High-performance ultra-thin vacuum insulation composite insulation board and production process thereof

Abstract

The application discloses a kind of high-performance ultra-thin vacuum heat insulation composite insulation board and production process thereof, it is related to building insulation material technical field, including vacuum heat insulation board and coating slurry, the coating slurry six coatings are in the outer surface of vacuum heat insulation board, the coating slurry solidification forms hard protective shell;The coating slurry includes the following weight parts of components: cement 290-310 parts, polyphenyl particle 3-5 parts, water 140-160 parts, reinforcing agent 2-4 parts, foaming agent 0.1-0.3 parts, glass short fiber 3-5 parts;The application is improved by coating slurry composition and proportion, and glass short fiber is added therein, in the case where coating slurry thickness is same, effectively improve the strength after coating slurry hardening, so that the thickness of the vacuum heat insulation composite insulation board can reach within 26mm, and make its performance meet the requirements of relevant standards.

Description

A high-performance ultra-thin vacuum thermal insulation composite insulation board and its manufacturing process Technical Field

[0001] This invention relates to the field of building insulation materials technology, specifically to a high-performance ultra-thin vacuum insulation composite insulation board and its production process. Background Technology

[0002] Vacuum insulation panels are a new type of thermal insulation material, mainly composed of a core material, a barrier film, and a getter. They effectively prevent heat transfer caused by air convection, significantly reducing the thermal conductivity. Vacuum insulation panels are widely used in the construction industry. However, because the barrier film on the surface of the vacuum insulation panel is easily damaged and leaks air, it needs to be wrapped with an outer layer to form a protective shell, thus creating a vacuum insulation composite insulation panel.

[0003] Because the protective shell formed by the cladding layer needs to have sufficient tensile and compressive strength to effectively protect the vacuum insulation board, the thickness of the cladding layer needs to be relatively thick. Currently, the thickness of the vacuum insulation composite insulation board needs to reach more than 30mm to meet the strength requirements. The thicker vacuum insulation composite insulation board not only occupies more space after being laid, but also has a higher production cost, which is not conducive to its use in the current construction industry.

[0004] Furthermore, in the production process of vacuum insulation composite panels, manual placement of laying jigs is required to position and lay the panels, ensuring they are neatly arranged at fixed intervals. After the panels are laid, the jigs must be removed before the next section is laid. This process can easily lead to deviations in the spacing between placements, affecting the position of the panels and consequently their performance and subsequent cutting and processing. This is especially true for thinner panels, where the coating is thin and misalignment can expose the coating, rendering it ineffective. Therefore, a high-performance, ultra-thin vacuum insulation composite panel and its manufacturing process are needed to solve these problems. Summary of the Invention

[0005] The purpose of this invention is to provide a high-performance ultra-thin vacuum thermal insulation composite insulation board and its manufacturing process, so as to solve the problems existing in the prior art mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A high-performance ultra-thin vacuum insulation composite insulation board includes a vacuum insulation board and a coating slurry. The coating slurry covers the outer surface of the vacuum insulation board on all six sides, and the coating slurry forms a rigid protective shell after curing.

[0008] The thickness H1 of the vacuum insulation composite insulation board is 14-26mm, and the thickness H2 of the vacuum insulation board is 4-15mm.

[0009] The coating slurry comprises the following components in parts by weight: 290-310 parts cement, 3-5 parts polystyrene particles, 140-160 parts water, 2-4 parts reinforcing agent, 0.1-0.3 parts foaming agent, and 3-5 parts glass short fibers.

[0010] Preferably, the vacuum insulation panel includes a membrane material, a core material, and a getter, wherein the core material and the getter are located inside the membrane material, and the vacuum insulation panel is obtained by vacuum sealing.

[0011] The core material is made of glass fiber with a diameter of 3-9µm, and the hot-pressing temperature for manufacturing the glass fiber is set to 650-720℃; the membrane material is a composite film with three or more layers of nylon or PET on the surface; the vacuuming time is 5-10 minutes; the air pressure inside the vacuum insulation board is less than 0.01Pa;

[0012] The density of the coating slurry is ≥240 kg / m³, and the density of the vacuum insulation board is ≤370 kg / m³.

[0013] Preferably, the vacuum insulation composite insulation board has a thermal conductivity ≤0.005W / (m·K), a compressive strength ≥0.2MPa, and a tensile strength perpendicular to the board surface ≥0.08MPa.

[0014] A manufacturing process for a high-performance ultra-thin vacuum thermal insulation composite insulation board includes the following steps:

[0015] S1: Take the plastic pallet and place it on the production equipment;

[0016] S2: Cover the plastic tray with non-woven fabric and alkali-resistant fiberglass mesh in sequence;

[0017] S3: Apply a coating slurry over the non-woven fabric and alkali-resistant fiberglass mesh, and then roll-form it.

[0018] S4: Stretch the tape and lay it flat on the surface of the coating paste, with the adhesive side facing upwards;

[0019] S5: Place a laying fixture above the tape and place the vacuum insulation board in the laying fixture to ensure that the vacuum insulation board is laid neatly.

[0020] S6: Remove the installation fixture frame, and fix the vacuum insulation panel in place by the adhesion of the tape;

[0021] S7: Apply a coating slurry to the surface of the vacuum insulation panel;

[0022] S8: Alkali-resistant fiberglass mesh and non-woven fabric are sequentially coated onto the surface of the coating slurry in S7, and then subjected to vibratory roller pressing;

[0023] S9: Place the product after vibratory roller pressing onto the tray and send it into the baking room for curing and hardening;

[0024] S10: Cut the product into a certain size according to the usage requirements to obtain a high-performance ultra-thin vacuum thermal insulation composite insulation board product.

[0025] A production equipment for high-performance ultra-thin vacuum thermal insulation composite insulation panels includes:

[0026] A frame on which a conveying mechanism is mounted for linearly conveying raw materials during the production process;

[0027] The first material rack and the second material rack are installed alternately on the frame and are used to place the roll material raw material;

[0028] A laying tooling circulation mechanism is installed on the frame and used to position the vacuum insulation panel during laying.

[0029] A tape cutting mechanism is installed on a laying tooling circulation mechanism and is used to intermittently cut the tape.

[0030] Preferably, the laying tooling circulation mechanism includes a transmission bracket, pulleys, and a transmission belt. The transmission bracket is installed on both sides of the frame, the pulleys are rotatably mounted on the transmission bracket, a transmission belt is installed between the two pulleys, and a second drive motor for driving the pulleys to rotate is installed on the transmission bracket.

[0031] The transmission belt is equipped with a connecting block, and two laying fixtures are provided between the transmission supports on the left and right sides of the frame. A connecting seat is provided in the middle of the laying fixture, and the connecting seat and the connecting block are rotatably connected by a connecting shaft. The two laying fixtures are arranged alternately up and down.

[0032] Preferably, the tape cutting mechanism includes a mounting plate, blades, and gears. The mounting plate is mounted on one end face of the laying fixture. Several blades are rotatably connected to the mounting plate, and gears are coaxially mounted on the blades.

[0033] A rack is slidably mounted laterally on the mounting plate. The rack meshes with a gear. A return spring is provided at one end of the rack, and a driven block is installed at the other end of the rack.

[0034] The laying fixture has positioning slots on both sides, and mounting brackets are installed on both sides of the frame. Active push blocks that can enter the positioning slots are installed on the mounting brackets, and the active push blocks are also used to push the driven blocks.

[0035] Compared with the prior art, the beneficial effects of the present invention are:

[0036] 1. This invention improves the composition and proportion of the coating slurry and adds short glass fibers to it, thereby effectively increasing the strength of the hardened coating slurry while maintaining the same coating slurry thickness. As a result, the thickness of the vacuum thermal insulation composite insulation board can be reduced to within 26mm, and its performance meets the requirements of relevant standards.

[0037] 2. By adding a step of laying adhesive tape in the production process, the present invention enables the tape to bond multiple vacuum insulation panels together, ensuring the stability of the spacing and position between the vacuum insulation panels, thereby improving the performance stability of the vacuum insulation composite insulation board.

[0038] 3. This invention improves the production equipment based on the production process. By setting up a cyclic mechanism for laying fixtures, two laying fixture frames can be cyclically attached to the upper surface of the coating slurry under the drive of the transmission belt. This makes the placement of the laying fixture frames standardized and uniform, and the spacing of the vacuum insulation panels more standardized, thus improving the quality uniformity of the product. Furthermore, the tape cutting mechanism can automatically cut the tape at the end of the previous laying fixture frame without manual intervention, improving production efficiency. At the same time, the tape cut is more neat and requires no subsequent trimming. Attached Figure Description

[0039] Figure 1 is a cross-sectional structural diagram of the vacuum thermal insulation composite insulation board of the present invention.

[0040] Figures 2 and 3 are schematic diagrams of the overall structure of the production equipment of the present invention from different perspectives.

[0041] Figure 4 is a schematic diagram of the laying tooling circulation mechanism of the present invention.

[0042] Figure 5 is a partial enlarged structural diagram of point A in Figure 4 of this invention.

[0043] Figure 6 is a schematic diagram of the tooling frame structure of the present invention.

[0044] Figure 7 is a schematic diagram of the tape cutting mechanism of the present invention.

[0045] In the diagram: 1. Frame; 2. Conveying mechanism; 21. Conveying roller; 22. Conveying belt; 23. Conveying motor; 3. First material rack; 31. First frame; 32. Guide roller; 4. Second material rack; 41. Second frame; 42. Pressure roller; 43. Tape placement shaft; 5. Laying fixture circulation mechanism; 51. Transmission bracket; 52. Pulley; 53. Transmission belt; 54. Connecting block; 55. Laying fixture frame; 56. Connecting seat; 57. Connecting shaft; 58. Second drive motor; 59. Positioning groove; 6. Tape cutting mechanism; 61. Mounting plate; 62. Blade; 63. Gear; 64. Rack; 65. Return spring; 66. Driven block; 67. Mounting frame; 68. Active push block; 7. Tape; 8. Coating slurry; 9. Vacuum insulation board. Detailed Implementation

[0046] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0047] Please refer to Figures 1-6. The present invention provides the following technical solutions:

[0048] A high-performance ultra-thin vacuum insulation composite insulation board includes a vacuum insulation board 9 and a coating slurry 8. The coating slurry 8 covers the outer surface of the vacuum insulation board 9 on all six sides. After curing, the coating slurry 8 forms a rigid protective shell. The coating slurry 8 includes the following components in parts by weight: 290-310 parts cement, 3-5 parts polystyrene particles, 140-160 parts water, 2-4 parts reinforcing agent, 0.1-0.3 parts foaming agent, and 3-5 parts glass short fiber.

[0049] Vacuum insulation panel 9 includes a membrane material, a core material, and a getter. The core material and getter are located inside the membrane material and are obtained by vacuum sealing. The core material is made of glass fiber with a diameter of 3-9µm. The hot pressing temperature for manufacturing the glass fiber is set to 650-720℃, which is lower than that for thicker core materials. This is because when the glass fiber core material is thin, the temperature can easily penetrate into the inner layer of the core material during the hot pressing process. In order to prevent the porosity of the glass fiber from decreasing, the temperature needs to be lowered.

[0050] The membrane material is a composite film with three or more layers of nylon or PET on the surface, which improves the adhesion between the vacuum insulation board 9 and the coating slurry 8; the vacuuming time is 5-10 minutes, and the air pressure inside the vacuum insulation board 9 is less than 0.01Pa, ensuring the thermal insulation performance of the vacuum insulation board 9.

[0051] Example

[0052] A manufacturing process for a high-performance ultra-thin vacuum thermal insulation composite insulation board includes the following steps:

[0053] S1: Take the plastic pallet and place it on the production equipment;

[0054] S2: Cover the plastic tray with non-woven fabric and alkali-resistant fiberglass mesh in sequence;

[0055] S3: A coating slurry is applied over non-woven fabric and alkali-resistant fiberglass mesh and then rolled into shape. The coating slurry consists of the following components by weight: 300 parts cement, 4 parts polystyrene particles, 150 parts water, 3 parts reinforcing agent, 0.2 parts foaming agent, and 4 parts glass short fiber, which are uniformly mixed to form the coating slurry.

[0056] S4: Stretch the tape and lay it flat on the surface of the coating slurry, with the adhesive side facing upwards, to facilitate bonding of the vacuum insulation panel.

[0057] S5: Place a laying fixture above the tape and place the vacuum insulation board in the laying fixture to ensure that the vacuum insulation board is laid neatly; the core material of the vacuum insulation board is 7µm diameter glass fiber, the membrane material is double-sided aluminum coated film, the vacuuming time is 8 minutes, and the thickness of the vacuum insulation board is 7mm.

[0058] S6: Remove the installation fixture frame, and fix the vacuum insulation panel in place by the adhesion of the tape;

[0059] S7: Apply a coating slurry to the surface of the vacuum insulation panel;

[0060] S8: Alkali-resistant fiberglass mesh and non-woven fabric are sequentially coated onto the surface of the coating slurry in S7, and then subjected to vibratory roller pressing;

[0061] S9: Place the product after vibratory roller pressing onto the tray and send it into the baking room for curing and hardening. The thickness of the hardened product is 15mm.

[0062] S10: Cut the product into a certain size according to the usage requirements to obtain a high-performance ultra-thin vacuum thermal insulation composite insulation board product.

[0063] Performance tests were conducted on the vacuum insulation composite insulation board in Example 1. The tensile strength perpendicular to the board surface was 85 kPa, which meets the requirement of ≥80 kPa in the current industry standard JG / T 438 "Vacuum Insulation Boards for Buildings". The compressive strength was 0.25 MPa, meeting the requirement of ≥0.20 MPa in GB / T 5486. The thermal conductivity of the central area of ​​the board was 0.004 W / (m·K), meeting the requirement of ≤0.005 W / (m·K) for Type I in the current industry standard JG / T 438 "Vacuum Insulation Boards for Buildings". This vacuum insulation composite insulation board, through improvements in the composition and proportion of the coating slurry and the addition of short glass fibers, effectively improved the hardened strength of the coating slurry while maintaining the same coating slurry thickness. Therefore, the thickness of the vacuum insulation composite insulation board can be reduced to within 26 mm, and its performance meets the requirements of relevant standards.

[0064] In addition, the method of the present invention adds a step of laying adhesive tape, which enables the tape to bond multiple vacuum insulation panels together, ensuring the stability of the spacing and position between the vacuum insulation panels, thereby improving the performance stability of the vacuum insulation composite insulation board.

[0065] This invention also discloses a production equipment for high-performance ultra-thin vacuum thermal insulation composite insulation board, comprising: a frame 1, on which a conveying mechanism 2 is installed, the conveying mechanism 2 being used for linearly conveying raw materials during the production process; the conveying mechanism 2 includes conveying rollers 21, a conveyor belt 22, and a conveying motor 23, a plurality of conveying rollers 21 being rotatably mounted on the frame 1, the conveyor belt 22 being mounted on the conveying rollers 21, and a conveying motor 23 being installed on the frame 1 for driving the conveying rollers 21 to rotate; the conveying motor 23 drives the conveying rollers 21 to rotate, so that the conveying rollers 21 drive the conveyor belt 22 to linearly convey the raw materials through each process station.

[0066] The first material rack 3 and the second material rack 4 are installed alternately on the frame 1 and are used to place roll material raw materials. The first material rack 3 includes a first frame body 31 and a guide roller 32. The first material rack 3 is installed on one side of the frame 1, and the guide roller 32 is installed on the lower side of the first frame body 31. The second material rack 4 includes a second frame body 41 and a pressure roller 42. The second frame body 41 is located on one side of the first frame body 31, and the lower end of the second frame body 41 is provided with a pressure roller 42. One side of the pressure roller 42 is provided with a tape placement shaft 43. Multiple tapes 7 are placed alternately on the tape placement shaft 43. The tapes 7 can rotate on the tape placement shaft 43 to facilitate the pulling out of the tapes 7. Both the first frame body 31 and the second frame body 41 are provided with a rotating shaft for installing non-woven fabric and alkali-resistant fiberglass mesh.

[0067] A laying fixture circulation mechanism 5 is installed on the frame 1 and is used to position the vacuum insulation panel 9 during laying. The laying fixture circulation mechanism 5 includes a transmission bracket 51, pulleys 52, and a transmission belt 53. The transmission bracket 51 is installed on both sides of the frame 1. The pulleys 52 are rotatably mounted on the transmission bracket 51, and the transmission belt 53 is installed between the two pulleys 52. A second drive motor 58 for driving the pulleys 52 is installed on the transmission bracket 51. The frame 3 is equipped with a connecting block 54. Two laying fixtures 55 are provided between the transmission supports 51 on the left and right sides of the frame 1. A connecting seat 56 is provided in the middle of the laying fixture 55. The connecting seat 56 and the connecting block 54 are rotatably connected by a connecting shaft 57. The two laying fixtures 55 are staggered vertically. Driven by the transmission belt 53, the two laying fixtures 55 can circulate and adhere to the upper surface of the coating slurry 8, so that the placement of the laying fixtures 55 is standardized and uniform, and the arrangement spacing of the vacuum insulation panels 9 is more standardized.

[0068] The bottom surface of the laying fixture 55 is provided with an anti-adhesion coating. The anti-adhesion coating can reduce the adhesion of the tape 7 to the bottom surface of the laying fixture 55, and prevent the laying fixture 55 from sticking to the tape 7 when it separates, which would cause the vacuum insulation board 9 to shift.

[0069] A tape cutting mechanism 6 is installed on the laying fixture circulation mechanism 5 and is used to intermittently cut the tape 7. The tape cutting mechanism 6 includes a mounting plate 61, blades 62, and gears 63. The mounting plate 61 is installed on one end face of the laying fixture frame 55. Several blades 62 are rotatably connected to the mounting plate 61, and gears 63 are coaxially mounted on the blades 62. A rack 64 is laterally slidably installed on the mounting plate 61. The rack 64 meshes with the gears 63. A return spring 65 is provided at one end of the rack 64, and a driven block 66 is installed at the other end of the rack 64. Positioning grooves 59 are provided on both sides of the laying fixture frame 55. Mounting frames 67 are installed on both sides of the frame 1. Active push blocks 68 that can enter the positioning grooves 59 are installed on the mounting frames 67. The active push blocks 68 are also used to push the driven blocks 66. During the repositioning and movement of the laying fixture 55 and the bonding of the coating slurry 8, the tape cutting mechanism 6 can automatically cut the tape at the end of the previous laying fixture 55 without manual intervention, which improves production efficiency. At the same time, the tape is cut more neatly and does not require subsequent trimming.

[0070] The working process of the production equipment of this invention is as follows:

[0071] First, the non-woven fabric and alkali-resistant fiberglass mesh rolls are placed on the first material rack 3. The non-woven fabric and alkali-resistant fiberglass mesh are pulled and laid onto the plastic tray on the conveying mechanism 2. The coating slurry 8 is applied between the first material rack 3 and the second material rack 4. The conveying mechanism 2 drives the coating slurry 8 forward, so that the coating slurry 8 forms a uniform layered structure after passing through the pressure roller 42.

[0072] The tape 7 is pulled and laid on the surface of the layered coating slurry 8 with the adhesive side facing up. The second drive motor 58 drives the pulley 52 to rotate. The pulley 52 drives the laying fixture 55 to move through the transmission belt 53, so that the laying fixture 55 falls onto the surface of the coating slurry 8 and presses the tape 7 onto the surface of the coating slurry 8. At this time, the vacuum insulation board 9 of the corresponding size is placed into the frame of the laying fixture 55 by manual labor or a robotic arm. The laying fixture 55 and the conveying mechanism 2 run at the same speed to complete the laying of the vacuum insulation board 9.

[0073] After a certain distance of vacuum insulation panel 9 is laid, the laying fixture 55 moves to the leftmost end and moves upward, detaching from the surface of the coating slurry 8. Meanwhile, another laying fixture 55 moves to the rightmost end and contacts the surface of the coating slurry 8. This cycle can be repeated to continuously position and lay the vacuum insulation panel 9.

[0074] During the process of another laying fixture 55 contacting and moving with the surface of the coating slurry 8, the active push block 68 will squeeze the driven block 66, causing the rack 64 to slide. The rack 64 drives the blade 62 to rotate through the gear 63, thereby cutting the tape 7 at the end of the front laying fixture 55 without manual intervention, which improves production efficiency.

[0075] Subsequently, the coating slurry 8 is added, non-woven fabric and alkali-resistant fiberglass mesh are covered, and vibratory roller pressing is performed to form the vacuum insulation composite insulation board. After forming, it is cured and hardened, and then cut as needed to obtain the final vacuum insulation composite insulation board product.

[0076] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A manufacturing process for a high-performance ultra-thin vacuum thermal insulation composite insulation board. Includes the following steps: S1: Take the plastic pallet and place it on the production equipment; S2: Cover the plastic tray with non-woven fabric and alkali-resistant fiberglass mesh in sequence; S3: Apply the coating slurry over the non-woven fabric and alkali-resistant fiberglass mesh, and roll it into shape; S4: Stretch the tape and lay it flat on the surface of the coating slurry, with the adhesive side facing upwards; S5: Place a laying fixture on top of the tape, and place the vacuum insulation board in the laying fixture to ensure that the vacuum insulation board is laid neatly; S6: Remove the laying fixture, and the vacuum insulation board is fixed in position by the adhesion of the tape; S7: Apply a coating slurry to the surface of the vacuum insulation panel; S8: Alkali-resistant fiberglass mesh and non-woven fabric are sequentially coated onto the surface of the coating slurry in S7, and then subjected to vibratory roller pressing; S9: Place the product after vibratory roller pressing onto the tray and send it into the baking oven for curing and hardening; S10: Cut the product into a certain size according to the usage requirements to obtain a high-performance ultra-thin vacuum thermal insulation composite insulation board product.

2. A production equipment for the production process described in claim 1, characterized in that, include: A frame (1) is provided with a conveying mechanism (2) for conveying raw materials in a straight line during the production process; a first material rack (3) and a second material rack (4) are provided on the frame (1) at intervals and are used to place roll material raw materials; a laying tooling circulation mechanism (5) is provided on the frame (1) and is used to position the laying of vacuum insulation board (9); and a tape cutting mechanism (6) is provided on the laying tooling circulation mechanism (5) and is used to intermittently cut tape (7).

3. The production equipment according to claim 2, characterized in that, The laying tooling circulation mechanism (5) includes a transmission bracket (51), a pulley (52), and a transmission belt (53). The transmission bracket (51) is installed on both sides of the frame (1). The pulley (52) is rotatably installed on the transmission bracket (51). A transmission belt (53) is installed between the two pulleys (52). A second drive motor (58) for driving the pulleys (52) to rotate is installed on the transmission bracket (51). A connecting block (54) is provided on the transmission belt (53). Two laying tooling frames (55) are provided between the transmission brackets (51) on the left and right sides of the frame (1). A connecting seat (56) is provided in the middle of the laying tooling frame (55). The connecting seat (56) and the connecting block (54) are rotatably connected by a connecting shaft (57). The two laying tooling frames (55) are staggered vertically.

4. The production equipment according to claim 3, characterized in that, The tape cutting mechanism (6) includes a mounting plate (61), blades (62), and gears (63). The mounting plate (61) is mounted on one side end face of the laying fixture (55). Several blades (62) are rotatably connected to the mounting plate (61), and gears (63) are coaxially mounted on the blades (62). A rack (64) is slidably mounted on the mounting plate (61). The rack (64) meshes with the gears (63). A return spring (65) is provided at one end of the rack (64), and a driven block (66) is installed at the other end of the rack (64). Positioning grooves (59) are provided on both sides of the laying fixture (55). Mounting frames (67) are installed on both sides of the frame (1). Active push blocks (68) that can enter the positioning grooves (59) are installed on the mounting frames (67). The active push blocks (68) are also used to push the driven blocks (66).

Images