane, and the surfactant is sodium lauryl sulfate. However, the above substances are only used as examples and can only represent the conventional choices in the preparation of the present application. Those skilled in the art can make reasonable adjustments according to actual conditions, and the scope of protection of the present application cannot be limited accordingly.

[0022] In summary, this application has the following beneficial technical effects: The present application utilizes high-impact polystyrene and styrene to produce small-particle beads, which are mixed with other large-particle polystyrene beads according to continuous grading to produce boards, taking into account both the mechanical strength and thermal insulation effect of the insulation board. At the same time, calcined kaolin, wollastonite and mica are compounded as inorganic fillers and blended with a water glass solution to produce an insulation material. After treatment with a polystyrene board, a polystyrene insulation board with good structural strength and integrity can be obtained, with a thermal conductivity of not more than 0.0432W / (m·K), a tensile strength of not less than 0.32MPa, and a combustion calorific value of not more than 3.1MJ / kg, having good thermal insulation performance, fire resistance and structural stability. DETAILED DESCRIPTION

[0023] Material Source Unless otherwise specified, the raw materials used in this application are all commercially available products, specifically: Water glass solution, effective content 40wt%, modulus 3.3; Alkaline silica sol, SiO2 content 30wt%; Silicone acrylic emulsion, solid content 48wt%; Polyethylene wax, viscosity at 140°C = 210 cps, acid value 16 mgKOH / g; Calcined kaolin, SiO2 content 46.3wt%, water content 12.4wt%, 1250 mesh; Wollastonite, SiO2 content 49-51wt%, CaO content 41-43wt%, thermal expansion coefficient 0.35, 1250 mesh; Mica, specific surface area 0.54m 2 / g, D50=14.2μm.

[0024] The present application is further described in detail below with reference to preparation examples, embodiments and comparative examples.

[0025] <Preparation Example 1.1> The preparation method of the modified water glass solution comprises the following steps: 100 kg of alkaline silica sol was slowly dripped into 200 kg of water glass solution. At a temperature of 55 ° C, methyltrimethoxysilane coupling agent was added three times, 2 kg each time, and the time interval between each addition was the same, 30 minutes. After reacting for 90 minutes, the system was cooled to 30 ° C, and 30 kg of silicone acrylic emulsion was added. The reaction was carried out at 35 ° C for 60 minutes to obtain a modified water glass solution.

[0026] <Preparation Example 1.2> The preparation method of the modified water glass solution comprises the following steps: 120 kg of alkaline silica sol was slowly dripped into 200 kg of water glass solution. At a temperature of 55 ° C, methyltrimethoxysilane coupling agent was added three times, 2 kg each time, and the time interval between each addition was the same, 30 minutes. After reacting for 90 minutes, the system was cooled to 30 ° C, and 20 kg of silicone acrylic emulsion was added. The reaction was carried out at 30 ° C for 60 minutes to obtain a modified water glass solution.

[0027] <Preparation Example 2.1> The preparation method of the modified water glass solution is different from that of Preparation Example 1.1 in that the amount of alkaline silica sol used is 110 kg and the amount of silicone acrylic emulsion used is 24 kg. The rest is the same as Preparation Example 1.1.

[0028] <Preparation Example 2.2> The preparation method of the modified water glass solution is different from that of Preparation Example 1.1 in that the amount of alkaline silica sol used is 110 kg and the amount of silicone acrylic emulsion used is 27 kg. The rest is the same as Preparation Example 1.1.

[0029] <Preparation Example 3.1> The preparation method of modified mica comprises the following steps: 2.5 kg of n-butyl acrylate, 1.5 kg of sodium p-styrenesulfonate and 0.5 kg of vinyltriethoxysilane were dispersed in 5 L of N,N-dimethylformamide, stirred and reacted for 10 min under nitrogen protection at 50 ° C, 12 g of azobisisobutyronitrile and 15 g of dodecanethiol were added dropwise, and the temperature was raised to 65 ° C and kept warm for 1.5 h to obtain a modifier. Subsequently, 0.45 kg of the modifier, 10 kg of mica and 25 L of water were blended and placed in a sand mill for 40 min. After the solid matter was taken out, 95 wt% ethanol was used as a solvent, Soxhlet extraction was carried out at 60 ° C for 12 h, drying, and ball milling to obtain modified mica with a specific surface area of ​​0.84 m 2 / g, D50=8.1μm.

[0030] <Preparation Example 3.2> The preparation method of modified mica comprises the following steps: 2.6 kg of n-butyl acrylate, 1.5 kg of sodium p-styrenesulfonate and 0.4 kg of vinyltriethoxysilane were dispersed in 5 L of N,N-dimethylformamide, stirred and reacted for 10 min under nitrogen protection at 50 ° C, 12 g of azobisisobutyronitrile and 15 g of dodecanethiol were added dropwise, and the temperature was raised to 65 ° C and kept warm for 1.5 h to obtain a modifier. Subsequently, 0.5 kg of the modifier, 10 kg of mica and 25 L of water were blended and placed in a sand mill for 40 min. After the solid matter was taken out, 95 wt% ethanol was used as a solvent, Soxhlet extraction was carried out at 60 ° C for 12 h, drying, and ball milling to obtain modified mica with a specific surface area of ​​0.86 m 2 / g, D50=7.9μm.

[0031] <Example 1.1> A method for preparing a polystyrene insulation board comprises the following steps: S1. Granulation: Disperse polyvinyl alcohol in water at 90°C and stir for 40 minutes. After cooling to room temperature, add 70 wt% of the total amount of dispersant (calcium phosphate and hydroxyethyl cellulose) and high-impact polystyrene. Continue stirring for 40 minutes, then add styrene and lubricant (polyethylene wax). After stirring for 20 minutes, heat to 85°C and keep the temperature for 1 hour. Then add initiator (sodium bisulfite and benzoyl peroxide) and crosslinker (divinylbenzene). Keep the temperature for 4.5 hours, and then add The remaining 30 wt% dispersant was added, and a blowing agent (pentane) was added under nitrogen protection. The mixture was kept warm at 120° C. and 1 MPa for 2 h, cooled to 35° C., and dehydrated to a constant weight to obtain expandable beads with a particle size distribution of 0.1-2 mm. Continuously graded expandable beads with particle sizes of 0.1-1.0 mm and 1.1-2.0 mm were sieved and designated as expandable beads A1 and expandable beads A2, respectively. The amounts of the various substances used are shown in Table 1. S2, foaming board making: the weight ratio of expandable beads A1, expandable beads A2, expandable beads B with a particle size of 2.1-3.0 mm, expandable beads C with a particle size of 3.1-4.0 mm, and expandable beads D with a particle size of 4.1-5.0 mm were blended, stirred evenly, and poured into the material box of the foaming machine, and the foaming conditions were adjusted (the steam switch of the foaming machine was turned on to adjust the system pressure to 7-8 Pa, and the temperature was set to 160-180° C.). When the temperature reached 90° C., foaming was observed in the system. The foaming was terminated by keeping the temperature for 40 seconds. The beads were then sent to an oxidation chamber for curing at a temperature of 30±5° C. for 7±0.5 h to obtain expandable beads. The beads were placed in a plate forming machine, plated at a steam pressure of 5-6 Pa, and dried in the shade to obtain a polystyrene board of 2 m×1 m×50 mm; S3. Preparation of thermal insulation material: Water glass solution, inorganic fillers (calcined kaolin, wollastonite and mica) and surfactant (sodium lauryl sulfate) were blended and stirred for 30 minutes to obtain a thermal insulation material. The amounts of each substance used are shown in Table 1. S4. Insulation treatment: Place the polystyrene board obtained in step S2 horizontally in a sealed container, then inject 8 kg of the insulation material obtained in step S3, evacuate the system to a system pressure of -70 cmHg in a closed system, let it stand for 5 minutes, take out the polystyrene board and dry it at 80°C to constant weight to obtain a polystyrene insulation board.

[0032] <Example 1.2> A method for preparing a polystyrene insulation board comprises the following steps: S1. Granulation: Disperse polyvinyl alcohol in water at 90°C and stir for 40 minutes. After cooling to room temperature, add 70 wt% of the total amount of dispersant (calcium phosphate and hydroxyethyl cellulose) and high-impact polystyrene. Continue stirring for 40 minutes, then add styrene and lubricant (polyethylene wax). After stirring for 20 minutes, heat to 85°C and keep the temperature for 1 hour. Then add initiator (sodium bisulfite and benzoyl peroxide) and crosslinker (divinylbenzene). Keep the temperature for 4.5 hours, and then add The remaining 30 wt% dispersant was added, and a blowing agent (pentane) was added under nitrogen protection. The mixture was kept warm at 120° C. and 1 MPa for 2 h, cooled to 35° C., and dehydrated to a constant weight to obtain expandable beads with a particle size distribution of 0.1-2 mm. Continuously graded expandable beads with particle sizes of 0.1-1.0 mm and 1.1-2.0 mm were sieved and designated as expandable beads A1 and expandable beads A2, respectively. The amounts of the various substances used are shown in Table 1. S2, foaming board making: the weight ratio of expandable beads A1, expandable beads A2, expandable beads B with a particle size of 2.1-3.0 mm, expandable beads C with a particle size of 3.1-4.0 mm, and expandable beads D with a particle size of 4.1-5.0 mm were blended, stirred evenly, and poured into the material box of the foaming machine, and the foaming conditions were adjusted (the steam switch of the foaming machine was turned on to adjust the system pressure to 7-8 Pa, and the temperature was set to 160-180° C.). When the temperature reached 90° C., foaming was observed in the system. The foaming was terminated by keeping the temperature for 40 seconds. The beads were then sent to an oxidation chamber for curing at a temperature of 30±5° C. for 7±0.5 h to obtain expandable beads, which were placed in a plate forming machine and formed into plates under a steam pressure of 5-6 Pa. The plates were dried in the shade to obtain polystyrene plates of 2 m×1 m×50 mm; S3. Preparation of thermal insulation material: Water glass solution, inorganic fillers (calcined kaolin, wollastonite and mica) and surfactant (sodium lauryl sulfate) were blended and stirred for 30 minutes to obtain a thermal insulation material. The amounts of each substance used are shown in Table 1. S4. Insulation treatment: Place the polystyrene board obtained in step S2 horizontally in a sealed container, then inject 7 kg of the insulation material obtained in step S3, evacuate the system to a system pressure of -80 cmHg in a closed system, let it stand for 5 minutes, take out the polystyrene board and dry it at 80°C to constant weight to obtain a polystyrene insulation board.

[0033] Table 1 Material usage (kg) <Example 1.3> A method for preparing a polystyrene insulation board, which differs from Example 1.1 in that, in step S2, the weight ratio of foamable beads A1, foamable beads A2, foamable beads B, foamable beads C, and foamable beads D is 22:23:20:26:19, and the rest is the same as Example 1.1.

[0034] <Example 1.4> A method for preparing a polystyrene insulation board, which differs from Example 1.1 in that, in step S2, the weight ratio of foamable beads A1, foamable beads A2, foamable beads B, foamable beads C, and foamable beads D is 23:22:20:28:17, and the rest is the same as Example 1.1.

[0035] <Example 2.1> A method for preparing a polystyrene insulation board is different from that of Example 1.3 in that, in step S3, the water glass solution is completely replaced by the modified water glass solution prepared in Preparation Example 1.1, and the rest is the same as that of Example 1.3.

[0036] <Example 2.2> A method for preparing a polystyrene insulation board is different from that of Example 1.3 in that, in step S3, the water glass solution is completely replaced by the modified water glass solution prepared in Preparation Example 1.2, and the rest is the same as that of Example 1.3.

[0037] <Example 2.3> A method for preparing a polystyrene insulation board is different from Example 2.1 in that, in step S3, the modified water glass solution prepared in Preparation Example 1.1 is completely replaced by the modified water glass solution prepared in Preparation Example 2.1, and the rest is the same as Example 2.1.

[0038] <Example 2.4> A method for preparing a polystyrene insulation board is different from Example 2.1 in that, in step S3, the modified water glass solution prepared in Preparation Example 1.1 is completely replaced by the modified water glass solution prepared in Preparation Example 2.2, and the rest is the same as Example 2.1.

[0039] <Example 3.1> A method for preparing a polystyrene insulation board is different from that of Example 1.3 in that, in step S3, all mica is replaced by the modified mica obtained in Preparation Example 3.1, and the rest is the same as that of Example 1.3.

[0040] <Example 3.2> A method for preparing a polystyrene insulation board is different from that of Example 1.3 in that, in step S3, all mica is replaced by the modified mica obtained in Preparation Example 3.2, and the rest is the same as that of Example 1.3.

[0041] <Comparative Example 1.1> The difference from Example 1.1 is that step S1 is removed, and the expandable beads A1 and expandable beads A2 in step S2 are all replaced with polystyrene beads of the same particle size. The rest is the same as Example 1.1.

[0042] <Comparative Example 1.2> The difference from Example 1.1 is that the expandable beads A1, expandable beads B, expandable beads C and expandable beads D in step S2 are removed, and the rest are the same as Example 1.1.

[0043] <Comparative Example 2.1> The difference from Example 1.1 is that the expandable beads D in step S2 are removed, and the rest are the same as Example 1.1.

[0044] <Comparative Example 2.2> The difference from Example 1.1 is that the expandable beads A1 in step S2 are removed, and polystyrene beads with a particle size of 5.1-6.0 mm are added in step S2, and the weight ratio of polystyrene beads to expandable beads D is controlled to be 1:1. The rest is the same as Example 1.1.

[0045] <Comparative Example 3.1> The difference from Example 1.1 is that the calcined kaolin in step S3 is removed, the amount of wollastonite used is 12.5 kg, the amount of mica used is 7.5 kg, and the rest is the same as Example 1.1.

[0046] <Comparative Example 3.2> The difference from Example 1.1 is that the wollastonite in step S3 is removed, the amount of calcined kaolin used is 10 kg, the amount of mica used is 10 kg, and the rest is the same as Example 1.1.

[0047] <Comparative Example 3.3> The difference from Example 1.1 is that the mica in step S3 is removed, the amount of wollastonite used is 12.5 kg, the amount of calcined kaolin used is 7.5 kg, and the rest is the same as Example 1.1.

[0048] Performance testing The performance of the polystyrene insulation boards obtained in the examples and comparative examples was tested, and the results are shown in the following table.

[0049] Table 2 Performance test table Group Thermal conductivity (W / (m·K)) Tensile strength (MPa) Combustion calorific value (MJ / kg) Example 1.1 0.0415 0.32 2.8 Example 1.2 0.0432 0.37 2.1 Example 1.3 0.0419 0.35 2.8 Example 1.4 0.0427 0.36 2.3 Example 2.1 0.0405 0.35 3.0 Example 2.2 0.0402 0.35 2.9 Example 2.3 0.0403 0.36 3.0 Example 2.4 0.0396 0.38 3.1 Example 3.1 0.0403 0.35 3.0 Example 3.2 0.0401 0.36 3.0 Comparative Example 1.1 0.0410 0.23 2.9 Comparative Example 1.2 0.0894 0.45 0.9 Comparative Example 2.1 0.0687 0.38 1.1 Comparative Example 2.2 0.0403 0.25 3.0 Comparative Example 3.1 0.0522 0.33 1.5 Comparative Example 3.2 0.0481 0.24 1.8 Comparative Example 3.3 0.0586 0.35 1.3 Data Analysis: As can be seen from Table 2, the thermal conductivity of the polystyrene insulation board of Examples 1.1-1.2 of the present application is 0.0415-0.0432 W / (m·K), and the tensile strength is 0.032-0.037 MPa, which proves that the polystyrene insulation board of the present application has good structural strength and integrity, and has good thermal insulation performance, fire resistance and structural stability.

[0050] The difference between Example 1.1 and Examples 1.3-1.4 lies in the different weight ratios of foamable beads A1, foamable beads A2, foamable beads B, foamable beads C, and foamable beads D. The results show that Example 1.3 has a lower thermal conductivity and a higher tensile strength, which proves that the present application further optimizes the weight ratio of foamable beads A1, foamable beads A2, foamable beads B, foamable beads C, and foamable beads D, and can optimize the ratio of the number of continuously graded beads in the system. Under the premise of having almost no effect on the thermal insulation and fire resistance properties of the polystyrene insulation board, the structural stability is greatly improved, and the tensile strength is increased by nearly 10%.

[0051] In Examples 2.1-2.4, the present application replaced the water glass solution with a modified water glass solution. The results showed that the thermal conductivity decreased and the tensile strength increased, proving that the present application used alkaline silica sol and silicone acrylic emulsion to modify the water glass solution, fully exerting the good compatibility between the alkaline silica sol and silicone acrylic emulsion and the water glass solution, and greatly improving the mechanical strength of the final cured film of the thermal insulation material, which can be more firmly filled in the gaps of the polystyrene board, thereby simultaneously optimizing the mechanical strength and thermal insulation effect of the polystyrene insulation board. Among them, the thermal conductivity of Example 2.4 reached 0.0396W / (m·K), and the tensile strength reached 0.38MPa, proving that the present application strictly controls the weight ratio of water glass solution, alkaline silica sol and silicone acrylic emulsion, so that the modified water glass solution can achieve the best improvement in the mechanical strength and thermal insulation effect of the polystyrene insulation board.

[0052] In Examples 3.1-3.2, the present application replaced mica with modified mica. The results showed that the thermal conductivity decreased and the tensile strength increased, proving that the present application used n-butyl acrylate, sodium p-styrenesulfonate and vinyltriethoxysilane to react to obtain a modifier, which was then blended with mica, sanded, and subjected to a series of treatments to obtain modified mica with a lower particle size, thereby improving its suspension ability in the thermal insulation material and enabling it to be stably dispersed in the liquid phase for a longer period of time, so that the various components in the thermal insulation material can be more fully and evenly filled in the gaps of the polystyrene board, thereby greatly optimizing the thermal insulation effect of the polystyrene insulation board.

[0053] In Comparative Example 1.1, all the expandable beads A1 and A2 were replaced with polystyrene beads of the same particle size. The results showed that the thermal conductivity decreased slightly, but the tensile strength decreased significantly, proving that the present application used high-impact polystyrene and styrene to produce small-particle beads, which were mixed with other large-particle polystyrene beads according to continuous grading to produce boards, taking into account both the mechanical strength and thermal insulation effect of the insulation board.

[0054] In Comparative Example 1.2, all beads were replaced with expandable beads A2. The results showed that the thermal conductivity coefficient soared to 0.0894 W / (m·K), proving that the continuous grading of beads in this application can form uniform and appropriate gaps inside the system, significantly improving the thermal insulation effect of the polystyrene insulation board.

[0055] In Comparative Example 2.1, this application lowered the bead particle size, and the results showed that the thermal conductivity coefficient increased sharply. In Comparative Example 2.2, this application increased the bead particle size, and the results showed that the tensile strength decreased significantly, proving that there is a correlation between the continuous grading particle size range controlled by this application and the amount of beads of each particle size, and that they are coordinated as a whole to improve the thermal insulation effect of the polystyrene insulation board.

[0056] In comparative examples 3.1-3.3, the present application removed calcined kaolin, wollastonite and mica respectively, and the results showed that the thermal conductivity and / or tensile strength were impaired, proving that the calcined kaolin, wollastonite and mica in the inorganic fillers of the present application have a good synergistic effect, which can fully improve the comprehensive performance of the polystyrene insulation board.

[0057] The embodiments of this specific implementation method are all preferred embodiments of the present application and are not intended to limit the scope of protection of the present application. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the scope of protection of the present application.

Claims

1. A polystyrene insulation board, characterized in that: The raw materials used include foamable beads A1, foamable beads A2, foamable beads B, foamable beads C and foamable beads D with continuously graded particle sizes and a weight ratio of (20-25): (20-25): 20: (25-30): (15-20), and also include thermal insulation materials; Among them, the particle size of the foamable beads A1 is 0.1-1.0 mm, the particle size of the foamable beads A2 is 1.1-2.0 mm, the particle size of the foamable beads B is 2.1-3.0 mm, the particle size of the foamable beads C is 3.1-4.0 mm, and the particle size of the foamable beads D is 4.1-5.0 mm; The raw materials used for expandable beads A1 and expandable beads A2 include high-impact polystyrene and styrene in a weight ratio of (2-2.5): (30-35), and expandable beads B, expandable beads C, and expandable beads D are all polystyrene beads; The thermal insulation material comprises a water glass solution and an inorganic filler in a weight ratio of (170-175):20, wherein the inorganic filler comprises calcined kaolin, wollastonite and mica.

2. A polystyrene insulation board according to claim 1, characterized in that: The weight ratio of the expandable beads A1, expandable beads A2, expandable beads B, expandable beads C and expandable beads D is 22:23:20:26:

19.

3. The polystyrene insulation board according to claim 1, characterized in that: The weight ratio of the calcined kaolin, wollastonite and mica is (5-8): (5-10): (5-7).

4. The polystyrene insulation board according to claim 1, characterized in that: The water glass solution is further subjected to a modification process, specifically: A water glass solution, an alkaline silica sol and a silicone acrylic emulsion are mixed in a weight ratio of 20:(10-12):(2-3), and a modified water glass solution is obtained after reaction.

5. The polystyrene insulation board according to claim 4, characterized in that: The weight ratio of the water glass solution, alkaline silica sol and silicone acrylic emulsion is 20:11:2.

7.

6. The polystyrene insulation board according to claim 1, characterized in that: The mica is further modified, specifically: The modifier and mica are blended in a weight ratio of (4.5-5):100, sand-milled, added with ethanol for Soxhlet extraction, dried, and ball-milled to obtain modified mica. The modifier is prepared from n-butyl acrylate, sodium p-styrenesulfonate, and vinyltriethoxysilane.

7. The method for preparing a polystyrene insulation board according to claim 6, characterized in that: The weight ratio of n-butyl acrylate, sodium p-styrenesulfonate and vinyltriethoxysilane is (2.5-2.6):1.5:(0.4-0.5).

8. A method for preparing the polystyrene insulation board according to any one of claims 1 to 7, characterized in that: The following steps are involved: S1, granulation: obtaining expandable beads A1 and expandable beads A2; S2. Foaming board making: Blending expandable beads A1, expandable beads A2, expandable beads B, expandable beads C, and expandable beads D, foaming, curing, forming, and drying at a system pressure of 7-8 Pa and a temperature of 160-180° C. to obtain a polystyrene board; S3, preparing thermal insulation materials; S4, heat preservation treatment: the polystyrene board obtained in step S2 and the heat preservation material obtained in step S3 are blended and dried under negative pressure to obtain a polystyrene heat preservation board.

9. The method for preparing a polystyrene insulation board according to claim 8, characterized in that: In step S4, the volume mass ratio of the polystyrene board obtained in step S2 and the thermal insulation material obtained in step S3 is controlled to be 1m 3 : (70-80) kg.

10. The method for preparing a polystyrene insulation board according to claim 8, characterized in that: In step S4, the system pressure is -80 cmHg to -70 cmHg.

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