Flexible aerogel heat insulation decorative composite board and preparation method thereof

Abstract

The invention relates to a flexible aerogel heat-insulation decorative composite board and a preparation method thereof, belongs to the technical field of building energy-saving thermal insulation materials and interface compounding, and particularly relates to the flexible aerogel heat-insulation decorative composite board and the preparation method thereof. The flexible inorganic mineral-based thermal insulation composite board comprises a flexible inorganic mineral-based facing layer, a silicon dioxide aerogel fiber felt thermal insulation core material layer and an interface interpenetrating bonding layer located between the flexible inorganic mineral-based facing layer and the silicon dioxide aerogel fiber felt thermal insulation core material layer. The interface interpenetrating bonding layer is of a three-dimensional interpenetrating network structure formed by controlled permeation of facing layer slurry into the aerogel fiber felt in an uncured state and in-situ curing; the whole composite board is a flexible system and can be bent, and interface layers are not separated. The hydrophobic rate of the composite board is greater than or equal to 99.5%, and the composite board has water vapor permeability. The invention provides the composite board for realizing interface bonding of the facing layer and the aerogel core material layer in an in-situ permeation anchoring manner, and the preparation method of the composite board, so that the problems of low interface strength, poor air permeability and flexibility mismatch existing in traditional adhesive compounding are solved.

Description

Technical Field

[0001] This invention relates to the field of building energy-saving insulation materials and interface composite technology, and in particular to a flexible aerogel thermal insulation decorative composite panel and its preparation method. Background Technology

[0002] Aerogel materials have broad application prospects in the field of building energy-saving insulation due to their extremely low thermal conductivity and excellent hydrophobic properties. In particular, silica aerogel fiber felt, which combines lightweight, flexibility and ultra-low thermal conductivity, is suitable for exterior walls and thermal bridge joints of high-end energy-saving buildings.

[0003] However, silica aerogels have significant technical characteristics: their surface is extremely hydrophobic, with a contact angle typically greater than 150°. At the same time, the surface has a nanoscale powder attachment structure, making it difficult to be wetted by liquid adhesives. Furthermore, the surface is covered with powder, making it easy for conventional adhesives to detach and clog micropores.

[0004] In existing technologies, aerogel insulation layers and decorative layers are typically bonded together using a "post-adhesive bonding" method, where the finishing material is adhered to the aerogel surface using a polymer adhesive. This method has the following drawbacks: due to the hydrophobic and microparticle structure of the aerogel surface, conventional adhesives struggle to penetrate fully, and long-term exposure to thermal expansion and contraction and environmental stress can easily lead to delamination, blistering, or detachment; continuous adhesive layers can block the microporous structure of the aerogel, obstructing the migration path of moisture within the wall and potentially causing condensation and mold growth inside the wall; the adhesive layer is usually a semi-rigid or rigid material, making it prone to interfacial shear failure during bending or curved construction; and organic adhesives may reduce the overall fire resistance rating. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings and deficiencies of existing technologies by providing a flexible aerogel thermal insulation decorative composite panel and its preparation method. It provides a composite panel and its preparation method that achieves interfacial bonding between the decorative layer and the aerogel core material layer through in-situ infiltration anchoring, thereby solving the problems of low interfacial strength, poor air permeability, and flexibility mismatch in traditional adhesive composites.

[0006] A flexible aerogel thermal insulation decorative composite panel includes a flexible inorganic mineral matrix finish layer 10, a silica aerogel fiber felt insulation core layer 20, and an interpenetrating bonding layer 30 located between the flexible inorganic mineral matrix finish layer 10 and the silica aerogel fiber felt insulation core layer 20. The interpenetrating bonding layer 30 is a three-dimensional interpenetrating network structure formed by controlled penetration and in-situ curing of the finishing layer slurry into the aerogel fiber felt in an uncured state. The flexible inorganic mineral-based decorative layer 10 is embedded in the gaps of the aerogel fiber structure to form a physical anchoring structure; the embedding depth is preferably 0.5 mm to 2.0 mm. The thickness of the flexible inorganic mineral-based decorative layer 10 is preferably 3mm to 10mm, which can be adjusted according to design requirements, but the thickness of this layer does not change with the thickness of the aerogel core material layer.

[0007] The thickness of the silica aerogel fiber felt insulation core layer 20 ranges from 3mm to 50mm and can be a single layer or a multi-layer stacked structure. The composite board is a flexible system that can be bent without the separation of the interface layers; the composite board has a hydrophobicity of ≥99.5% and also has water vapor permeability. The flexible inorganic mineral-based finishing layer 10 preferably contains a silane coupling agent, which forms a chemical bond with the hydroxyl groups of the aerogel skeleton during the curing process.

[0008] The interfacial bonding strength of the interpenetrating bonding layer 30 is greater than the strength of the aerogel body, and the interfacial peeling failure mode is the aerogel body failure.

[0009] The silica aerogel fiber felt insulation core layer 20, on the side opposite to the finishing layer, is also composited with a wall bonding interface layer 201 for anchoring to the building substrate; preferably, the wall bonding interface layer 201 is a reinforced structure composed of polymer bonding mortar and fiberglass mesh, or a roughened layer coated with a special interface agent.

[0010] A method for preparing a flexible aerogel thermal insulation decorative composite panel includes: S1: Micro-wetting treatment is performed on one side of the silica aerogel fiber felt insulation core layer 20; S2: Preparation of inorganic mineral-based active slurry containing silane coupling agent; specifically, mixing modified inorganic mineral powder, aqueous flexible emulsion, cellulose thickener and silane coupling agent in proportion to prepare an active slurry with controllable rheological properties; S3: The slurry is laid to form a wet finishing layer, and the silica aerogel fiber felt insulation core material layer 20 is covered on the wet layer; S4: Perform staged temperature and pressure treatment on the structure of step S3 to allow the slurry to penetrate into the aerogel fiber structure and solidify to form an interpenetrating bonding layer 30.

[0011] The step S4 staged temperature and pressure treatment includes: the first stage of penetration period: 60℃~80℃, 0.5~1.0MPa pressure, time: 5~10 minutes; the second stage of cross-linking period: temperature: 120℃~150℃, time: 20~30 minutes; the slurry is completely cured to form a three-dimensional interpenetrating anchoring structure, and no independent adhesive barrier layer is set in the whole process.

[0012] In step S1, the wetting depth of the microwetting treatment is controlled between 0.5 mm and 1.0 mm. This process only changes the surface interfacial tension and does not damage the internal hydrophobic structure.

[0013] The working principle of this invention is as follows: Through in-situ interfacial penetration anchoring technology, a three-dimensional interpenetrating network structure is formed between the flexible inorganic mineral-based finishing layer and the silica aerogel fiber felt insulation core layer. First, the aerogel fiber felt is micro-wetted on one side, reducing the interfacial tension within a 0.5mm to 1.0mm range on its surface. This establishes a controllable channel for subsequent slurry penetration without damaging the internal hydrophobic structure. Then, an inorganic mineral-based active slurry containing a silane coupling agent is laid to form a wet layer, and the treated aerogel fiber felt is placed on top. Under the temperature and pressure conditions of 60℃ to 80℃ and 0.5 to 1.0MPa in the first stage, the slurry is in a flowable state and, under pressure, undergoes controlled penetration into the gaps between the aerogel fibers, forming an embedded distribution structure of 0.5mm to 2.0mm, producing a "tree root"-like physical anchoring morphology. In the second stage, at 120℃~150℃, the slurry undergoes full cross-linking and curing, locking the matrix material that has penetrated into the fiber structure. Simultaneously, the silane coupling agent forms chemical bonds with the hydroxyl groups on the surface of the aerogel skeleton, transforming the interface from a simple contact interface into a volumetrically interwoven three-dimensional interpenetrating network structure. Ultimately, a flexible synergistic composite system without an independent adhesive barrier layer is formed, which does not separate at the interface under bending conditions and maintains hydrophobic and air-permeable properties.

[0014] After adopting the above technical solution, the beneficial effects of the present invention are as follows: it controls the penetration of the decorative layer slurry into the interior of the aerogel fiber structure in an uncured state and cures it in situ to form a three-dimensional interpenetrating network anchoring interface, so that the interface bonding method is changed from the traditional surface adhesive to a volume embedded physical anchoring and chemical bonding synergistic structure, the interface bonding strength is significantly improved, and the peeling failure mode is manifested as the destruction of the aerogel body, which fundamentally solves the problems of delamination, blistering and detachment.

[0015] Furthermore, by adding a wall bonding interface layer on the back of the aerogel core material, it completely overcomes the industry pain point that aerospace-grade superhydrophobic materials cannot be directly bonded with cement-based materials in traditional building construction. Together with the front finishing layer, it forms a complete 'sandwich' structure, achieving true flexible thermal insulation and decoration integration, meeting the 'plug-and-play' construction requirements of building exterior walls, and significantly reducing the risk of system detachment and construction costs.

[0016] By eliminating the dense adhesive barrier layer and utilizing the micron-level pore structure of the MCM matrix itself, the resulting composite panel maintains a water repellency rate of over 99.7%. Simultaneously, due to the absence of an independent dense adhesive barrier layer, the composite panel maintains a water repellency rate of ≥99.5% while still possessing excellent water vapor permeability, achieving a "breathing" function for the exterior wall. Furthermore, both the finishing layer and the aerogel core material are flexible materials with an interpenetrating network structure at their interface, maintaining interface stability under bending construction conditions. This makes it suitable for curved walls and thermal bridge joints, offering comprehensive advantages such as high interface strength, breathability, fire safety, and flexible synergy. Through in-situ composite molding technology, this invention successfully achieves stable production from 3mm ultra-thin panels to 50mm thick panels, meeting the needs of large-area exterior wall insulation while perfectly solving the insulation problems of "thermal bridge" joints such as window frames and internal corners, while maintaining the dual flexibility of the overall system. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the composite plate of the present invention.

[0019] Explanation of reference numerals in the attached drawings: 10 Flexible inorganic mineral-based finishing layer, 20 Silica aerogel fiber felt insulation core material layer, 30 Interpenetrating interface bonding layer, 201 Wall bonding interface layer. Detailed Implementation

[0020] See Figure 1As shown, the technical solution adopted in this specific embodiment is as follows: A flexible aerogel thermal insulation decorative composite board includes a flexible inorganic mineral matrix facing layer 10, a silica aerogel fiber felt insulation core layer 20, and an interpenetrating interface bonding layer 30 located between the flexible inorganic mineral matrix facing layer 10 and the silica aerogel fiber felt insulation core layer 20; the interpenetrating interface bonding layer 30 is a three-dimensional interpenetrating network structure formed by the controlled penetration and in-situ curing of the facing layer slurry into the aerogel fiber felt in an uncured state; the flexible inorganic mineral matrix facing layer... The aerogel fiber structure 10 is embedded in the gaps of the aerogel fiber structure to form a physical anchoring structure; the embedding depth is preferably 1 mm; the thickness of the silica aerogel fiber felt insulation core layer 20 is in the range of 20 mm, and can be a single layer or a three-layer stacked structure; the composite board as a whole is a flexible system, which can be bent without the separation of the interface layers; the composite board has a hydrophobicity ≥99.5% and also has water vapor permeability; the flexible inorganic mineral matrix finishing layer 10 preferably contains a silane coupling agent, which forms a chemical bond with the hydroxyl groups of the aerogel skeleton during the curing process. The interfacial bonding strength of the interpenetrating bonding layer 30 is greater than the strength of the aerogel body, and the interface peeling failure mode is the failure of the aerogel body.

[0021] A method for preparing a flexible aerogel thermal insulation decorative composite panel includes: S1: micro-wetting treatment on one side of the silica aerogel fiber felt insulation core layer 20; S2: preparing an inorganic mineral-based active slurry containing a silane coupling agent; specifically, mixing modified inorganic mineral powder, aqueous flexible emulsion, cellulose thickener and silane coupling agent in proportion to prepare an active slurry with controllable rheological properties; S3: laying the slurry to form a wet decorative layer, and covering the silica aerogel fiber felt insulation core layer 20 on the wet layer; S4: performing a staged temperature and pressure treatment on the structure of step S3, so that the slurry penetrates into the interior of the aerogel fiber structure and solidifies to form an interpenetrating bonding layer 30. The step S4, a phased temperature and pressure treatment, includes: a first-stage penetration period at 70°C and 1.0 MPa pressure for 8 minutes; and a second-stage cross-linking period at 150°C for 20 minutes. The slurry is fully cured, forming a three-dimensional interpenetrating anchoring structure. No independent adhesive barrier layer is used throughout the process. The wetting depth in the micro-wetting treatment in step S1 is controlled to 1.0 mm. This process only alters the surface interfacial tension without damaging the internal hydrophobic structure. The wetting agent used in the micro-wetting treatment is an aqueous solution containing trace amounts of surfactant, or a mixture of water and ethanol, applied to the surface via atomized spraying.

[0022] This specific embodiment achieves controlled penetration and in-situ curing of the decorative layer slurry into the aerogel fiber structure in an uncured state, forming a three-dimensional interpenetrating network anchoring interface. This transforms the interface bonding method from traditional surface adhesive to a synergistic structure of volume-embedded physical anchoring and chemical bonding, significantly improving the interface bonding strength. The peeling failure mode manifests as the destruction of the aerogel itself, fundamentally solving the problems of delamination, blistering, and detachment.

[0023] Furthermore, by adding a wall bonding interface layer on the back of the aerogel core material, it completely overcomes the industry pain point that aerospace-grade superhydrophobic materials cannot be directly bonded with cement-based materials in traditional building construction. Together with the front finishing layer, it forms a complete 'sandwich' structure, achieving true flexible thermal insulation and decoration integration, meeting the 'plug-and-play' construction requirements of building exterior walls, and significantly reducing the risk of system detachment and construction costs.

[0024] By eliminating the dense adhesive barrier layer and because the MCM matrix itself has a micron-sized pore structure, the resulting composite panel maintains a water repellency rate of over 99.7% while possessing excellent water vapor permeability (high moisture flow density), thus enabling the exterior wall to "breathe" and effectively preventing mold growth.

[0025] Meanwhile, due to the absence of an independent dense adhesive barrier layer, the composite board maintains excellent water vapor permeability while retaining a water repellency rate of ≥99.5%, achieving a "breathing" function for the exterior wall. Furthermore, both the finishing layer and the aerogel core material are flexible materials with an interpenetrating network structure at their interface, ensuring interface stability under bending construction conditions. This makes it suitable for curved walls and thermal bridge joints, offering comprehensive advantages such as high interface strength, breathability, fire safety, and flexible synergy. Through in-situ composite molding technology, this invention has successfully achieved stable production from 3mm ultra-thin panels to 50mm thick panels, meeting the needs of large-area exterior wall insulation while perfectly solving the insulation problems of "thermal bridge" joints such as window frames and internal corners, while maintaining the dual flexibility of the overall system.

[0026] The above description is only used to illustrate the technical solution of the present invention and is not intended to limit it. Any other modifications or equivalent substitutions made by those skilled in the art to the technical solution of the present invention, as long as they do not depart from the spirit and scope of the technical solution of the present invention, should be covered within the scope of the claims of the present invention.

Claims

1. A flexible aerogel thermal insulation decorative composite panel, characterized in that: It includes a flexible inorganic mineral-based decorative layer (10), a silica aerogel fiber felt insulation core layer (20), and an interpenetrating bonding layer (30) between the flexible inorganic mineral-based decorative layer (10) and the silica aerogel fiber felt insulation core layer (20). The interpenetrating bonding layer (30) is a three-dimensional interpenetrating network structure formed by controlled penetration and in-situ curing of the finishing layer slurry into the aerogel fiber felt in an uncured state.

2. The flexible aerogel thermal insulation decorative composite panel according to claim 1, characterized in that: The flexible inorganic mineral-based decorative layer (10) is embedded in the gaps of the aerogel fiber structure to form a physical anchoring structure; the embedding depth is 0.5 mm to 2.0 mm; the thickness of the flexible inorganic mineral-based decorative layer (10) is 3 mm to 100 mm.

3. The flexible aerogel thermal insulation decorative composite panel according to claim 1, characterized in that: The thickness of the silica aerogel fiber felt insulation core layer (20) ranges from 3mm to 50mm, and can be a single layer or a multi-layer stacked structure.

4. The flexible aerogel thermal insulation decorative composite panel according to claim 1, characterized in that: The composite board is a flexible system that can be bent without the separation of the interface layers; the composite board has a hydrophobicity of ≥99.5% and also has water vapor permeability.

5. The flexible aerogel thermal insulation decorative composite panel according to claim 1, characterized in that: The flexible inorganic mineral-based finishing layer (10) preferably contains a silane coupling agent, which forms a chemical bond with the hydroxyl groups of the aerogel skeleton during the curing process.

6. The flexible aerogel thermal insulation decorative composite panel according to claim 1, characterized in that: The interfacial bonding strength of the interpenetrating bonding layer (30) is greater than the strength of the aerogel body, and the interfacial peeling failure mode is the aerogel body failure.

7. The flexible aerogel thermal insulation decorative composite panel according to claim 1, characterized in that: On the side of the silica aerogel fiber felt insulation core material layer (20) facing away from the finishing layer, a wall bonding interface layer (201) for anchoring with the building base is also provided; the wall bonding interface layer (201) is a reinforced structure composed of polymer bonding mortar and fiberglass mesh, or a roughened treatment layer coated with a special interface agent.

8. A method for preparing a flexible aerogel thermal insulation decorative composite panel, characterized in that: The preparation method includes the following steps; S1: Micro-wetting treatment is performed on one side of the silica aerogel fiber felt insulation core material layer (20); S2: Preparation of inorganic mineral-based active slurry containing silane coupling agent; specifically, mixing modified inorganic mineral powder, aqueous flexible emulsion, cellulose thickener and silane coupling agent in proportion to prepare an active slurry with controllable rheological properties; S3: The slurry is laid to form a wet finishing layer, and the silica aerogel fiber felt insulation core material layer (20) is covered on the wet layer; S4: Perform staged temperature and pressure treatment on the structure of step S3 to allow the slurry to penetrate into the aerogel fiber structure and solidify to form an interpenetrating bonding layer (30).

9. The method for preparing a flexible aerogel thermal insulation decorative composite panel according to claim 8, characterized in that: The step S4 staged temperature and pressure treatment includes: the first stage of penetration period: 60℃~80℃, 0.5~1.0MPa pressure, time: 5~10 minutes; the second stage of cross-linking period: temperature: 120℃~150℃, time: 20~30 minutes; the slurry is completely cured to form a three-dimensional interpenetrating anchoring structure, and no independent adhesive barrier layer is set in the whole process.

10. The method for preparing a flexible aerogel-bonded thermal insulation decorative composite panel according to claim 8, characterized in that: In step S1, the wetting depth of the microwetting treatment is controlled between 0.5 mm and 1.0 mm.

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