Thermal insulation board for portable house and preparation method of thermal insulation board

Abstract

The invention relates to the technical field of novel building energy-saving materials and green building materials, in particular to a heat insulation board for a portable house and a preparation method of the heat insulation board. According to the invention, a unique multi-layer composite structure of exterior decoration protection, radiation buffering, main heat preservation, heat insulation enhancement, intelligent temperature adjustment and interior decoration is constructed, and frontier technologies of radiation reflection, vacuum heat insulation, phase change energy storage, intelligent temperature adjustment and the like are creatively integrated. All the functional layers are synergistically combined through well-designed interface treatment and a gradient modulus adhesive system, and the technical problems of stress concentration, interface stripping and the like caused by physical property difference between different material layers of a traditional insulation board are solved. The thermal insulation board prepared by the invention not only realizes ultralow heat conductivity coefficient and excellent fireproof safety level, but also has dynamic thermal response capability, can automatically adjust indoor thermal comfort according to environment temperature, and also has healthy environment regulation and control functions such as antibiosis and release of negative oxygen ions.

Description

A thermal insulation board for prefabricated houses and its preparation method Technical Field

[0001] This invention relates to the field of new building energy-saving materials and green building materials technology, specifically to a heat insulation board for prefabricated houses and its preparation method. Background Technology

[0002] Prefabricated houses, as a type of mobile temporary construction, are widely used in construction site dormitories, field work areas, and post-disaster resettlement sites. Under extreme climatic conditions, the technical requirements for thermal insulation materials are particularly prominent, needing to meet requirements for rapid installation, long-term stability, and environmental adaptability, while also considering fire resistance and environmental friendliness. Especially in environments with alternating high summer temperatures and severe winter cold, materials must possess highly efficient thermal insulation capabilities to prevent excessive heat conduction leading to indoor temperature fluctuations, and ensure that the structure does not deform or degrade in performance during frequent disassembly and transportation. Furthermore, the materials must comply with green construction standards, reducing the release of harmful gases and avoiding any impact on human health.

[0003] Currently, the existing solutions for this technical requirement mainly include the following:

[0004] Phenolic foam composite board technology: Using phenolic foam as the core material, the overall strength is enhanced through a multi-layer composite structure. Its fire resistance reaches a high standard, and its thermal conductivity is low, providing good thermal insulation performance. It is suitable for prefabricated houses with high safety requirements.

[0005] Polyurethane sandwich panel technology: using polyurethane foam as the core material, with colored steel plates on both sides to form a sandwich structure. It utilizes its excellent sealing properties to reduce air penetration and significantly improve the thermal insulation effect, but flame retardants need to be added to improve its flammability.

[0006] Double-layer insulation structure design: The wall panels and roof are combined with double-layer insulation materials, with an air gap in the middle. The heat conduction efficiency is reduced by the principle of air insulation, which takes into account both fire prevention and high insulation requirements.

[0007] While the above methods have achieved some success in specific scenarios, the following problems still exist:

[0008] Composite boards are brittle: Although phenolic foam materials have excellent fire resistance, they are relatively brittle and are prone to cracking or powdering during transportation and installation, which affects the integrity and service life of the overall structure.

[0009] Poor fire resistance: Although adding flame retardants can improve the combustion performance of polyurethane, its fire resistance rating is still difficult to reach the highest standard, and flame retardants may decompose at high temperatures to produce harmful gases, posing a safety hazard.

[0010] Construction is complex and difficult: Although the design of air gap can improve the heat insulation effect, it requires precise control of the interlayer distance and sealing. In actual construction, the gap is prone to failure due to process errors, and the double-layer structure significantly increases material costs and construction period. Summary of the Invention

[0011] To address the shortcomings of existing technologies, this invention provides a heat-insulating board for prefabricated houses and its preparation method, thus solving the problems mentioned above in the background technology.

[0012] According to a first aspect of the present invention, a method for preparing a thermal insulation board for prefabricated houses is provided, comprising the following steps:

[0013] (a) Preparation of the exterior protective layer: A two-component PPGDuranar® PVDF fluorocarbon resin coating is applied to the surface of 300-400 parts of AA3003-H14 aluminum alloy substrate and cured at 200-250°C for 15-25 minutes to obtain the exterior protective layer;

[0014] (b) Preparation of radiation-air buffer layer: On the inner side of the outer protective layer, an annular plastic spacer with a height of 5-8 mm is set to obtain a reserved cavity; in the reserved cavity, a composite radiation barrier composed of 120-130 parts of double-sided aluminized polyester film and 5-10 parts of hydrophobic fumed silica slurry is assembled to obtain the radiation-air buffer layer.

[0015] (c) Preparation of the main thermal insulation-fireproof composite core layer: 100-120 parts of rigid polyurethane foam, 20-25 parts of basalt fiber and 1-3 parts of organic modified bentonite are mixed and foamed on site using a high-pressure spraying equipment. At the same time, 2-5 parts of phosphorus-nitrogen synergistic flame retardant solution containing terminal hydroxyl polysiloxane are sprayed during the foaming process. The mixture is cured at 50-70℃ for 2-4 hours and then wrapped with a high-permeability glass fiber mesh cloth treated with 5-8 parts of silane coupling agent to obtain the main thermal insulation-fireproof composite core layer.

[0016] (d) Preparation of the thermal insulation reinforcement layer: 90-95 parts of nano-silica aerogel precursor sol and 5-8 parts of short-cut para-aramid nanofibers are uniformly mixed, and then 1-2 parts of inorganic and organic hybrid interface coupling agent are added. After supercritical drying, the thermal insulation reinforcement layer is obtained.

[0017] (e) Preparation of intelligent temperature-regulating-structural support composite layer: 15-25 parts of phase change microcapsules, 2-4 parts of graphene nanosheets, 2-4 parts of modified boron nitride nanosheets and 60-80 parts of lightweight magnesium cement foaming base material are mixed, and 1-3 parts of modified porous diatomaceous earth are added. After stirring and foaming, the mixture is injected into a mold and cured at 60-80℃ and 60-80% relative humidity for 48-72 hours to obtain the intelligent temperature-regulating-structural support composite layer.

[0018] (f) Preparation of interior decoration-health function layer: 50-60 parts of bamboo and wood fiber, 0.5-1.5 parts of composite ionic antibacterial agent, 3-8 parts of negative oxygen ion releasing mineral powder and 10-15 parts of polyurethane adhesive are mixed, and the mixture is generated by hot pressing and surface micropore processing.

[0019] (g) Gradient assembly: The outer protective layer, radiation-air buffer layer, main insulation-fireproof composite core layer, heat insulation enhancement layer, intelligent temperature regulation-structural support composite layer and the inner decoration-health function layer are stacked in sequence, and 5-10 parts of gradient modulus transition adhesive are applied between the layers to obtain a composite board semi-finished product.

[0020] (h) Post-processing: The composite board semi-finished product prepared in step (g) is aged at 50-70℃ and 30-60% relative humidity for 24-48 hours to obtain the heat insulation board.

[0021] According to an embodiment of the present invention, in step (a), the two-component PPG Duranar® PVDF fluorocarbon resin coating is a coating mixture powder composed of a PVDF fluorocarbon resin coating mixture, nano titanium dioxide and composite filler in a mass ratio of 80:1:2-100:3:5.

[0022] The PVDF fluorocarbon resin coating mixture is a composite resin base material prepared by melting and mixing polyvinylidene fluoride resin, acrylic resin and alicyclic epoxy resin at a mass ratio of 70:5:5-80:15:15 at 100-120℃; the composite filler is a gray-black powder prepared by mixing nano boron nitride and reduced graphene oxide at a mass ratio of 2:1-4:1.

[0023] According to an embodiment of the present invention, in step (a), polyvinylidene fluoride resin, acrylic resin, and alicyclic epoxy resin are melt-blended to form a dense, weather-resistant continuous phase matrix, which not only possesses excellent environmental resistance but also provides a stable carrier for functional components. Nano-titanium dioxide is uniformly dispersed in the resin matrix, endowing the coating with long-lasting photocatalytic self-cleaning ability. The composite filler composed of nano-boron nitride and reduced graphene oxide constructs a highly efficient thermal conductivity and reflection network in the matrix. On the one hand, it significantly reduces solar radiation heat gain through synergistic reflection; on the other hand, it promotes lateral heat diffusion through high in-plane thermal conductivity, avoiding local overheating, and together ensuring the high reflectivity and structural integrity of the coating during long-term service.

[0024] According to an embodiment of the present invention, in step (b), the double-sided aluminized polyester film is a composite film made by depositing an aluminum layer with a thickness of 0.05-0.07 μm onto a polyethylene terephthalate film with a thickness of 10-12 μm through vacuum evaporation, resulting in a thickness of 120-125 μm; the hydrophobic fumed silica slurry is a white emulsion slurry made by mixing hydrophobic fumed silica, deionized water and silane coupling agent KH-570 in a mass ratio of 1:8:0.02-1:12:0.05 and then emulsifying it by high-speed shearing.

[0025] According to an embodiment of the present invention, in step (b), the double-sided aluminized polyester film effectively blocks long-wave infrared radiation heat transfer due to its ultra-low surface emissivity, while the hydrophobic fumed silica slurry forms a functional layer with microporous breathability after being cast into a film. The composite radiation barrier constructed by the two forms a unique synergistic mechanism of "radiation shielding and breathability regulation" within the closed cavity. The aluminized film layer acts as the reflective core, minimizing radiative heat transfer; the hydrophobic silica microporous membrane, through its precisely controlled pore structure, maintains the thermal insulation performance of the static air layer in the cavity while allowing water vapor molecules to diffuse slowly, cleverly solving the technical problem of condensation easily caused by temperature changes in traditional closed cavities. This multi-layered barrier design, combining rigidity and flexibility, enables the layer to not only ensure excellent thermal insulation performance but also possess humidity regulation capabilities, significantly improving the durability and thermal stability of the wall system.

[0026] According to an embodiment of the present invention, in step (c), the rigid polyurethane foam composition is a foaming mixture made by mixing polyether polyol, polymethylene polyphenyl polyisocyanate, fluoroethane and dibutyltin dilaurate in a mass ratio of 100:120:5:1-100:150:10:2; the organic modified bentonite is a light gray powder obtained by reacting sodium bentonite and phosphate ester flame retardant plasticizer in a mass ratio of 10:1-5:1; the phosphorus-nitrogen synergistic flame retardant solution containing hydroxyl-terminated polysiloxane is composed of hydroxyl-terminated polysiloxane, cage-like pentaerythritol... The flame retardant liquid is a mixture of alkoxyphosphate and melamine polyphosphate in a mass ratio of 1:2:1-1.5:3:1.5; the basalt fiber has a single filament diameter of 9-13μm, a melting point >1000℃, and is A1 grade non-flammable; the high air permeability glass fiber mesh is formed by twisting glass fiber yarns to form a mesh with a mesh size of 4mmx4mm-5mmx5mm, and coated with a coating adhesive, which is a gel-like solution prepared by silane coupling agent KH-550, acrylate and nano-silicon in a mass ratio of 1:10:2-1:15:3.

[0027] According to an embodiment of the present invention, in step (c), the main thermal insulation skeleton formed by rigid polyurethane foam and the highly permeable glass fiber mesh with a special coating are firmly bonded at the interface through a silane coupling agent, ensuring both structural strength and maintaining the air permeability requirements during the foaming process. An innovative composite solution of hydroxyl-terminated polysiloxane and phosphorus-nitrogen flame retardant is introduced into the foaming system, which produces a synergistic flame retardant effect with organically modified bentonite. The polysiloxane forms a dense silicon-carbon protective layer at high temperatures, the phosphorus-nitrogen system promotes expansion into char, and the bentonite sheets enhance the thermal stability of the char layer; together, these three elements construct a highly efficient ceramicized barrier system. Simultaneously, high-melting-point basalt fibers form a three-dimensional network fireproof skeleton within the foam matrix, effectively blocking flame propagation and working synergistically with the reinforced foam char layer to maintain structural integrity at high temperatures, achieving a perfect balance between thermal insulation performance and fire safety.

[0028] According to an embodiment of the present invention, in step (d), the nano-silica aerogel precursor sol is a transparent sol formed by hydrolysis and condensation of tetraethyl orthosilicate, anhydrous ethanol, deionized water and hydrochloric acid catalyst in a mass ratio of 1:8:0.2:0.01-1:12:0.4:0.02; the short-cut para-aramid nanofibers have a length of 50-100 μm and a diameter of 50-100 nm; the inorganic-organic hybrid interface coupling agent is a transparent solution formed by hydrolysis of vinyltriethoxysilane and tetrabutyl titanate in a mass ratio of 3:1-3:1.5.

[0029] According to an embodiment of the present invention, in step (d), the nano-silica aerogel precursor sol undergoes hydrolysis and condensation to form a three-dimensional nanoporous framework, laying the foundation for ultra-low thermal conductivity. Short-cut para-aramid nanofibers, with their high aspect ratio and surface activity, are interwoven and distributed within the sol to form a micro-nano scale toughness-enhancing network. The key innovation lies in the introduction of an inorganic-organic hybrid interface coupling agent, whose molecules contain both silanoxy and titanate groups, enabling simultaneous chemical coupling with the silanol groups of the aerogel framework and the functional groups on the surface of the aramid fibers, constructing a robust silicon-oxygen-titanium covalent bond bridge at the interface between the inorganic and organic phases. This unique interface engineering not only effectively suppresses the drying shrinkage of the aerogel but also achieves efficient stress transfer and dispersion within the three-dimensional network, allowing the material to maintain excellent thermal insulation performance while achieving unprecedented structural integrity and crack resistance.

[0030] According to an embodiment of the present invention, in step (e), the phase change microcapsules are white microspheres formed by in-situ polymerization of paraffin wax, melamine resin, and nano-silica hybrid shells in a mass ratio of 4:1:1-3:1:1; the modified boron nitride nanosheets are modified nanofillers obtained by electrostatic self-assembly of boron nitride nanosheets, phytic acid, and chitosan in an aqueous phase in a mass ratio of 5:1:1-3:1:1; the lightweight magnesium cement foaming base is a dry mixture formed by mixing lightly calcined magnesium oxide powder, magnesium chloride hexahydrate, and hydrogen peroxide in a mass ratio of 5:3:1-6:4:1.5; and the modified porous diatomaceous earth is a hydrophobic carrier particle obtained by reacting diatomaceous earth with a particle size of 300-500 mesh and stearic acid in a mass ratio of 10:1-10:3.

[0031] According to an embodiment of the present invention, in step (e), the phase change microcapsules achieve efficient energy storage and stable encapsulation through a hybrid shell of melamine resin and nano-silica. Graphene nanosheets and boron nitride nanosheets modified with phytic acid and chitosan form a three-dimensional thermally conductive network in a lightweight magnesium cement foam matrix. The former provides a rapid in-plane thermal diffusion channel, while the latter enhances the bonding force with the matrix through interface modification and exerts a synergistic flame-retardant effect of phosphorus and nitrogen. Modified porous diatomaceous earth, as a hydrophobic carrier, not only fixes the phase change material to prevent leakage through capillary action, but its porous structure also forms a dual-pore system with the foam matrix, buffering the volumetric stress of the phase change while maintaining the lightweight and high strength of the structure. Through precise proportioning and interface design, the components ultimately achieve a multifunctional synergy of heat absorption and release, rapid heat equalization, flame retardant safety, and mechanical support.

[0032] According to an embodiment of the present invention, in step (f), the composite ionic antibacterial agent is a white nanoparticle powder obtained by calcining silver nitrate and zinc nitrate at 300-400°C after mixing them in a molar ratio of 1:1-1:2; the negative oxygen ion releasing mineral powder is a grayish-white mineral powder obtained by mechanically grinding tourmaline powder and montmorillonite powder in a mass ratio of 1:1-2:1 to a particle size of 800-1000 mesh; the polyurethane adhesive is a viscous liquid obtained by mixing hydroxyl-terminated polyurethane prepolymer and isocyanate in a mass ratio of 10:1-8:1.

[0033] According to an embodiment of the present invention, in step (f), the porous framework formed by bamboo and wood fibers provides a stable carrier for the functional components. The polyurethane adhesive, through the active groups on its molecular chain, forms a three-dimensional cross-linked network with the fibers and functional particles, ensuring structural integrity. The silver-zinc composite ion antibacterial agent significantly broadens the antibacterial spectrum and inhibits the development of microbial drug resistance through the synergistic effect of the two metal ions. The mineral composite composed of tourmaline and montmorillonite continuously releases high concentrations of negative oxygen ions through the synergistic effect of intercrystalline potential difference and adsorption effect. More importantly, the surface microporous structure not only enhances sound wave absorption but also strengthens the release efficiency of antibacterial ions and negative oxygen ions by increasing the specific surface area, forming a deep coupling between physical structure and chemical function, ultimately achieving the integration of multiple health benefits such as antibacterial purification, negative ion release, and humidity regulation.

[0034] According to an embodiment of the present invention, in step (g), the gradient modulus transition adhesive is a transitional gel composed of a high-elasticity silicone sealant and a rigid epoxy and polyurethane interpenetrating network adhesive in a mass ratio of 1:2 to 1:3.

[0035] The high-elasticity silicone sealant is a paste-like substance formed by mixing and grinding hydroxyl-terminated polydimethylsiloxane, methyltrimethoxysilane and nano-calcium carbonate in a mass ratio of 100:5:10-100:10:15; the rigid epoxy and polyurethane interpenetrating network adhesive is a semi-transparent viscous liquid formed by reacting bisphenol epoxy resin, hydroxyl-terminated polyurethane and dimethyl methylphosphonate in a mass ratio of 3:2:1-5:3:1.

[0036] According to an embodiment of the present invention, in step (g), the high-elasticity silicone sealant uses hydroxyl-terminated polydimethylsiloxane as a matrix, combined with a crosslinking agent and nanofillers, to form a soft and aging-resistant elastic buffer layer, effectively absorbing and releasing the internal stress generated by thermal expansion and contraction of each structural layer. Simultaneously, the rigid epoxy polyurethane interpenetrating network adhesive, through the interpenetrating network reaction of bisphenol epoxy resin and hydroxyl-terminated polyurethane, and in synergy with a reactive flame retardant, constructs a rigid interface with high strength, high modulus, and flame retardant properties. When the two are compounded in a specific ratio, a continuous modulus transition from flexible to rigid is formed in the overall bonding system. This not only perfectly matches the different physical properties of each functional layer, but also fundamentally solves the technical contradiction of traditional single adhesives being unable to simultaneously achieve elastic deformation and high-strength bonding through the synergy of chemical bonding and physical interlocking, ensuring the long-term structural integrity and durability of the composite board under complex working conditions.

[0037] According to a second aspect of the present invention, a thermal insulation board for prefabricated houses prepared by the above method is provided, characterized in that the thermal insulation board has ultra-low thermal conductivity, dynamic thermal response capability, excellent fire safety level and long-term durability, and integrates multiple thermal control mechanisms such as radiation reflection, phase change energy storage and aerogel thermal insulation, and also has the functions of antibacterial purification, release of negative oxygen ions and humidity regulation for a healthy environment.

[0038] According to embodiments of the present invention, the thermal insulation board is suitable for various building energy-saving enclosure systems, temporary housing walls, industrial plants and cold chain logistics insulation boxes, and has broad application prospects, especially in green buildings and special buildings with high standards for indoor thermal comfort, fire safety and healthy living environment.

[0039] Gradient composite structure and synergistic thermal control mechanism: Breaking through the traditional thinking of stacking single materials, a multi-physics field synergistic thermal control system integrating reflection, blocking, absorption, energy storage and regulation is constructed. Through gradient matching of material properties and interface synergistic design, the unity of ultra-low thermal conductivity and dynamic thermal response capability is achieved.

[0040] Multifunctional integration and healthy environment control: It innovatively integrates thermal performance with environmental health functions. While ensuring the core function of heat insulation, it endows the wall with multiple healthy environment control capabilities such as antibacterial purification, release of negative oxygen ions and humidity regulation, realizing a leap from single heat insulation to a healthy environment.

[0041] Interface engineering and long-term durability assurance: By developing a gradient modulus transition adhesive system and multi-scale interface treatment technology, the problems of stress concentration and interface delamination caused by the differences in physical properties between different material layers are solved, ensuring the long-term stability and durability of the composite structure under complex working conditions.

[0042] Intelligent response and active thermal management: The introduction of phase change energy storage units and high thermal conductivity nanomaterials to build an intelligent temperature regulation system enables the wall to have the ability to adapt to temperature regulation. It can actively absorb or release heat according to changes in ambient temperature, significantly improving indoor thermal comfort and reducing energy consumption.

[0043] Breakthroughs in nanotechnology and material performance: The extensive application of nanomaterials and nanotechnology, including nanoaerogels, nanofibers and various nanofunctional fillers, has achieved a synergistic improvement in the thermal insulation performance, mechanical strength and functional properties of materials through nanoscale effects and interface optimization.

[0044] This invention not only makes a fundamental innovation in the design principle of wall structure, but also endows traditional thermal insulation materials with multiple innovative characteristics such as intelligent response, health regulation and long-term durability through the cross-integration of multidisciplinary technologies and the fine control of material interfaces.

[0045] This invention offers the following advantages: It provides a thermal insulation board for prefabricated houses and its preparation method. Through innovative material combinations and structural design, this method not only significantly improves the product's overall thermal performance and fire safety level but also successfully integrates healthy environmental regulation and intelligent thermal management functions. This creates a novel wall material that combines multiple advantages such as ultra-low thermal conductivity, dynamic temperature regulation, high fire resistance, and health and comfort, greatly expanding the application value and development space of thermal insulation materials in green building and special application fields.

[0046] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0047] Figure 1 is a flowchart of the preparation method according to an embodiment of the present invention. Detailed Implementation

[0048] This application proposes a thermal insulation board for prefabricated houses and its preparation method, aiming to comprehensively improve the overall thermal performance, fire safety level and healthy environment control capability of the insulation board by constructing a "five-layer nine-phase" gradient composite structure, integrating nano-insulation materials, phase change energy storage units and intelligent humidity and heat control systems.

[0049] Example 1

[0050] Preparation of the outer protective layer: A two-component PVDF fluorocarbon resin coating is applied to the surface of a 400g AA3003-H14 aluminum alloy substrate and cured at 250℃ for 25 minutes.

[0051] Preparation of radiation-air buffer layer: An 8 mm high annular plastic spacer strip is set on the inner side of the outer protective layer to form a cavity. A radiation barrier composed of 130 g double-sided aluminized polyester film and 10 g hydrophobic fumed silica slurry is assembled in the cavity.

[0052] Preparation of the main insulation-fireproof composite core layer: 120 grams of rigid polyurethane foam, 25 grams of basalt fiber and 3 grams of organic modified bentonite are mixed and foamed using a high-pressure spraying equipment, while 5 grams of phosphorus and nitrogen synergistic flame retardant solution containing terminal hydroxyl polysiloxane are sprayed. The mixture is cured at 70°C for 4 hours and then wrapped with a high-permeability glass fiber mesh cloth treated with 8 grams of silane coupling agent.

[0053] Preparation of the thermal insulation reinforcement layer: 95 grams of nano-silica aerogel precursor sol were mixed with 8 grams of short-cut para-aramid nanofibers, and 2 grams of inorganic-organic hybrid interface coupling agent were added. The mixture was then dried and shaped by supercritical drying.

[0054] Preparation of intelligent temperature regulation-structural support composite layer: 25g phase change microcapsules, 4g graphene nanosheets, 4g modified boron nitride nanosheets and 80g lightweight magnesium cement foam base were mixed, and 3g modified porous diatomaceous earth was added. The mixture was cured at 80℃ and 80% humidity for 72 hours.

[0055] Preparation of the interior decoration - health function layer: Mix 60 grams of bamboo and wood fiber, 1.5 grams of composite ionic antibacterial agent, 8 grams of negative oxygen ion releasing mineral powder and 15 grams of polyurethane adhesive and hot press them into shape.

[0056] Gradient assembly: Stack the layers in sequence and apply 10 grams of gradient modulus transition adhesive for bonding.

[0057] Post-treatment: Grind at 70℃ and 60% humidity for 48 hours.

[0058] Test data: thermal conductivity 0.010W / (m·K), fire rating A1, thermal inertia index 4.5, latent heat of phase change 185kJ / kg, negative oxygen ion release 850ions / cm³.

[0059] Example 2

[0060] Preparation of the outer protective layer: A two-component PVDF fluorocarbon resin coating is applied to the surface of a 300g AA3003-H14 aluminum alloy substrate and cured at 200℃ for 15 minutes.

[0061] Preparation of radiation-air buffer layer: A 5 mm high annular plastic spacer strip is set on the inner side of the outer protective layer to form a cavity. A radiation barrier composed of 120 g double-sided aluminized polyester film and 5 g hydrophobic fumed silica slurry is assembled in the cavity.

[0062] Preparation of the main insulation-fireproof composite core layer: 100g of rigid polyurethane foam, 20g of basalt fiber and 1g of organic modified bentonite are mixed and foamed using a high-pressure spraying equipment, while 2g of phosphorus and nitrogen synergistic flame retardant solution containing terminal hydroxyl polysiloxane is sprayed. The mixture is cured at 50℃ for 2 hours and then wrapped with a high-permeability glass fiber mesh cloth treated with 5g of silane coupling agent.

[0063] Preparation of the thermal insulation reinforcement layer: 90 grams of nano-silica aerogel precursor sol was mixed with 5 grams of short-cut para-aramid nanofibers, 1 gram of inorganic-organic hybrid interface coupling agent was added, and the mixture was shaped by supercritical drying.

[0064] Preparation of intelligent temperature regulation-structural support composite layer: 15g phase change microcapsules, 2g graphene nanosheets, 2g modified boron nitride nanosheets and 60g lightweight magnesium cement foam base were mixed, and 1g modified porous diatomaceous earth was added. The mixture was cured at 60℃ and 60% humidity for 48 hours.

[0065] Preparation of the interior decoration - health function layer: Mix 50 grams of bamboo and wood fiber, 0.5 grams of composite ionic antibacterial agent, 3 grams of negative oxygen ion releasing mineral powder and 10 grams of polyurethane adhesive and hot press them into shape.

[0066] Gradient assembly: Stack the layers in sequence and apply 5 grams of gradient modulus transition adhesive for bonding.

[0067] Post-treatment: Grind at 50℃ and 30% humidity for 24 hours.

[0068] Test data: thermal conductivity 0.014 W / (m·K), fire rating A1, thermal inertia index 3.8, latent heat of phase change 175 kJ / kg, negative oxygen ion release 650 ions / cm³.

[0069] Example 3

[0070] Preparation of the outer protective layer: A two-component PVDF fluorocarbon resin coating was applied to the surface of a 350g AA3003-H14 aluminum alloy substrate and cured at 225℃ for 20 minutes.

[0071] Preparation of radiation-air buffer layer: A cavity is formed by setting an annular plastic spacer with a height of 6.5 mm on the inner side of the outer protective layer. A radiation barrier composed of 125 g of double-sided aluminized polyester film and 7.5 g of hydrophobic fumed silica slurry is assembled in the cavity.

[0072] Preparation of the main insulation-fireproof composite core layer: 110g of rigid polyurethane foam, 22.5g of basalt fiber and 2g of organic modified bentonite are mixed and foamed using a high-pressure spraying device, while 3.5g of phosphorus-nitrogen synergistic flame retardant solution containing terminal hydroxyl polysiloxane is sprayed. The mixture is cured at 60℃ for 3 hours and then covered with a high-permeability glass fiber mesh cloth treated with 6.5g of silane coupling agent.

[0073] Preparation of the thermal insulation reinforcement layer: 92.5 g of nano-silica aerogel precursor sol was mixed with 6.5 g of short-cut para-aramid nanofibers, and 1.5 g of inorganic-organic hybrid interface coupling agent was added. The mixture was then dried and shaped by supercritical drying.

[0074] Preparation of intelligent temperature regulation-structural support composite layer: 20g phase change microcapsules, 3g graphene nanosheets, 3g modified boron nitride nanosheets and 70g lightweight magnesium cement foam base were mixed, and 2g modified porous diatomaceous earth was added. The mixture was cured at 70℃ and 70% humidity for 60 hours.

[0075] Preparation of the interior decoration - health function layer: Mix 55g of bamboo and wood fiber, 1g of composite ionic antibacterial agent, 5.5g of negative oxygen ion releasing mineral powder and 12.5g of polyurethane adhesive and hot press them into shape.

[0076] Gradient assembly: Stack the layers in sequence and apply 7.5 grams of gradient modulus transition adhesive for bonding.

[0077] Post-treatment: Grind at 60℃ and 45% humidity for 36 hours.

[0078] Test data: thermal conductivity 0.012W / (m·K), fire rating A1, thermal inertia index 4.2, latent heat of phase change 180kJ / kg, negative oxygen ion release 750ions / cm³.

[0079] Example 4

[0080] Preparation of the outer protective layer: A two-component PVDF fluorocarbon resin coating was applied to the surface of a 380g AA3003-H14 aluminum alloy substrate and cured at 240℃ for 22 minutes.

[0081] Preparation of radiation-air buffer layer: A 7 mm high annular plastic spacer strip is set on the inner side of the outer protective layer to form a cavity. A radiation barrier composed of 128 g of double-sided aluminized polyester film and 8 g of hydrophobic fumed silica slurry is assembled in the cavity.

[0082] Preparation of the main insulation-fireproof composite core layer: 115g of rigid polyurethane foam, 23g of basalt fiber and 2.5g of organic modified bentonite are mixed and foamed using a high-pressure spraying device, while 4g ​​of phosphorus and nitrogen synergistic flame retardant solution containing terminal hydroxyl polysiloxane is sprayed. The mixture is cured at 65℃ for 3.5 hours and then covered with a high-permeability glass fiber mesh cloth treated with 7g of silane coupling agent.

[0083] Preparation of the thermal insulation reinforcement layer: 94 g of nano-silica aerogel precursor sol was mixed with 7 g of short-cut para-aramid nanofibers, and 1.8 g of inorganic-organic hybrid interface coupling agent was added. The mixture was then dried and shaped by supercritical drying.

[0084] Preparation of intelligent temperature regulation-structural support composite layer: 22 g of phase change microcapsules, 3.5 g of graphene nanosheets, 3.5 g of modified boron nitride nanosheets and 75 g of lightweight magnesium cement foam base were mixed and 2.5 g of modified porous diatomaceous earth was added. The mixture was cured at 75℃ and 75% humidity for 66 hours.

[0085] Preparation of the interior decoration - health function layer: 58 grams of bamboo and wood fiber, 1.2 grams of composite ionic antibacterial agent, 6 grams of negative oxygen ion releasing mineral powder and 14 grams of polyurethane adhesive are mixed and hot-pressed into shape.

[0086] Gradient assembly: Stack the layers in sequence and apply 9 grams of gradient modulus transition adhesive for bonding.

[0087] Post-treatment: Grind at 65℃ and 50% humidity for 42 hours.

[0088] Test data: thermal conductivity 0.011W / (m·K), fire rating A1, thermal inertia index 4.3, latent heat of phase change 182kJ / kg, negative oxygen ion release 800ions / cm³.

[0089] Comparative Example 1 (Traditional polyurethane sandwich panel preparation method)

[0090] The traditional polyurethane sandwich panel manufacturing process was used, and the specific steps were carried out in accordance with the method described in the existing literature CN 108867968 A.

[0091] Test data:

[0092] Thermal conductivity: 0.028 W / (m·K)

[0093] Fire rating: B1

[0094] Thermal inertia index: 2.5

[0095] Latent heat of phase transition: 0 kJ / kg

[0096] Negative oxygen ion release: 0 ions / cm³

[0097] Comparative Example 2 (Traditional Rock Wool Composite Board Preparation Method)

[0098] The traditional rock wool composite board preparation process was used, and the specific steps were carried out in accordance with the method in the existing literature CN 107419832 B.

[0099] Test data:

[0100] Thermal conductivity: 0.040 W / (m·K)

[0101] Fire resistance rating: A2

[0102] Thermal inertia index: 3.0

[0103] Latent heat of phase transition: 0 kJ / kg

[0104] Negative oxygen ion release: 0 ions / cm³

[0105] Comparative analysis

[0106] By comparing the test data of thermal insulation boards prepared by different methods, it can be seen that the preparation method provided by the present invention has significant advantages:

[0107] The thermal conductivity is significantly reduced: the thermal conductivity of all embodiments is less than 0.015 W / (m·K), which is much lower than the conventional method in the comparative example.

[0108] Fire resistance rating improved: The product prepared by the method of this invention meets the A1 non-combustible standard, while the products prepared by the comparative method are B1 and A2 respectively.

[0109] Improved thermal inertia index: The thermal inertia index of the product prepared by the method of the present invention reaches 3.8 or above, which is significantly higher than that of the product prepared by the comparative method.

[0110] Innovative Functional Characteristics: The product prepared by the method of this invention has phase change temperature regulation function and negative oxygen ion release function. The latent heat of phase change reaches more than 175kJ / kg and the negative oxygen ion release reaches more than 650 ions / cm³. These characteristics cannot be achieved by traditional methods.

[0111] Superior overall performance: Through the innovative "five-layer nine-phase" gradient composite structure design, this invention achieves the unity of multiple functions such as ultra-low thermal conductivity, dynamic temperature regulation, high-level fire resistance and healthy environment control, significantly exceeding the performance limits of traditional thermal insulation materials.

[0112] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including both the preferred embodiments and all changes and modifications falling within the scope of the invention.

[0113] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A method for preparing a heat-insulating board for prefabricated houses, characterized in that, Includes the following steps: (a) Preparation of the exterior protective layer: A two-component PPG Duranar® PVDF fluorocarbon resin coating is applied to the surface of 300-400 parts of AA3003-H14 aluminum alloy substrate and cured at 200-250℃ for 15-25 minutes to obtain the exterior protective layer; (b) Preparation of the radiation-air buffer layer: An annular plastic spacer strip with a height of 5-8 mm is set on the inner side of the exterior protective layer to obtain a reserved cavity; a composite radiation barrier composed of 120-130 parts of double-sided aluminized polyester film and 5-10 parts of hydrophobic fumed silica slurry is assembled in the reserved cavity to obtain the radiation-air buffer layer; (c) Preparation of the main thermal insulation-fireproof composite core layer: 100-120 parts of rigid polyurethane foam composite material, 20-25 parts of basalt fiber and 1-3 parts of organically modified bentonite are mixed and foamed on-site using a high-pressure spraying device. Simultaneously, 2-5 parts of a phosphorus-nitrogen synergistic flame retardant solution containing terminal hydroxyl polysiloxane are sprayed during the foaming process. The mixture is cured at 50-70℃ for 2-4 hours, and then coated with a high-permeability glass fiber mesh treated with 5-8 parts of silane coupling agent to obtain the main thermal insulation-fireproof composite core layer; (d) Preparation of the thermal insulation reinforcement layer: 90-95 parts of nano-silica aerogel precursor sol and 5-8 parts of chopped para-aramid nanofibers are uniformly mixed, and then 1-2 parts of an inorganic-organic hybrid interface coupling agent are added. After supercritical drying, the thermal insulation reinforcement layer is obtained; (e) Preparation of the intelligent temperature-regulating-structural support composite layer: 15-25 parts of phase change microcapsules, 2-4 parts of graphene nanosheets, 2-4 parts of modified boron nitride nanosheets, and 60-80 parts of lightweight magnesium cement foaming base are mixed, and 1-3 parts of modified porous diatomaceous earth are added. After stirring and foaming, the mixture is injected into a mold and cured at 60-80℃ and 60-80% relative humidity for 48-72 hours to obtain the intelligent temperature-regulating-structural support composite layer; (f) Preparation of the interior decoration-health function layer: 50-60 parts of bamboo and wood fiber, 0.5-1.5 parts of composite ionic antibacterial agent, 3-8 parts of negative oxygen ion releasing mineral powder, and 10-15 parts of polyurethane adhesive are mixed, and the mixture is hot-pressed and processed with surface micropores to generate the interior decoration-health function layer; (g) Gradient assembly: The outer protective layer, radiation-air buffer layer, main insulation-fireproof composite core layer, heat insulation reinforcement layer, intelligent temperature regulation-structural support composite layer and the inner decoration-health function layer are stacked in sequence, and 5-10 parts of gradient modulus transition adhesive are applied between the layers to obtain a composite board semi-finished product; (h) Post-treatment: The composite board semi-finished product prepared in step (g) is cured at 50-70℃ and relative humidity of 30-60% for 24-48 hours to obtain the heat insulation board.

2. The preparation method according to claim 1, characterized in that: In step (a), the two-component PPG Duranar® PVDF fluorocarbon resin coating is a coating mixture powder composed of a PVDF fluorocarbon resin coating mixture, nano-titanium dioxide, and composite filler in a mass ratio of 80:1:2-100:3:5; wherein, the PVDF fluorocarbon resin coating mixture is a composite resin base material prepared by melt mixing polyvinylidene fluoride resin, acrylic resin, and alicyclic epoxy resin in a mass ratio of 70:5:5-80:15:15 at 100-120℃; the composite filler is a gray-black powder composed of nano-boron nitride and reduced graphene oxide in a mass ratio of 2:1-4:

1.

3. The preparation method according to claim 1, characterized in that: In step (b), the double-sided aluminized polyester film is a composite film made by depositing an aluminum layer with a thickness of 0.05-0.07 μm onto a polyethylene terephthalate film with a thickness of 10-12 μm through vacuum evaporation, resulting in a thickness of 120-125 μm; the hydrophobic fumed silica slurry is a white emulsion slurry made by mixing hydrophobic fumed silica, deionized water and silane coupling agent KH-570 in a mass ratio of 1:8:0.02-1:12:0.05 and then emulsifying it through high-speed shearing.

4. The preparation method according to claim 1, characterized in that: In step (c), the rigid polyurethane foam composition is a foaming mixture made by mixing polyether polyol, polymethylene polyphenyl polyisocyanate, fluoroethane, and dibutyltin dilaurate in a mass ratio of 100:120:5:1-100:150:10:2; the organic modified bentonite is a light gray powder obtained by reacting sodium bentonite with phosphate ester flame retardant plasticizer in a mass ratio of 10:1-5:1; the phosphorus-nitrogen synergistic flame retardant solution containing hydroxyl-terminated polysiloxane is composed of hydroxyl-terminated polysiloxane, cage-like pentaerythritol phosphate, and... The flame retardant liquid is a mixture of melamine polyphosphate in a mass ratio of 1:2:1-1.5:3:1.5; the basalt fiber has a single filament diameter of 9-13μm, a melting point >1000℃, and is A1 grade non-flammable; the high air permeability glass fiber mesh is formed by twisting glass fiber yarns to form a mesh with a mesh size of 4mmx4mm-5mmx5mm, and coated with a coating adhesive, which is a gel-like solution prepared by silane coupling agent KH-550, acrylate and nano-silicon in a mass ratio of 1:10:2-1:15:

3.

5. The preparation method according to claim 1, characterized in that: In step (d), the nano-silica aerogel precursor sol is a transparent sol formed by hydrolysis and condensation of tetraethyl orthosilicate, anhydrous ethanol, deionized water and hydrochloric acid catalyst in a mass ratio of 1:8:0.2:0.01-1:12:0.4:0.02; the short-cut para-aramid nanofibers have a length of 50-100 μm and a diameter of 50-100 nm; the inorganic-organic hybrid interface coupling agent is a transparent solution formed by hydrolysis of vinyltriethoxysilane and tetrabutyl titanate in a mass ratio of 3:1-3:1.

5.

6. The preparation method according to claim 1, characterized in that: In step (e), the phase change microcapsules are white microspheres formed by in-situ polymerization of paraffin wax, melamine resin, and nano-silica hybrid shells in a mass ratio of 4:1:1-3:1:1; the modified boron nitride nanosheets are modified nanofillers obtained by electrostatic self-assembly of boron nitride nanosheets, phytic acid, and chitosan in an aqueous phase in a mass ratio of 5:1:1-3:1:1; the lightweight magnesium cement foaming base is a dry mixture formed by mixing lightly calcined magnesium oxide powder, magnesium chloride hexahydrate, and hydrogen peroxide in a mass ratio of 5:3:1-6:4:1.5; and the modified porous diatomaceous earth is a hydrophobic carrier particle obtained by reacting diatomaceous earth with a particle size of 300-500 mesh and stearic acid in a mass ratio of 10:1-10:

3.

7. The preparation method according to claim 1, characterized in that: In step (f), the composite ionic antibacterial agent is a white nanoparticle powder obtained by calcining silver nitrate and zinc nitrate at 300-400℃ after mixing them in a molar ratio of 1:1-1:2; the negative oxygen ion releasing mineral powder is a grayish-white mineral powder obtained by mechanically grinding tourmaline powder and montmorillonite powder in a mass ratio of 1:1-2:1 to a particle size of 800-1000 mesh; and the polyurethane adhesive is a viscous liquid obtained by mixing hydroxyl-terminated polyurethane prepolymer and isocyanate in a mass ratio of 10:1-8:

1.

8. The preparation method according to claim 1, characterized in that: In step (g), the gradient modulus transition adhesive is a transitional gel composed of high-elasticity silicone sealant and rigid epoxy / polyurethane interpenetrating network adhesive in a mass ratio of 1:2-1:3; wherein, the high-elasticity silicone sealant is a paste formed by mixing and grinding hydroxyl-terminated polydimethylsiloxane, methyltrimethoxysilane and nano-calcium carbonate in a mass ratio of 100:5:10-100:10:15; the rigid epoxy / polyurethane interpenetrating network adhesive is a semi-transparent viscous liquid formed by reacting bisphenol epoxy resin, hydroxyl-terminated polyurethane and dimethyl methylphosphonate in a mass ratio of 3:2:1-5:3:

1.

9. A heat insulation board for prefabricated houses prepared by the preparation method according to any one of claims 1 to 8.

10. The application of the thermal insulation board according to claim 9 in building energy-saving envelope systems, temporary housing walls, or insulated boxes for cold chain logistics.

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