Ecological insulation board with mixed reinforced core layer

Abstract

The invention relates to an ecological insulation board with a mixed reinforced core layer. The ecological insulation board is composed of at least one core layer, at least one surface layer covering the surface of the core layer, and at least one reinforced layer bonded between the core layer and the surface layer. A reinforcing material for preparing the reinforcing layer consists of bio-based resin, a curing catalyst, natural fibers and a heat stabilizer or a flame retardant. And the reinforcing material is arranged between the core layer and the surface layer and is positioned in one or more of an edge area, an anchoring point, a gap part and a structural rib of the core layer and the surface layer. The ecological insulation board can fix the edge and enhance the thermal cycle resistance and the mechanical fatigue resistance. The cured bio-based resin has stronger dimensional stability, and expansion or shrinkage difference can be reduced to the greatest extent, so that warping is reduced.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of board, in particular to an ecological insulation board with a hybrid reinforced core. BACKGROUND

[0002] With the rapid development of the construction industry, the innovative application of building insulation materials is also very extensive. Building insulation materials in the wall surface insulation system not only meet the thermal performance requirements, but also the fire rating must reach the national standard. As a new type of building insulation material, the insulation board not only meets the thermal performance requirements, but also reaches the national A-level standard, and has the advantages of good hydrophobicity, light weight, good sound insulation, low cost, and is widely used in building engineering in different climate regions in China with insulation energy saving requirements. It is simple to construct, saves resources and energy, reduces environmental pollution, and has good economic and social benefits.

[0003] The current defects of the insulation board are due to the insufficient stability of the materials used, such as petroleum-based resins and adhesives used for bonding the insulation core material and the structural surface layer. These synthetic resins composed of petroleum-based resins and adhesives will degrade when exposed to heat, humidity and ultraviolet radiation for a long time, resulting in warping, delamination and mechanical strength reduction of the board. At the same time, the above problems will be further worsened due to the mismatch of the thermal expansion coefficients between the resin and the core material and the surface layer material. SUMMARY

[0004] Therefore, the present application provides an ecological insulation board with a hybrid reinforced core to solve the above technical problems.

[0005] An ecological insulation board with a hybrid reinforced core is made of at least one core layer, at least one surface layer covering the surface of the core layer, and at least one reinforcing layer bonded between the core layer and the surface layer. The reinforcing material for preparing the reinforcing layer is composed of a bio-based resin, a curing catalyst, a natural fiber, a thermal stabilizer or a flame retardant. The weight percentage content of the bio-based resin is 60% to 80%, the weight percentage content of the curing catalyst is 5% to 10%, the weight percentage content of the natural fiber is 10% to 20%, the weight percentage content of the thermal stabilizer is 0.5% to 2%, and the weight percentage content of the flame retardant is 1% to 10%. The reinforcing material is arranged between the core layer and the surface layer and located in one or several of the edge zone, the anchoring point, the gap site and the structural rib of the core layer and the surface layer.

[0006] Further, the bio-based resin is one or several of epoxidized soybean oil, epoxidized linseed oil, and castor oil-based polyol, and the curing catalyst is a Lewis acid or a tertiary amine.

[0007] Further, the bio-based resin is a furan resin, the curing catalyst is an acidic catalyst, and the acidic catalyst is p-toluenesulfonic acid or phosphoric acid.

[0008] Further, the bio-based resin is a polylactic acid-polyol system, and the curing catalyst is an organotin compound or an organometallic salt.

[0009] Further, the thermal stabilizer is a phosphite, a calcium-zinc stabilizer, or an antioxidant, and the antioxidant is sodium hypophosphite.

[0010] Further, the natural fiber is one or a mixture of several of the following: chopped hemp fiber, flax, kenaf, wood flour, or cellulose microfibers.

[0011] Further, the core layer is one or a combination of several of the following: expanded polystyrene insulation board, extruded polystyrene insulation board, or natural fiber insulation board.

[0012] Further, the flame retardant is ammonium polyphosphate, magnesium hydroxide, or aluminum trihydroxide.

[0013] Further, the surface layer is surface-modified by providing a microstructure on the surface layer, and the microstructure is a relief texture, a porous coating, or a composite coating containing natural fibers or cork particles.

[0014] Further, the reinforcing material is injected between the core layer and the surface layer and located in one or several of the following: the edge zone, the anchoring points, the voids, and the structural ribs of the core layer and the surface layer.

[0015] Compared with the prior art, the ecological insulation board with the mixed reinforced core layer provided by the application injects a reinforcing material for forming a reinforced bonding layer between the core layer and the surface layer, and the reinforcing material is made of a bio-based resin, a curing catalyst, natural fibers, a heat stabilizer or a flame retardant. The bio-based resin will undergo a thermosetting chemical reaction to form a cross-linked polymer network, thereby chemically bonding with the adjacent core layer and surface layer, filling micro voids or weak areas, and further forming a structurally complete reinforced area, thereby fixing the edges and enhancing the ability to resist thermal cycling and mechanical fatigue. The cured bio-based resin has stronger dimensional stability, which can minimize the difference in expansion or contraction, thereby reducing warping. In addition, the strong interfacial adhesion between the bio-based resin and the core layer and the surface layer can prevent delamination, especially at the joints or high stress points. In addition, the partial reinforcement can further achieve a multi-layer structure with a density gradient, in which the lower density foam board is still located in the main material of the core layer, and the mixed reinforced layer with higher density is located in the place where reinforcement is needed. By changing the material composition and density at different positions, the ecological insulation board achieves local stiffness and load-bearing capacity at key positions without affecting the overall weight or thermal insulation performance of the insulation board. DETAILED DESCRIPTION

[0016] The specific embodiments of the application are further described in detail below. It should be understood that the description of the embodiments of the application herein is not intended to limit the protection scope of the application.

[0017] The application provides an ecological insulation board with a mixed reinforced core layer, which comprises at least one core layer, at least one surface layer covering the surface of the core layer, and at least one reinforced bonding layer bonded between the core layer and the surface layer. It is conceivable that the ecological insulation board with a mixed reinforced core layer further comprises other functional layers, such as a paint layer arranged on the surface layer, and the like, which are known to those skilled in the art and will not be described here.

[0018] The core layer can be composed of multiple core layers or only one core layer. When the core layer is formed by multiple core layers, the multiple core layers can be made of the same material or different materials.

[0019] The core layer can be one or a combination of several of expanded polystyrene (EPS) insulation board, extruded polystyrene (XPS) insulation board, and natural fiber insulation board. The expanded polystyrene insulation board, the extruded polystyrene insulation board, and the natural fiber insulation board are all prior art and are widely used in building and home decoration industries, so they will not be described in detail here.

[0020] The surface layer can be one layer, i.e. only bonded on one side surface of the core layer. The surface layer can also be two layers, i.e. two layers of the surface layer are bonded on two side surfaces of the core layer respectively. The surface layer can be a wear-resistant layer or a decorative layer, which are prior art and will not be described here. In order to achieve better acoustic effect, microstructure can be provided on the surface layer for surface modification, such as embossed texture, porous coating or composite coating containing natural fibers or cork particles. These processing methods can disperse incident sound waves, and absorb sound wave energy through micropores, or diffuse sound wave energy through the irregularity of the surface, thereby avoiding the generation of echo.

[0021] The reinforced adhesive layer is used to bond the surface layer and the core layer, or to strengthen the bonding force between the surface layer and the core layer, so the adhesive layer can be spread between the core layer and the surface layer. In order to save costs, the middle part between the surface layer and the core layer can be bonded with ordinary glue, such as using melamine adhesive, and the reinforced adhesive layer can be filled in the edge area of the surface layer and the core layer, or form a structural rib, or be formed in the gap part to be locally increased by glue injection, or form a plurality of anchor points between the surface layer and the core layer and then form the reinforced adhesive layer on the anchor points by glue injection. The above-mentioned edge area, structural rib, gap part and anchor point are collectively referred to as the reinforced area.

[0022] The reinforced adhesive layer is made of bio-based resin, curing catalyst, natural fiber, thermal stabilizer or flame retardant. Specifically, the weight percentage content of the bio-based resin is 60% to 80%, the weight percentage content of the curing catalyst is 5% to 10%, the weight percentage content of the natural fiber is 10% to 20%, the weight percentage content of the thermal stabilizer is 0.5% to 2%, and the weight percentage content of the flame retardant is 1% to 10%.

[0023] The bio-based resin can be epoxidized soybean oil, epoxidized linseed oil, furan resin, castor oil-based polyol and lignin modified epoxy system. These resins can be used alone or in combination according to the required viscosity, curing time and mechanical reinforcement effect.

[0024] The curing catalysts are used to promote polymerization and foam stability during the foaming process, thus achieving efficient cell formation and mechanical rigidity. The specific catalyst depends on the type of bio-resin used. In epoxidized soybean oil, epoxidized linseed oil, or castor oil based polyols, Lewis acids or tertiary amines such as triethylenediamine or (DABCO) are used. In furan resin foams, acidic catalysts such as p-toluene sulfonic acid or phosphoric acid are typically used to initiate ring-opening and condensation reactions. In polylactic acid-polyol systems, cross-linking of polyurethanes with isocyanates is promoted by catalysts such as organotin compounds like dibutyltin dilaurate or organometallic salts. The preferred content of the curing catalyst is 5-10% of the total weight of the resin formulation, but can vary depending on the reactivity of the resin and the desired curing time.

[0025] The natural fibers are used to further increase toughness and strength, which can be short hemp fibers, flax, kenaf, wood flour or cellulose microfibers. These fibers help load distribution, crack resistance and anchorage strength in the injected zone.

[0026] The thermal stabilizers are used to improve heat-aging resistance, which can be phosphite esters, calcium-zinc stabilizers or antioxidants. The antioxidants can be sodium hypophosphite (BHT) The flame retardants are used to improve fire resistance, which can be ammonium polyphosphate, magnesium hydroxide or aluminum trihydroxide.

[0027] Since the core layer and the surface layer are to be injected by an injection process, the bio-based resin, natural fibers, and functional additives including flame retardants or thermal stabilizers are first formed into a homogeneous injectable mixture by physical mixing. During the injection process, the core function of the bio-based resin is transformed by chemical reactions, i.e. by thermoset cross-linking, and occurs when the mixture is heated by the injection machine while injecting the surface layer and the core layer into the voids or reinforcement zones. In the case of epoxidized soybean oil, epoxidized linseed oil, or castor oil based polyols, the curing process by heating involves ring-opening polymerization of the epoxy groups catalyzed by acids, amines or metal salts, thus forming a three-dimensional cross-linked polymer network. In furan resin systems, the chemical curing upon heating is by acid-catalyzed polycondensation reactions between furan alcohol monomers, thus forming a rigid thermoset matrix. For polylactic acid-polyol based systems, they react with isocyanates upon heating to form polyurethane linkages. Although the cellulose fibers, flame retardants and mineral fillers are typically physically dispersed in the matrix and do not participate in chemical bonding, they can exhibit secondary interactions such as hydrogen bonding or compatibility of the fillers with the matrix, thus improving dispersion and strengthening the polymer network.

[0028] When the above materials are cured, the bio-based resin undergoes a thermoset chemical reaction to form a cross-linked polymer network, which chemically bonds to the adjacent core and surface layers, filling micro voids or weak areas. This forms a structurally sound reinforcement zone that secures the edges and enhances the ability to withstand thermal cycling and mechanical fatigue. The cured bio-based resin has greater dimensional stability, minimizing expansion or contraction differences, thereby reducing warping. Additionally, the strong interfacial adhesion between the bio-based resin and the core and surface layers prevents delamination, especially at the joints or high stress points.

[0029] The local reinforcement also enables a density gradient multi-layer structure, where the lower density foam board is still in the main material of the core, and the mixed reinforced layer after local reinforcement has a higher density, which is located where reinforcement is needed. By changing the material composition and density at different parts, the ecological insulation board realizes local stiffness and load-bearing capacity at key parts without affecting the overall weight or thermal insulation performance of the board. This density gradient design also realizes a synergistic balance, that is, the low-density foam provides thermal insulation and sound absorption, while the high-density injection-molded resin area provides mechanical strength, fastener fixation, and dimensional stiffness.

[0030] The bio-based resin, curing catalyst, natural fibers, thermal stabilizer, and flame retardant do not act in isolation, but synergistically to enhance the mechanical, thermal, and flame-retardant properties of the structural insulation board. The bio-based resin is the main structural matrix, which, after curing with the cooperation of the curing catalyst, can form a rigid cross-linked polymer network, binding the injection-molded area and integrating with the adjacent core and surface layers. When the natural fibers such as hemp, flax, or cellulose are added to the resin matrix, they not only act as passive fillers but also as reinforcing agents, dispersing mechanical stress, improving toughness, and reducing shrinkage or cracking during curing.

[0031] The thermal stabilizers such as phosphite or hindered phenolic antioxidants added can prevent thermal degradation of the resin and fibers at high temperatures or during long-term use, thereby maintaining the dimensional stability and strength of the board. At the same time, the flame retardants such as ammonium polyphosphate or aluminum trihydroxide work in the same matrix, promoting the formation of carbon, reducing smoke release, delaying ignition, and thus improving the fire resistance of the reinforcement zone. Therefore, the formulation of the reinforced core is not a simple physical mixture of isolated materials, but a coordinated system in which each component supports and enhances the function of the other components. Compared with the use of any single material alone, they collectively produce a locally composite reinforced material inside the board, which provides excellent mechanical properties, thermal durability, and fire resistance.

[0032] At the time of manufacture, the reinforcing material is injected between the core and surface layers by an injection process. The injection process is typically performed during or after assembly of the core and surface layers, but prior to final curing. Injection can be performed using low pressure metering and dispensing equipment, such as a two-component resin injection machine, which can be equipped with a gear or piston pump connected to a mixing head with an injection nozzle. For accurate dispensing, the injection nozzle can be inserted into a void between the core and surface layers or into an inlet or groove aligned with a reinforcement channel, while the resin is injected under controlled flow rate to prevent deformation of the foam core and ensure uniform filling.

[0033] The surface layer can be a wear resistant layer or a decorative layer, which are themselves known in the art and will not be described in detail here. To achieve better acoustic performance, the surface layer can be surface modified with microstructures such as embossed textures, porous coatings, or composite coverings containing natural fibers or cork particles. These treatments can break up incident sound waves and absorb sound energy through micro pores or diffuse sound energy through surface irregularities. Additionally, to achieve better acoustic performance, one or more intermediate layers can be added to the ecological insulation panel, which can be made of acoustic damping materials such as porous or fibrous fillers (e.g. cork particles, natural fiber mats), or micro-perforated bio-resin composites that scatter and absorb incident sound energy.

[0034] Compared to the prior art, the ecological insulation panel with a hybrid reinforced core layer of the present application has a reinforcing material for forming a reinforced bonding layer injected between the core and surface layers, which is made of a bio-based resin, a curing catalyst, natural fibers, a thermal stabilizer, or a flame retardant. The bio-based resin undergoes a thermosetting chemical reaction to form a cross-linked polymer network, which chemically bonds with the adjacent core and surface layers, fills in micro voids or weak areas, and thus forms a structurally complete reinforcement zone that can fix the edges and enhance the ability to withstand thermal cycling and mechanical fatigue. The cured bio-based resin has greater dimensional stability, which minimizes the difference in expansion or contraction and thus reduces warping. In addition, the strong interfacial adhesion between the bio-based resin and the core and surface layers prevents delamination, especially at the joints or high stress points. Furthermore, the partial reinforcement also enables a multi-layer structure with a density gradient, in which the lower density foam panel is still located in the main material of the core, while the hybrid reinforced layer with higher density is located where reinforcement is needed. By changing the material composition and density at different locations, the ecological insulation panel achieves local stiffness and load-bearing capacity at critical locations without affecting the overall weight or thermal insulation performance of the panel.

[0035] The above merely describes the preferred embodiments of the present application and is not intended to limit the scope of protection of the present application. Any modifications, equivalent replacements, or improvements within the spirit of the present application are encompassed within the scope of the claims of the present application.

Claims

1. An eco-friendly insulation board with a hybrid reinforced core layer, which is composed of... At least one core layer, At least one surface layer covering the surface of the core layer. And at least one reinforcing layer bonded between the core layer and the surface layer, wherein the reinforcing material for preparing the reinforcing layer is made of bio-based resin, curing catalyst, natural fiber, heat stabilizer or flame retardant, and the bio-based resin has a weight percentage content of 60% to 80%. The curing catalyst has a weight percentage content of 5% to 10%. The natural fiber content is 10% to 20% by weight. The heat stabilizer has a weight percentage content of 0.5% to 2%. The flame retardant has a weight percentage content of 1% to 10%. The reinforcing material is disposed between the core layer and the surface layer and is located in one or more of the edge areas, anchor points, voids, and structural ribs of the core layer and the surface layer.

2. The eco-friendly insulation board with a hybrid reinforced core layer as described in claim 1, characterized in that: The bio-based resin is one or more of epoxidized soybean oil, epoxidized linseed oil, and castor oil-based polyols, and the curing catalyst is a Lewis acid or a tertiary amine.

3. The eco-friendly insulation board with a hybrid reinforced core layer as described in claim 1, characterized in that: The bio-based resin is a furan resin, and the curing catalyst is an acidic catalyst, which is p-toluenesulfonic acid or phosphoric acid.

4. The eco-friendly insulation board with a hybrid reinforced core layer as described in claim 1, characterized in that: The bio-based resin is a polylactic acid-polyol system, and the curing catalyst is an organotin compound or an organometallic salt.

5. The eco-friendly insulation board with a hybrid reinforced core layer as described in claim 1, characterized in that: The heat stabilizer is a phosphite, a calcium-zinc stabilizer, or an antioxidant, wherein the antioxidant is sodium hypophosphite.

6. The eco-friendly insulation board with a hybrid reinforced core layer as described in claim 1, characterized in that: The natural fiber is one or a mixture of several of the following: chopped hemp fiber, flax, hibiscus, wood flour, or cellulose microfiber.

7. The eco-friendly insulation board with a hybrid reinforced core layer as described in claim 1, characterized in that: The core layer is one or a combination of expanded polystyrene insulation board, extruded polystyrene insulation board, and natural fiber insulation board.

8. The eco-friendly insulation board with a hybrid reinforced core layer as described in claim 1, characterized in that: The flame retardant is ammonium polyphosphate, magnesium hydroxide, or aluminum trioxide.

9. The eco-friendly insulation board with a hybrid reinforced core layer as described in claim 1, characterized in that: The surface layer is provided with microstructures for surface modification, and the microstructures are embossed textures, porous coatings, or composite coverings containing natural fibers or cork particles.

10. The eco-friendly insulation board with a hybrid reinforced core layer as described in claim 1, characterized in that: The reinforcing material is injected between the core layer and the surface layer and is located in one or more of the edge areas, anchor points, voids, and structural ribs of the core layer and the surface layer.