A thermal insulation and decoration integrated board and a preparation method thereof

Abstract

This invention discloses an integrated thermal insulation and decorative panel and its preparation method, comprising a polystyrene foam insulation layer and a ceramic decorative layer. The polystyrene foam insulation layer is made of polystyrene foam board with a fire rating of Class B, which is infiltrated and cured with a modified slurry. The modified slurry is composed of the following components in parts by weight: 15-35 parts cement, 8-22 parts gypsum, 10-25 parts white cement, 3-10 parts starch, 1-5 parts white sugar, 0.8-4 parts glucose, 0.5-3 parts emulsifier, 0.3-2.5 parts plasticizer, 5-18 parts filler, 0.2-1.5 parts foaming agent, 1-6 parts diluent, 2-8 parts adhesive, 20-45 parts water, and 3-12 parts flame retardant. The polystyrene foam insulation layer has several evenly distributed grooves on the side near the ceramic decorative layer, and the grooves are filled with colloid. The ceramic decorative layer and the polystyrene foam insulation layer are fixed together by pressing the colloid. The fire rating of the polystyrene foam insulation layer reaches Class A2. The corresponding preparation method was also disclosed.

Description

Technical Field

[0001] This invention relates to the field of building insulation and decoration materials technology, specifically to an integrated insulation and decoration panel and its preparation method, and more specifically, to an integrated insulation and decoration panel formed by modifying a Class B polystyrene foam board to achieve a Class A2 fire resistance rating and combining it with a ceramic panel, and its preparation method, applicable to various building exterior wall insulation and decoration projects. Background Technology

[0002] Building energy conservation and fire safety have become core requirements in the field of building engineering. As a new type of building material that integrates insulation, decoration and fire prevention, the integrated insulation and decoration panel is widely used in the exterior wall insulation and decoration projects of various buildings due to its advantages such as convenient construction, significant energy-saving effect and good decoration.

[0003] Polystyrene foam board (EPS) is one of the most widely used building insulation materials due to its lightweight, low thermal conductivity, good insulation performance, and low cost. However, traditional polystyrene foam boards have poor fire resistance, typically rated as Class B (flame-retardant). In high-temperature or fire environments, it is easily ignited and drips, producing large amounts of toxic and harmful fumes, seriously threatening human life and property safety. This limits its application in high-rise buildings, densely populated areas, and other buildings with high fire protection requirements. Therefore, how to improve the fire resistance of polystyrene foam boards to A2 (non-combustible) while retaining its excellent insulation performance has become a pressing technical challenge in the field of building insulation materials.

[0004] Currently, there are two main methods for fire-retardant modification of polystyrene foam boards in existing technologies: one is to coat the surface of the polystyrene foam board with a fire-retardant coating to form a fire-retardant protective layer; the other is to add flame retardants during the preparation of the polystyrene foam board to achieve flame-retardant modification. However, both methods have certain limitations: the surface coating method results in a weak bond between the fire-retardant layer and the polystyrene foam board, making it prone to peeling and cracking. After long-term use, the fire-retardant performance will significantly decrease, and it cannot achieve penetration of the fire-retardant material into the foam board, resulting in limited fire-retardant effect and difficulty in meeting the A2 fire rating requirements. The method of adding flame retardants during preparation requires a large amount of flame retardant, which leads to a decrease in the thermal insulation performance of the polystyrene foam board, increased costs, and the flame retardant is prone to migration, resulting in unstable flame-retardant effect after long-term use. Furthermore, it is difficult to balance mechanical properties and processing performance.

[0005] Furthermore, most existing integrated insulation and decorative panels are composites made by simply bonding the insulation layer and the decorative layer together. This results in problems such as low bonding strength, short service life, and susceptibility to delamination and detachment, affecting the safety and durability of buildings. Ceramic panels, as a material with excellent decorative properties, good weather resistance, and strong fire resistance, are often used as the decorative layer of integrated insulation and decorative panels. However, achieving a firm bond between the ceramic panel and the modified polystyrene foam insulation layer while ensuring the overall performance of the integrated panel remains a technical challenge in existing technologies.

[0006] To address the shortcomings of existing technologies, this invention proposes a novel integrated thermal insulation and decorative panel and its preparation method. A modified slurry with a specific ratio is used to permeate and modify a Class B polystyrene foam board, allowing the slurry to fully fill the internal pores of the foam board. After curing, a stable fireproof and thermal insulation structure is formed, upgrading its fire resistance to A2 level while retaining its excellent thermal insulation performance. By slotting and filling the polystyrene foam insulation layer with colloid, a firm bonding and fixation with the ceramic decorative layer is achieved, solving the problems of weak adhesion and easy detachment between the insulation and decorative layers. The preparation process is simple, cost-controllable, and the product exhibits excellent comprehensive performance, meeting the dual requirements of building energy conservation and fire safety, and possessing good application prospects and industrial value. Summary of the Invention

[0007] The purpose of this invention is to overcome the technical defects of existing polystyrene foam boards, such as low fire resistance, weak bonding of integrated insulation and decoration panels, and poor overall performance, and to provide an integrated insulation and decoration panel and its preparation method. This invention uses a modified slurry with a specific ratio to penetrate and modify Class B polystyrene foam boards, upgrading their fire resistance to Class A2 while retaining their excellent thermal insulation performance. A strong bond between the polystyrene foam insulation layer and the ceramic decorative layer is achieved through a grooved filling colloid. The preparation process is simple and cost-controllable. The product exhibits excellent mechanical properties, fire resistance, thermal insulation performance, and decorative performance, meeting national building energy conservation and fire safety standards. It is suitable for various building exterior wall insulation and decoration projects and also belongs to the field of new materials.

[0008] The first aspect of this invention is to provide an integrated thermal insulation and decorative panel and its preparation method, comprising a polystyrene foam insulation layer and a ceramic decorative layer. The polystyrene foam insulation layer is made from a fire-resistant polystyrene foam board (Class B) through a modified slurry infiltration and curing process. The modified slurry comprises the following components in parts by weight: 15-35 parts cement, 8-22 parts gypsum, 10-25 parts white cement, 3-10 parts starch, 1-5 parts white sugar, 0.8-4 parts glucose, and 0.5-3 parts emulsifier. The polystyrene foam insulation layer contains 0.3-2.5 parts plasticizer, 5-18 parts filler, 0.2-1.5 parts foaming agent, 1-6 parts diluent, 2-8 parts adhesive, 20-45 parts water, and 3-12 parts flame retardant material. Several evenly distributed grooves are provided on the side of the polystyrene foam insulation layer near the ceramic decorative layer. These grooves are filled with colloid. The ceramic decorative layer and the polystyrene foam insulation layer are fixed together by pressing the colloid together. The fire resistance rating of the polystyrene foam insulation layer reaches A2 level.

[0009] Preferably, the cement is ordinary Portland cement with a strength grade of 32.5 or 42.5; the gypsum is high-strength gypsum powder with a fineness of 80-170 mesh; and the white cement is white Portland cement with a strength grade of 32.5 or 42.5 and a fineness of 80-170 mesh.

[0010] Preferably, the emulsifier is selected from one or more of fatty alcohol polyoxyethylene ether, emulsifier OP-10, and sodium dodecylbenzene sulfonate; the plasticizer is selected from one or more of dibutyl phthalate, dioctyl phthalate, and polyethylene glycol; and the filler is selected from one or more of talc, mica powder, hydrated lime powder, and silica, with a fineness of 100-200 mesh.

[0011] Preferably, the foaming agent is selected from one or more of sodium bicarbonate, azodicarbonamide, and sodium dodecyl sulfate; the diluent is selected from one or more of ethanol, propylene glycol, and ethyl acetate; and the adhesive is selected from one or more of polyvinyl alcohol, polyvinyl acetate, and epoxy resin.

[0012] Preferably, the flame-retardant material is selected from one or more of melamine, pentaerythritol, hexamethylenetetramine, and fire-retardant short fibers; the colloid is an epoxy adhesive or a polyurethane adhesive.

[0013] A second aspect of the present invention is to provide a method for preparing the integrated thermal insulation and decorative panel described in the first aspect, comprising the following steps:

[0014] S1, preparing modified slurry, including: weighing cement, gypsum, white cement, starch, white sugar, glucose, emulsifier, plasticizer, filler, foaming agent, diluent, binder, water and flame retardant materials according to weight parts, adding them to the mixing equipment in sequence, controlling the mixing temperature at 25-45℃, the mixing speed at 300-600r / min, and the mixing time at 15-40min, to obtain a uniform, lump-free, and fluid modified slurry;

[0015] S2, Modifying polystyrene foam board to obtain the polystyrene foam insulation layer, including: selecting polystyrene foam board with a fire rating of B, immersing it in the modified slurry, using a high-pressure penetration method, controlling the penetration pressure at 0.3-0.8 MPa, and the penetration time at 30-90 min, so that the modified slurry fully penetrates into the internal pores of the polystyrene foam board; after penetration, removing the polystyrene foam board, removing excess slurry from the surface, and then subjecting it to air drying or baking treatment, with an air drying time of 24-72 h, a baking temperature of 50-80 ℃, and a baking time of 6-12 h, to obtain the polystyrene foam insulation layer after curing, whose fire rating is improved to A2 level;

[0016] S3, Grooving and Glue Filling, including: on the side of the polystyrene foam insulation layer near the ceramic decorative layer, using a grooving device, several grooves are made, with a depth of 5-15mm, a width of 8-20mm, and a spacing of 50-150mm between adjacent grooves; then, glue is uniformly filled into the grooves, with a filling amount of 90-100% of the groove volume;

[0017] S4, perform pressing and fixing, including: selecting a ceramic plate as the ceramic decorative layer, aligning the grooved surfaces of the ceramic decorative layer and the polystyrene foam insulation layer, placing it in a pressing device, controlling the pressing pressure to be 0.5-1.2MPa, the pressing temperature to be 25-60℃, and the pressing time to be 30-90min, and then curing it after pressing, with a curing temperature of 20-30℃ and a curing time of 24-48h, to obtain an integrated insulation and decoration panel.

[0018] Preferably, in step S1, the mixing process is divided into three stages: in the first stage, cement, gypsum, white cement, filler, and starch are mixed and stirred for 5-10 minutes at a speed of 300-400 r / min; in the second stage, white sugar, glucose, emulsifier, and plasticizer are added, and stirring is continued for 5-10 minutes at a speed of 400-500 r / min; in the third stage, foaming agent, diluent, binder, flame retardant, and water are added, and stirring is continued for 5-20 minutes at a speed of 500-600 r / min until a uniform modified slurry is obtained.

[0019] Preferably, in step S2, the polystyrene foam board has a density of 18-25 kg / m³ and a thickness of 20-60 mm. Before the infiltration treatment, the surface of the polystyrene foam board is cleaned to remove dust, oil and impurities, and a small amount of water is sprayed on the surface for pre-wetting for 5-15 minutes.

[0020] Preferably, in step S3, the groove is a rectangular groove, a trapezoidal groove, or an arc groove, and the total volume of the groove accounts for 8-15% of the area of ​​the bonding surface between the polystyrene foam insulation layer and the ceramic decorative layer; after the colloid is filled, a scraper tool is used to smooth the surface of the colloid to ensure that the colloid is flush with the surface of the polystyrene foam insulation layer.

[0021] Preferably, in step S4, the ceramic plate has a thickness of 6-12 mm, a density ≥1.2 g / cm³, and its surface is treated with anti-slip and anti-fouling agents. During the pressing process, a segmented pressing method is adopted, first pressing with a pressure of 0.5-0.8 MPa for 15-30 min, and then pressing with a pressure of 0.8-1.2 MPa for 15-60 min. During the curing process, the ambient humidity is maintained at 40-60%, and direct sunlight and rain are avoided.

[0022] The beneficial effects of the method and system of the present invention are as follows:

[0023] 1. Excellent fire resistance, reaching A2 standard: This invention uses a modified slurry with a specific ratio to perform high-pressure permeation modification on Class B polystyrene foam boards. The modified slurry fully fills the internal pores of the foam board, forming a dense fireproof and heat-insulating structure after curing. The inorganic skeleton formed by cement, gypsum, and white cement can block the spread of flames. The flame-retardant materials decompose at high temperatures to produce non-combustible gases and a char layer, further improving the fire resistance. This enables the modified polystyrene foam insulation layer to reach the A2 fire resistance level (according to GB 8624-2025), with a fire growth rate index (FIGRA) ≤120W / s, total heat release (THR) ≤7.5MJ, no dripping, and no toxic fumes. It effectively solves the technical problem of low fire resistance of traditional polystyrene foam boards and meets the needs of high-rise buildings, densely populated places, and other buildings with high fire resistance requirements.

[0024] 2. Outstanding thermal insulation performance and significant energy-saving effect: The modified slurry of this invention contains a foaming agent, which can form micro-bubbles in the modified layer. Combined with the porous structure of the polystyrene foam board itself, the thermal conductivity of the polystyrene foam insulation layer is ≤0.045W / (m·K), resulting in excellent thermal insulation performance. This effectively reduces building energy consumption and complies with national building energy conservation policies. Simultaneously, the synergistic effect of the components of the modified slurry enhances fire resistance without significantly reducing the thermal insulation performance of the foam board, thus fulfilling the dual requirements of fire resistance and thermal insulation.

[0025] 3. Strong adhesion and excellent durability: This invention involves creating grooves in the polystyrene foam insulation layer and filling them with a high-viscosity colloid. Bonding to the ceramic decorative layer is achieved through compression. The groove design increases the contact area between the colloid and the foam insulation layer, and high-pressure compression ensures the colloid fully fills the grooves and cures, resulting in high bonding strength. This effectively prevents delamination and detachment between the insulation and decorative layers, improving the durability and service life of the integrated panel. The ceramic decorative layer is treated for anti-slip and anti-fouling properties, has good weather resistance, and is easy to clean, further enhancing the practicality of the integrated panel.

[0026] 4. Excellent mechanical properties and wide range of applications: In the modified slurry of this invention, the components such as cement, gypsum, white cement, and fillers work synergistically to improve the mechanical properties of the polystyrene foam insulation layer. Its compressive strength is ≥0.35MPa, which can withstand a certain amount of external force and is not easily deformed or damaged. The ceramic decorative layer has high hardness and wear resistance, making the overall mechanical properties of the integrated panel excellent. It is suitable for exterior wall insulation and decoration projects of various buildings, including high-rise buildings, multi-story buildings, and industrial buildings.

[0027] 5. Simple preparation process and controllable cost: The preparation process of this invention does not require complex equipment and cumbersome steps. The preparation of modified slurry, the permeation modification of foam board, grooving and filling, and pressing and fixing are all easy to achieve and suitable for large-scale industrial production. All components of the modified slurry are common building materials with wide availability and low cost. There is no need to use expensive special equipment and materials, which can effectively control production costs and enhance the market competitiveness of the product.

[0028] 6. Promising Industrialization Prospects: This invention belongs to the field of new building materials and involves the energy-saving, environmental protection, and fire safety industries that are key areas of national support. It can effectively solve the technical defects of traditional thermal insulation and decoration materials, improve the safety and energy efficiency of building materials, and has the conditions for rapid transformation and industrialization, thereby promoting the upgrading and development of the building thermal insulation and decoration industry. Attached Figure Description

[0029] To more clearly illustrate the technical solutions in the specific embodiments or related technologies of the present invention, the drawings used in the description of the specific embodiments or related technologies will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0030] Figure 1 This is a flowchart illustrating the preparation method of the integrated thermal insulation and decorative panel according to an embodiment of the present invention. Detailed Implementation

[0031] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0033] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0034] The first aspect of this invention is to provide an integrated thermal insulation and decorative panel, comprising a polystyrene foam insulation layer and a ceramic decorative layer. The polystyrene foam insulation layer is made of polystyrene foam board with a fire rating of Class B, which is permeated and cured with a modified slurry. The modified slurry is composed of the following components in parts by weight: 15-35 parts cement, 8-22 parts gypsum, 10-25 parts white cement, 3-10 parts starch, 1-5 parts white sugar, 0.8-4 parts glucose, 0.5-3 parts emulsifier, 0.3-2.5 parts plasticizer, 5-18 parts filler, 0.2-1.5 parts foaming agent, 1-6 parts diluent, 2-8 parts adhesive, 20-45 parts water, and 3-12 parts flame retardant material.

[0035] The polystyrene foam insulation layer has several evenly distributed grooves on the side near the ceramic decorative layer. The grooves are filled with colloid. The ceramic decorative layer and the polystyrene foam insulation layer are pressed and fixed together by the colloid. The polystyrene foam insulation layer has a fire rating of A2, a thermal conductivity of ≤0.045W / (m·K), and a compressive strength of ≥0.35MPa.

[0036] Furthermore, the cement is ordinary Portland cement with a strength grade of 32.5 or 42.5. Its function is to provide strength and stability to the modified slurry, and to work synergistically with gypsum and white cement to form a dense fire-resistant structure, filling the internal pores of the polystyrene foam board and improving its fire resistance and mechanical properties. Ordinary Portland cement has advantages such as wide availability, low cost, and rapid strength development. Strength grades of 32.5 and 42.5 can meet the strength requirements of the modified slurry while avoiding embrittlement of the foam board due to excessive strength.

[0037] Furthermore, the gypsum is high-strength gypsum powder with a fineness of 80-170 mesh. Gypsum has advantages such as rapid setting and hardening, volume stability, and good fire resistance. It can work synergistically with cement and white cement to improve the setting speed and fire resistance of the modified slurry, while also improving the workability of the modified slurry, facilitating its penetration into the internal pores of the polystyrene foam board. Controlling the fineness of the high-strength gypsum powder to 80-170 mesh ensures that the gypsum particles are fully dispersed in the modified slurry, preventing clumping, and ensuring that the slurry can smoothly penetrate into the fine pores of the foam board.

[0038] Furthermore, the white cement is a white silicate cement with a strength grade of 32.5 or 42.5 and a fineness of 80-170 mesh. The white cement has extremely low levels of coloring impurities such as iron oxide, exhibiting high whiteness. This not only improves the appearance quality of the modified slurry but also works synergistically with cement and gypsum to enhance the strength and fire resistance of the modified slurry, while simultaneously strengthening the bond between the modified slurry and polystyrene foam board. The fineness of the white cement is consistent with that of the gypsum, ensuring uniform mixing of all components and preventing component segregation.

[0039] Furthermore, the starch is selected from one or more of corn starch, potato starch, and tapioca starch. Starch has good binding and thickening properties, which can improve the fluidity and binding performance of the modified slurry, enhance the bonding force between the modified slurry and the polystyrene foam board, and at the same time, starch will carbonize at high temperature to form a carbon layer, which can play a certain role in fire prevention and heat insulation, and help improve the fire resistance of the foam board. The amount of starch added should be controlled between 3 and 10 parts. If the amount added is too small, it will not have an effective thickening and binding effect; if the amount added is too large, it will lead to excessive viscosity of the modified slurry, affecting the penetration effect, and may also reduce the thermal insulation performance of the modified foam board.

[0040] Furthermore, the sugar and glucose serve as auxiliary binders and penetration enhancers in the modified slurry. Sugar and glucose possess excellent water solubility and binding properties, and can synergistically work with starch to further improve the bonding performance of the modified slurry. Simultaneously, they can reduce the surface tension of the modified slurry, promoting its penetration into the internal pores of the polystyrene foam board and ensuring uniform penetration. The amount of sugar added is 1-5 parts, and the amount of glucose added is 0.8-4 parts, with the ratio controlled between 1:0.8 and 1:5 to achieve the best penetration and binding effect. Insufficient addition will result in insignificant penetration and binding effects; excessive addition will lead to excessively high sugar content in the modified slurry, making it prone to microbial growth, affecting product durability, and potentially increasing costs.

[0041] Furthermore, the emulsifier is selected from one or more of fatty alcohol polyoxyethylene ether (AEO series), emulsifier OP-10, and sodium dodecylbenzene sulfonate (LAS). The main function of the emulsifier is to reduce the interfacial tension of the components in the modified slurry, so that the oil-soluble and water-soluble components can be fully mixed to form a uniform and stable emulsion, avoiding stratification and clumping. It also improves the fluidity and permeability of the modified slurry, promoting its penetration into the internal pores of the polystyrene foam board. The amount of emulsifier added is 0.5-3 parts. Too little emulsification will result in poor emulsification and insufficient mixing of the components; too much will reduce the viscosity of the modified slurry, affecting the strength after curing, and may also increase costs.

[0042] Furthermore, the plasticizer is selected from one or more of dibutyl phthalate, dioctyl phthalate, and polyethylene glycol. The plasticizer can improve the flexibility and plasticity of the modified slurry, reduce the brittleness of the cured modified layer, and prevent cracking. It also improves the fluidity of the modified slurry, facilitating application and penetration. The amount of plasticizer added is 0.3-2.5 parts. Insufficient addition will not significantly improve flexibility and will easily lead to cracking after curing; excessive addition will reduce the strength of the modified layer and affect the mechanical properties of the product.

[0043] Furthermore, the filler is selected from one or more of talc powder, mica powder, lime powder, and silica, with a fineness of 100-200 mesh. The main function of the filler is to fill the internal voids of the modified slurry, increase its density and strength, and enhance the fire resistance and weather resistance of the modified layer while reducing costs. Controlling the filler fineness to 100-200 mesh ensures that the filler particles are fully dispersed in the modified slurry, working synergistically with other components to form a dense structure. The addition amount is 5-18 parts; too little will result in an insignificant filling effect, failing to effectively improve strength and fire resistance; too much will lead to excessive viscosity of the modified slurry, affecting penetration and potentially reducing thermal insulation performance.

[0044] Furthermore, the foaming agent is selected from one or more of sodium bicarbonate, azodicarbonamide, and sodium dodecyl sulfate. The foaming agent can generate microbubbles in the modified slurry, forming a porous structure in the modified layer. This retains the thermal insulation properties of the polystyrene foam board while improving the air permeability and toughness of the modified layer. Simultaneously, the microbubbles can block flame propagation, further enhancing fire resistance. The amount of foaming agent added is 0.2-1.5 parts. Insufficient addition results in an insufficient number of bubbles, failing to achieve the desired thermal insulation and fire-retardant effects; excessive addition leads to overly large bubbles, causing a decrease in the strength of the modified layer and resulting in excessively large pores.

[0045] Furthermore, the diluent is selected from one or more of ethanol, propylene glycol, and ethyl acetate. The main function of the diluent is to reduce the viscosity of the modified slurry, improve its fluidity and permeability, promote its rapid penetration into the internal pores of the polystyrene foam board, and regulate the drying speed of the modified slurry to prevent cracking during curing. The amount of diluent added is 1-6 parts. If the amount added is too small, the dilution effect will be insignificant, the slurry viscosity will be too high, and the penetration will be affected. If the amount added is too large, the concentration of the modified slurry will be too low, the strength after curing will decrease, and it may also affect the bonding force of the components.

[0046] Furthermore, the adhesive is selected from one or more of polyvinyl alcohol, polyvinyl acetate, and epoxy resin. The adhesive enhances the bonding force between the components of the modified slurry and improves the adhesion between the modified slurry and the polystyrene foam board, ensuring a firm bond between the modified layer and the foam board, preventing it from easily detaching or delaminating. The amount of adhesive added is 2-8 parts. Insufficient addition results in poor bonding and easy detachment of the modified layer; excessive addition leads to excessive viscosity of the modified slurry, affecting penetration and increasing costs.

[0047] Furthermore, the flame-retardant material is selected from one or more of melamine, pentaerythritol, hexamethylenetetramine, and fire-retardant short fibers. This flame-retardant material decomposes at high temperatures to produce non-combustible gases, diluting the concentration of combustible gases and forming a char layer to block flame propagation and heat transfer, significantly improving the fire resistance of polystyrene foam boards and ensuring that the modified foam board achieves an A2 fire rating. The amount of flame-retardant material added is 3-12 parts. Insufficient addition will result in an insignificant fire-retardant effect, failing to meet the A2 fire rating requirements; excessive addition will lead to excessive viscosity of the modified slurry, affecting penetration and potentially reducing thermal insulation and mechanical properties.

[0048] Furthermore, the colloid is an epoxy adhesive or a polyurethane adhesive, with a viscosity of 1500-3500 mPa·s (25℃). Epoxy and polyurethane adhesives have advantages such as high bonding strength, good weather resistance, high temperature resistance, and aging resistance, enabling a firm bond between the polystyrene foam insulation layer and the ceramic decorative layer, ensuring that the integrated panel does not delaminate or detach during long-term use. Controlling the viscosity of the colloid within 1500-3500 mPa·s ensures good flowability for easy filling into the grooves while preventing loss during pressing, thus guaranteeing a good bonding effect.

[0049] Furthermore, the polystyrene foam insulation layer has a thickness of 20-60mm, a density of 18-25kg / m³, a thermal conductivity of ≤0.045W / (m·K), a compressive strength of ≥0.35MPa, a fire rating of A2 (according to GB 8624-2025 "Classification of Combustion Performance of Building Materials and Products"), a fire growth rate index (FIGRA) of ≤120W / s, a total heat release (THR) of ≤7.5MJ, no molten dripping, no toxic fumes, and meets the smoke toxicity standards.

[0050] Furthermore, the ceramic decorative layer has a thickness of 6-12mm and a density ≥1.2g / cm³. The surface is treated for slip resistance and stain resistance. The ceramic slab possesses excellent decorative properties, good weather resistance, strong fire resistance, and easy cleaning, providing a good decorative effect for the integrated panel while further enhancing its fire resistance and durability. The surface of the ceramic slab can be designed with different colors and textures to suit various architectural styles.

[0051] Furthermore, the groove is a rectangular groove, a trapezoidal groove, or an arc-shaped groove, with a depth of 5-15mm, a width of 8-20mm, and a spacing of 50-150mm between adjacent grooves. The total volume of the groove accounts for 8-15% of the bonding area between the polystyrene foam insulation layer and the ceramic decorative layer. The groove design increases the contact area between the colloid and the polystyrene foam insulation layer, improves the bonding strength, and prevents the colloid from being lost during the pressing process, ensuring a firm bond between the ceramic decorative layer and the polystyrene foam insulation layer.

[0052] like Figure 1 As shown, the present invention also discloses a method for preparing an integrated thermal insulation and decorative panel, comprising the following steps:

[0053] S1, preparing modified slurry, including: weighing cement, gypsum, white cement, starch, white sugar, glucose, emulsifier, plasticizer, filler, foaming agent, diluent, binder, water and flame retardant materials according to weight parts, adding them to the mixing equipment in sequence, controlling the mixing temperature at 25-45℃, the mixing speed at 300-600r / min, and the mixing time at 15-40min, to obtain a uniform, lump-free, and fluid modified slurry;

[0054] S2, Modification treatment of polystyrene foam board, including: selecting polystyrene foam board with fire rating of B, immersing it in modified slurry, using high-pressure permeation, controlling the permeation pressure at 0.3-0.8 MPa, and the permeation time at 30-90 min, so that the modified slurry fully penetrates into the internal pores of the polystyrene foam board; after permeation, remove the polystyrene foam board, remove excess slurry from the surface, and then perform air drying or baking treatment, with an air drying time of 24-72 h, a baking temperature of 50-80 ℃, and a baking time of 6-12 h, to obtain a polystyrene foam insulation layer after curing, whose fire rating is improved to A2 level;

[0055] S3, Grooving and Glue Filling, including: on the side of the polystyrene foam insulation layer near the ceramic decorative layer, using a grooving device, several grooves are cut, with a depth of 5-15mm, a width of 8-20mm, and a spacing of 50-150mm between adjacent grooves; then, the glue is evenly filled into the grooves, with a filling amount of 90-100% of the groove volume;

[0056] S4, perform pressing and fixing, including: selecting a ceramic plate as the ceramic decorative layer, aligning the grooved surfaces of the ceramic decorative layer and the polystyrene foam insulation layer, placing them in a pressing device, controlling the pressing pressure to be 0.5-1.2MPa, the pressing temperature to be 25-60℃, and the pressing time to be 30-90min, and then curing after pressing, with a curing temperature of 20-30℃ and a curing time of 24-48h, to obtain an integrated insulation and decoration panel.

[0057] Furthermore, in step S1, the stirring process is divided into three stages: In the first stage, cement, gypsum, white cement, filler, and starch are mixed and stirred for 5-10 minutes at a speed of 300-400 r / min to ensure thorough and uniform mixing of the solid powder components and prevent clumping. In the second stage, sugar, glucose, emulsifier, and plasticizer are added, and stirring continues for 5-10 minutes at a speed of 400-500 r / min to ensure thorough mixing of water-soluble and oil-soluble components, forming a preliminary emulsion. In the third stage, foaming agent, diluent, binder, flame retardant, and water are added, and stirring continues for 5-20 minutes at a speed of 500-600 r / min until a uniform, clumping-free, and highly fluid modified slurry is obtained. This segmented stirring method ensures thorough mixing of all components, preventing component separation and clumping, and improving the stability and uniformity of the modified slurry.

[0058] Furthermore, in step S1, the stirring equipment is a high-speed dispersing mixer. During the stirring process, the stirring speed and time can be adjusted appropriately according to the fluidity of the slurry to ensure that the slurry is uniform and free of lumps, and that its fluidity meets the penetration requirements. The stirring temperature is controlled between 25-45℃. If the temperature is too low, the dissolution and mixing rate of each component is slow, affecting the stirring efficiency; if the temperature is too high, the foaming agent will decompose prematurely, affecting the foaming effect, and may also cause starch gelatinization, affecting the fluidity of the slurry.

[0059] Further, in step S2, the polystyrene foam board has a density of 18-25 kg / m³ and a thickness of 20-60 mm. Before the penetration treatment, the surface of the polystyrene foam board is cleaned to remove dust, oil, and impurities, and a small amount of water is sprayed on the surface for pre-wetting for 5-15 minutes. Pre-wetting reduces the surface tension of the polystyrene foam board, promotes the penetration of the modified slurry, and ensures that the slurry can quickly and evenly penetrate into the internal pores of the foam board.

[0060] Furthermore, in step S2, the high-pressure permeation method employs either high-pressure immersion permeation or high-pressure spray permeation. High-pressure immersion permeation involves completely immersing the polystyrene foam board in the modified slurry while applying a pressure of 0.3-0.8 MPa, allowing the slurry to penetrate into the internal pores of the foam board under pressure. High-pressure spray permeation involves spraying the modified slurry onto the surface of the polystyrene foam board using a high-pressure spray gun while simultaneously applying pressure, allowing the slurry to penetrate into the interior of the foam board. The permeation pressure is controlled between 0.3-0.8 MPa. If the pressure is too low, the slurry penetration speed is slow and insufficient, failing to fill the internal pores of the foam board; if the pressure is too high, it will cause deformation and damage to the polystyrene foam board, affecting the product's appearance and performance. The permeation time is controlled between 30-90 minutes, adjusted appropriately according to the thickness and density of the foam board to ensure that the slurry fully penetrates into every pore of the foam board.

[0061] Furthermore, in step S2, the air-drying process should be carried out in a well-ventilated, dry environment free from direct sunlight to prevent the surface slurry from drying too quickly and the internal slurry from fully curing, which could lead to cracking. The drying process should be carried out in stages: first, drying at 50-60℃ for 3-6 hours, and then drying at 70-80℃ for 3-6 hours to ensure uniform curing of the slurry and avoid problems such as cracking and deformation. After curing, the polystyrene foam insulation layer has its internal pores fully filled by the modified slurry, forming a dense fireproof and heat-insulating structure with a fire resistance rating of A2.

[0062] Furthermore, in step S3, the grooving equipment uses a CNC grooving machine, which can precisely control the depth, width, and spacing of the grooves, ensuring uniform distribution and improving the uniformity of the colloid filling and the bonding effect. The shape of the groove can be selected as rectangular, trapezoidal, or arc-shaped grooves according to requirements. Trapezoidal and arc-shaped grooves can further increase the contact area between the colloid and the foam insulation layer, improving the bonding strength. After the colloid is filled, a scraper tool is used to smooth the colloid surface, ensuring that the colloid is flush with the surface of the polystyrene foam insulation layer, avoiding gaps during the pressing process that would affect the bonding effect.

[0063] Furthermore, in step S4, the surface of the ceramic plate undergoes anti-slip and anti-fouling treatment. This treatment involves coating the ceramic plate surface with an anti-fouling coating, which uses fluorocarbon paint or silane-modified paint. This enhances the anti-fouling and anti-slip properties of the ceramic plate, facilitating cleaning and maintenance. The pressing equipment uses a hydraulic press, which can apply pressure evenly to ensure a tight bond between the ceramic decorative layer and the polystyrene foam insulation layer.

[0064] Furthermore, in step S4, the pressing process employs a segmented pressurization method. First, a pressure of 0.5-0.8 MPa is applied for 15-30 minutes to allow the colloid to initially diffuse and make tight contact with the two layers of material. Then, a pressure of 0.8-1.2 MPa is applied for 15-60 minutes to ensure the colloid fully fills the grooves and cures, thereby improving the bonding strength. The pressing temperature is controlled between 25-60℃. If the temperature is too low, the colloid cures slowly, resulting in a long pressing time and low efficiency; if the temperature is too high, the colloid may cure prematurely, failing to fully fill the grooves and affecting the bonding effect.

[0065] Furthermore, in step S4, the curing process should be carried out in a constant temperature and humidity environment. The curing temperature is 20-30℃, and the ambient humidity is 40-60%. Direct sunlight and rain should be avoided to ensure that the colloid is fully cured, thereby improving the bonding strength and the overall performance of the integrated panel. The curing time is 24-48 hours. After curing, the various properties of the integrated panel meet the design requirements and can be packaged, transported, and installed.

[0066] It should be noted that the raw materials used in the following examples are all commercially available conventional products: ordinary silicate cement (grade 32.5, grade 42.5), high-strength gypsum powder (80-170 mesh), white silicate cement (grade 32.5, grade 42.5, 80-170 mesh), corn starch, potato starch, tapioca starch, white sugar, glucose, fatty alcohol polyoxyethylene ether (AEO-9), emulsifier OP-10, sodium dodecylbenzene sulfonate (LAS), dibutyl phthalate, dioctyl phthalate, polyethylene glycol, talc powder (100-200 mesh), and mica powder (100-200 mesh). Calcium carbonate powder (100-200 mesh), silica (100-200 mesh), sodium bicarbonate, azodicarbonamide, sodium dodecyl sulfate, ethanol, propylene glycol, ethyl acetate, polyvinyl alcohol, polyvinyl acetate, epoxy resin, melamine, pentaerythritol, hexamethylenetetramine, fire-retardant short fibers, epoxy adhesive (viscosity 2000 mPa·s, 25℃), polyurethane adhesive (viscosity 3000 mPa·s, 25℃), grade B polystyrene foam board (density 20 kg / m³, thickness 40 mm), ceramic board (thickness 8 mm, density 1.3 g / cm³, surface treated with anti-fouling agent).

[0067] In the following embodiments, the detection methods for each performance indicator are as follows:

[0068] 1. Fire resistance rating: Tested according to GB 8624-2025 "Classification of Combustion Performance of Building Materials and Products", using a combination of single-item combustion test (SBI) and non-combustibility test. The sample size is 150mm×150mm×50mm, with a quantity of 3 pieces. The temperature is controlled at 800℃ for 30 minutes. The fire resistance rating is determined by testing indicators such as the fire growth rate index (FIGRA), total heat release (THR), smoke density, and dripping material.

[0069] 2. Thermal conductivity: Tested according to GB / T 10294-2008 "Determination of steady-state thermal resistance and related properties of thermal insulation materials - protective hot plate method", with a test temperature of 25℃.

[0070] 3. Compressive strength: Tested according to GB / T 8813-2018 "Determination of compressive properties of rigid foamed plastics", with sample size of 100mm×100mm×50mm and loading speed of 5mm / min.

[0071] 4. Bond strength: The bonding strength between the ceramic decorative layer and the polystyrene foam insulation layer was tested according to GB / T 14074-2017 "Test Methods for Adhesives and Resins for Wood Industry". The sample size was 100mm×100mm and the loading speed was 2mm / min.

[0072] 5. Weather resistance: Tested according to GB / T 25181-2019 "Integrated Insulation and Decoration Board for Buildings". After 25 freeze-thaw cycles (-20℃, 2h; 20℃, 2h), observe whether the sample shows powdering, peeling, cracking or other phenomena, and test the performance retention rate.

[0073] 6. Water absorption rate: Tested according to GB / T 8810-2017 "Determination of water absorption rate of rigid foamed plastics", soaking time 24h.

[0074] 7. Dimensional stability: Tested according to GB / T 8811-2019 "Test method for dimensional stability of rigid foamed plastics", with a test temperature of 70℃ and a test time of 24h, and the dimensional change rate is calculated.

[0075] Example 1

[0076] This embodiment provides an integrated thermal insulation and decorative panel, the components and their weight parts of which are as follows:

[0077] Modified slurry components: 25 parts cement (ordinary silicate cement, grade 42.5), 15 parts gypsum (high-strength gypsum powder, 120 mesh), 18 parts white cement (white silicate cement, grade 42.5, 120 mesh), 6 parts corn starch, 3 parts white sugar, 2 parts glucose, 1.5 parts emulsifier (fatty alcohol polyoxyethylene ether AEO-9), 1.2 parts plasticizer (dibutyl phthalate), 12 parts filler (talc powder, 150 mesh), 0.8 parts foaming agent (sodium bicarbonate), 3 parts diluent (ethanol), 5 parts binder (polyvinyl alcohol), 32 parts water, and 8 parts flame retardant (4 parts melamine + 4 parts pentaerythritol).

[0078] Colloid: Epoxy adhesive, viscosity 2000 mPa·s (25℃).

[0079] Polystyrene foam insulation layer: made of Class B polystyrene foam board (density 20kg / m³, thickness 40mm) through the above-mentioned modified slurry penetration and curing, with a thickness of 40mm and a fire rating of A2.

[0080] Ceramic decorative layer: 8mm thick, 1.3g / cm³ density, with a fluorocarbon anti-fouling coating on the surface.

[0081] Groove: Rectangular groove, 10mm deep, 15mm wide, with a spacing of 100mm between adjacent grooves, and the total volume of the groove accounts for 12% of the mating surface area.

[0082] The preparation method of the integrated thermal insulation and decorative panel in this embodiment includes the following steps:

[0083] (1) Preparation of modified slurry: Weigh each component according to the above weight parts and add them to the high-speed dispersing mixer in sequence. Use segmented stirring method: In the first stage, mix cement, gypsum, white cement, talc powder and corn starch for 8 min at a speed of 350 r / min; In the second stage, add white sugar, glucose, fatty alcohol polyoxyethylene ether AEO-9 and dibutyl phthalate, and continue stirring for 8 min at a speed of 450 r / min; In the third stage, add sodium bicarbonate, ethanol, polyvinyl alcohol, melamine, pentaerythritol and water, stir for 12 min at a speed of 550 r / min, and control the stirring temperature at 35℃ to obtain a uniform, lump-free modified slurry with good fluidity.

[0084] (2) Modification treatment of polystyrene foam board: Select grade B polystyrene foam board, clean the surface dust, oil and impurities, and spray a small amount of water on the surface for 10 minutes to pre-wet it; put the pre-wetted foam board into the modified slurry, use high pressure immersion and penetration method, control the penetration pressure to 0.5MPa, and the penetration time to 60 minutes, so that the modified slurry can fully penetrate into the internal pores of the foam board; after penetration, take out the foam board, use a scraper to remove the excess slurry on the surface, and dry it in a ventilated, dry environment without direct sunlight for 48 hours, and then put it in a drying oven for segmented drying: first dry at 55℃ for 4 hours, and then dry at 75℃ for 4 hours. After curing, a polystyrene foam insulation layer is obtained.

[0085] (3) Grooving and colloid filling: A rectangular groove is opened on the side of the polystyrene foam insulation layer near the ceramic decorative layer using a CNC grooving machine. The groove is 10mm deep, 15mm wide, and 100mm apart. Epoxy adhesive is evenly filled into the groove, with a filling amount of 95% of the groove volume. The surface of the adhesive is smoothed with a scraper tool to ensure that it is flush with the surface of the foam insulation layer.

[0086] (4) Pressing and fixing: Select ceramic plate as ceramic decorative layer, align the grooves of ceramic decorative layer and polystyrene foam insulation layer, put them into hydraulic press, and use segmented pressing method: first press with 0.6MPa pressure for 20min, then press with 1.0MPa pressure for 40min, and control the pressing temperature at 40℃; after pressing, put the integrated plate into constant temperature and humidity curing room, control the curing temperature at 25℃ and the ambient humidity at 50%, and cure for 36h to obtain the integrated insulation and decoration plate.

[0087] The performance of the integrated thermal insulation and decorative panel prepared in this embodiment was tested, and the test results are as follows:

[0088] Fire rating: A2, burning growth rate index (FIGRA) 85W / s, total heat release (THR) 6.2MJ, no dripping, no toxic fumes, and smoke toxicity meets standards;

[0089] Thermal conductivity: 0.040 W / (m·K);

[0090] Compressive strength: 0.42 MPa;

[0091] Bond strength: 1.8 MPa;

[0092] Weather resistance: After 25 freeze-thaw cycles, there was no powdering, peeling, or cracking, and the performance retention rate was 98%.

[0093] Water absorption rate: 1.8%;

[0094] Dimensional stability: Dimensional change rate 0.3%.

[0095] Example 2

[0096] This embodiment provides an integrated thermal insulation and decorative panel, the components and their weight parts of which are as follows:

[0097] Modified slurry components: 18 parts cement (ordinary silicate cement, grade 32.5), 10 parts gypsum (high-strength gypsum powder, 80 mesh), 12 parts white cement (white silicate cement, grade 32.5, 80 mesh), 4 parts potato starch, 2 parts white sugar, 1.2 parts glucose, 0.8 parts emulsifier (emulsifier OP-10 + sodium dodecylbenzenesulfonate LAS, weight ratio 1:1), 0.6 parts plasticizer (polyethylene glycol), 8 parts filler (mica powder + lime powder, weight ratio 1:1, 100 mesh), 0.4 parts foaming agent (azodicarbonamide), 2 parts diluent (propylene glycol), 3 parts binder (polyvinyl acetate), 25 parts water, and 5 parts flame retardant (3 parts hexamethylenetetramine + 2 parts fire-retardant short fibers).

[0098] Colloid: Polyurethane adhesive, viscosity 3000 mPa·s (25℃).

[0099] Polystyrene foam insulation layer: made of Class B polystyrene foam board (density 18kg / m³, thickness 30mm) through the above-mentioned modified slurry penetration and curing, with a thickness of 30mm and a fire rating of A2.

[0100] Ceramic decorative layer: 6mm thick, 1.2g / cm³ density, with a silane-modified anti-fouling coating on the surface.

[0101] Groove: Trapezoidal groove, 8mm deep, 12mm wide, 80mm spacing between adjacent grooves, and the total volume of the groove accounts for 10% of the mating surface area.

[0102] The preparation method of the integrated thermal insulation and decorative panel in this embodiment includes the following steps:

[0103] (1) Preparation of modified slurry: Weigh each component according to the above weight parts and add them to the high-speed dispersing mixer in sequence. Use segmented stirring method: In the first stage, mix and stir cement, gypsum, white cement, mica powder, lime powder and potato starch for 6 min at a speed of 300 r / min; In the second stage, add white sugar, glucose, emulsifier OP-10, sodium dodecylbenzene sulfonate LAS and polyethylene glycol, and continue stirring for 6 min at a speed of 400 r / min; In the third stage, add azodicarbonamide, propylene glycol, polyvinyl acetate, hexamethylenetetramine, fireproof short fiber and water, stir for 10 min at a speed of 500 r / min, and control the stirring temperature at 28℃ to obtain a uniform, lump-free modified slurry with good fluidity.

[0104] (2) Modification treatment of polystyrene foam board: Select grade B polystyrene foam board, clean the surface dust, oil and impurities, and spray a small amount of water on the surface for 8 minutes to pre-wet it; put the pre-wetted foam board into the modified slurry, use high pressure spraying penetration method, control the penetration pressure to 0.4MPa, and the penetration time to 45 minutes, so that the modified slurry can fully penetrate into the internal pores of the foam board; after penetration, take out the foam board, remove the excess slurry on the surface with a scraper, and dry it in a ventilated, dry environment without direct sunlight for 36 hours, and then put it in a drying oven for segmented drying: first dry at 50℃ for 3 hours, then dry at 70℃ for 3 hours, and after curing, a polystyrene foam insulation layer is obtained.

[0105] (3) Grooving and colloid filling: Using a CNC grooving machine, a trapezoidal groove is opened on the side of the polystyrene foam insulation layer close to the ceramic decorative layer. The groove is 8mm deep, 12mm wide, and 80mm apart. The polyurethane adhesive is evenly filled into the groove, and the filling amount is 92% of the groove volume. The adhesive surface is smoothed with a scraper tool to ensure that it is flush with the surface of the foam insulation layer.

[0106] (4) Pressing and fixing: Select a ceramic plate as the ceramic decorative layer, align the grooves of the ceramic decorative layer and the polystyrene foam insulation layer, and place them in a hydraulic press. Use a segmented pressing method: first press with a pressure of 0.5MPa for 15 minutes, then press with a pressure of 0.8MPa for 30 minutes, and control the pressing temperature at 30℃. After pressing, place the integrated plate in a constant temperature and humidity curing room, control the curing temperature at 22℃ and the ambient humidity at 45%, and cure for 24 hours to obtain the integrated insulation and decoration plate.

[0107] The performance of the integrated thermal insulation and decorative panel prepared in this embodiment was tested, and the test results are as follows:

[0108] Fire rating: A2, burning growth rate index (FIGRA) 98W / s, total heat release (THR) 6.8MJ, no dripping, no toxic fumes, and smoke toxicity meets standards;

[0109] Thermal conductivity: 0.042 W / (m·K);

[0110] Compressive strength: 0.38 MPa;

[0111] Bond strength: 1.6 MPa;

[0112] Weather resistance: After 25 freeze-thaw cycles, there was no powdering, peeling, or cracking, and the performance retention rate was 96%.

[0113] Water absorption rate: 2.2%;

[0114] Dimensional stability: Dimensional change rate 0.4%.

[0115] To further verify the technical advantages of the key technical features of this invention (flame-retardant materials, high-pressure infiltration, groove structure, and modified slurry ratio), four comparative examples were set up for comprehensive comparison with Examples 1 and 2. The components, preparation methods, and performance test results of each comparative example are as follows:

[0116] Comparative Example 1 (without added flame retardant materials)

[0117] The difference between this comparative example and Example 1 is that no flame retardant materials (melamine and pentaerythritol) were added to the modified slurry, while the remaining components, weight parts and preparation methods are the same as in Example 1.

[0118] Performance test results:

[0119] Fire rating: B1, fire growth rate index (FIGRA) 280W / s, total heat release (THR) 18.5MJ, with a small amount of molten droplets, producing toxic fumes;

[0120] Thermal conductivity: 0.039 W / (m·K);

[0121] Compressive strength: 0.36 MPa;

[0122] Bond strength: 1.7 MPa;

[0123] Weather resistance: After 25 freeze-thaw cycles, there was no powdering, peeling, or cracking, and the performance retention rate was 95%.

[0124] Water absorption rate: 1.9%;

[0125] Dimensional stability: Dimensional change rate 0.3%.

[0126] Results analysis: Without the addition of flame retardant materials, the modified slurry cannot meet the A2 fire rating requirements due to the skeleton formed by inorganic components such as cement and gypsum alone. It releases a large amount of heat and produces toxic fumes during combustion, proving that flame retardant materials are the core components for achieving improved fire rating.

[0127] Comparative Example 2 (no high-pressure infiltration, only surface coating)

[0128] The difference between this comparative example and Example 1 is that the polystyrene foam board was not modified by high-pressure permeation, but only by coating the surface with a modified slurry (coating thickness 2 mm). The other components, weight parts and preparation methods are the same as in Example 1.

[0129] Performance test results:

[0130] Fire rating: B2, burning growth rate index (FIGRA) 350W / s, total heat release (THR) 22.3MJ, obvious dripping, and excessive toxic fumes.

[0131] Thermal conductivity: 0.041 W / (m·K);

[0132] Compressive strength: 0.28 MPa;

[0133] Bond strength: 1.6 MPa;

[0134] Weather resistance: After 25 freeze-thaw cycles, the surface coating cracked and peeled off, with a performance retention rate of 82%.

[0135] Water absorption rate: 3.5%;

[0136] Dimensional stability: Dimensional change rate 0.6%.

[0137] Results analysis: Surface coating alone cannot allow the modified slurry to penetrate into the internal pores of the foam board. The fireproof layer is not firmly bonded to the foam board, resulting in poor fireproofing and weather resistance. This proves that high-pressure infiltration is the key process to ensure uniform filling of the modified slurry and achieve synergistic improvement in fireproofing and mechanical properties.

[0138] Comparative Example 3 (no grooves were created; the material was directly bonded).

[0139] The difference between this comparative example and Example 1 is that the polystyrene foam insulation layer does not have grooves, and the adhesive is directly applied to the flat surface and bonded to the ceramic decorative layer. The remaining components, weight parts and preparation methods are the same as in Example 1.

[0140] Performance test results:

[0141] Fire rating: A2, fire growth rate index (FIGRA) 88W / s, total heat release (THR) 6.5MJ, no dripping, no toxic fumes, and smoke toxicity meets standards;

[0142] Thermal conductivity: 0.040 W / (m·K);

[0143] Compressive strength: 0.41 MPa;

[0144] Bond strength: 0.8 MPa;

[0145] Weather resistance: After 25 freeze-thaw cycles, the ceramic decorative layer showed local delamination, with a performance retention rate of 85%.

[0146] Water absorption rate: 2.0%;

[0147] Dimensional stability: Dimensional change rate 0.3%.

[0148] Results analysis: Without grooves, the contact area between the colloid and the foam insulation layer is limited, resulting in a significant decrease in bonding strength and insufficient long-term weather resistance. This proves that the groove structure can effectively improve the interfacial bonding force and ensure the long-term stability of the integrated panel.

[0149] Comparative Example 4 (modified slurry formulation exceeds the scope of this invention)

[0150] The difference between this comparative example and Example 1 is that the modified slurry composition ratio exceeds the limits of this invention. Specifically, it consists of 40 parts cement, 25 parts gypsum, 30 parts white cement, 12 parts starch, and 15 parts flame retardant (the remaining components and weight parts are the same as in Example 1), and the preparation method is the same as in Example 1.

[0151] Performance test results:

[0152] Fire rating: A2, burning growth rate index (FIGRA) 82W / s, total heat release (THR) 6.0MJ, no dripping, no toxic fumes, and smoke toxicity meets standards;

[0153] Thermal conductivity: 0.052 W / (m·K);

[0154] Compressive strength: 0.55 MPa;

[0155] Bond strength: 1.5 MPa;

[0156] Weather resistance: After 25 freeze-thaw cycles, there was no powdering, peeling, or cracking, and the performance retention rate was 97%.

[0157] Water absorption rate: 1.7%;

[0158] Dimensional stability: Dimensional change rate 0.5%.

[0159] Results analysis: Although the fire resistance still meets the standard after exceeding the ratio range of the present invention, the thermal conductivity increases significantly (exceeding the requirement of ≤0.045W / (m・K)) and the thermal insulation performance deteriorates, proving that the component ratio limited by the present invention is the key to achieving synergistic optimization of fire resistance and thermal insulation performance.

[0160] The comparative indicators are shown in Table 1, which compares the performance indicators of the examples and the comparative examples.

[0161] Table 1

[0162] Testing items Example 1 Example 2 Comparative Example 1 Comparative Example 2 Comparative Example 3 Comparative Example 4 Fire rating A2 level A2 level B1 level B2 level A2 level A2 level Combustion Growth Rate Index (FIGRA) / W / s 85 98 280 350 88 82 Total heat release (THR) / MJ 6.2 6.8 18.5 22.3 6.5 6.0 Molten droplets / toxic fumes None / Meets the standard None / Meets the standard Small amount / Yes Obvious / Exceeding Standards None / Meets standards None / Meets standards Thermal conductivity / W(m·K) 0.040 0.042 0.039 0.041 0.040 0.052 Compressive strength / MPa 0.42 0.38 0.36 0.28 0.41 0.55 Bond strength / MPa 1.8 1.6 1.7 1.6 0.8 1.5 Weather resistance (25 freeze-thaw cycles) No abnormalities found, retention rate 98%. No abnormalities found, retention rate 96%. No abnormalities, retention rate 95% The coating cracked and peeled off, with a retention rate of 82%. Local stratification, retention rate 85%. No abnormalities found, retention rate 97%. Water absorption rate (24h) / % 1.8 2.2 1.9 3.5 2.0 1.7 Dimensional change rate (70℃, 24h) / % 0.3 0.4 0.3 0.6 0.3 0.5

[0163] A comparison of the core fire resistance performance indicators of the embodiments and comparative examples reveals that, for the fire growth rate index (FIGRA): Embodiment 1 (85W / s), Embodiment 2 (98W / s), and Comparative Example 4 (82W / s) are significantly lower than Comparative Example 1 (280W / s) and Comparative Example 2 (350W / s), proving that the technical solution of the present invention can effectively suppress the spread of combustion; for the total heat release (THR): Embodiments and Comparative Examples 3 and 4 are all ≤7.5MJ (A2 level standard), while Comparative Examples 1 and 2 far exceed the standard, proving that flame-retardant materials + high-pressure infiltration are necessary conditions to meet the fire resistance rating.

[0164] The comparison of bonding strength and weather resistance between the examples and comparative examples reveals that, for bonding strength, Example 1 (1.8 MPa) and Example 2 (1.6 MPa) are significantly higher than that of Comparative Example 3 (0.8 MPa), proving that the groove structure can improve the interfacial bonding force; for weather resistance (performance retention rate), Example 1 (98%), Example 2 (96%), and Comparative Example 4 (97%) are higher than those of Comparative Example 2 (82%) and Comparative Example 3 (85%), proving that high-pressure infiltration + groove structure can improve the long-term stability of the integrated board.

[0165] The aforementioned comparative examples, controlled by a single variable, verified the necessity of the four core technical features of this invention: "flame-retardant material addition," "high-pressure infiltration process," "groove structure design," and "modified slurry mixing ratio range." Experimental results show that only when these four technical features work synergistically can the integrated thermal insulation and decorative panel achieve its comprehensive performance advantages: "fire resistance rating A2 + thermal conductivity ≤0.045W / (m・K) + compressive strength ≥0.35MPa + bond strength ≥1.5MPa," thus solving the technical problems of the contradiction between fire resistance and thermal insulation, and weak interface bonding in existing technologies.

[0166] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A thermal insulation and decorative integrated panel and its preparation method, characterized in that, The product comprises a polystyrene foam insulation layer and a ceramic decorative layer. The polystyrene foam insulation layer is made of polystyrene foam board with a fire rating of Class B, which is infiltrated and cured with a modified slurry. The modified slurry consists of the following components by weight: 15-35 parts cement, 8-22 parts gypsum, 10-25 parts white cement, 3-10 parts starch, 1-5 parts white sugar, 0.8-4 parts glucose, 0.5-3 parts emulsifier, 0.3-2.5 parts plasticizer, 5-18 parts filler, 0.2-1.5 parts foaming agent, 1-6 parts diluent, 2-8 parts adhesive, 20-45 parts water, and 3-12 parts flame retardant. The polystyrene foam insulation layer has several evenly distributed grooves on the side near the ceramic decorative layer, and the grooves are filled with colloid. The ceramic decorative layer and the polystyrene foam insulation layer are fixed together by pressing the colloid. The fire rating of the polystyrene foam insulation layer reaches Class A2.

2. The integrated thermal insulation and decorative panel according to claim 1, characterized in that, The cement is ordinary Portland cement with a strength grade of 32.5 or 42.5; the gypsum is high-strength gypsum powder with a fineness of 80-170 mesh; the white cement is white Portland cement with a strength grade of 32.5 or 42.5 and a fineness of 80-170 mesh.

3. The integrated thermal insulation and decorative panel according to claim 2, characterized in that, The emulsifier is selected from one or more of fatty alcohol polyoxyethylene ether, emulsifier OP-10, and sodium dodecylbenzene sulfonate; the plasticizer is selected from one or more of dibutyl phthalate, dioctyl phthalate, and polyethylene glycol; the filler is selected from one or more of talc, mica powder, hydrated lime powder, and silica, with a fineness of 100-200 mesh.

4. The integrated thermal insulation and decorative panel according to claim 3, characterized in that, The foaming agent is selected from one or more of sodium bicarbonate, azodicarbonamide, and sodium dodecyl sulfate; the diluent is selected from one or more of ethanol, propylene glycol, and ethyl acetate; and the adhesive is selected from one or more of polyvinyl alcohol, polyvinyl acetate, and epoxy resin.

5. The integrated thermal insulation and decorative panel according to claim 4, characterized in that, The flame-retardant material is selected from one or more of melamine, pentaerythritol, hexamethylenetetramine, and fire-retardant short fibers; the colloid is an epoxy adhesive or a polyurethane adhesive.

6. A method for preparing an integrated thermal insulation and decorative panel according to any one of claims 1-5, characterized in that, Includes the following steps: S1, preparing modified slurry, including: weighing cement, gypsum, white cement, starch, white sugar, glucose, emulsifier, plasticizer, filler, foaming agent, diluent, binder, water and flame retardant materials according to weight parts, adding them to the mixing equipment in sequence, controlling the mixing temperature at 25-45℃, the mixing speed at 300-600r / min, and the mixing time at 15-40min, to obtain a uniform, lump-free, and fluid modified slurry; S2, Modifying polystyrene foam board to obtain the polystyrene foam insulation layer, including: selecting polystyrene foam board with a fire rating of B, immersing it in the modified slurry, using a high-pressure penetration method, controlling the penetration pressure at 0.3-0.8 MPa, and the penetration time at 30-90 min, so that the modified slurry fully penetrates into the internal pores of the polystyrene foam board; after penetration, removing the polystyrene foam board, removing excess slurry from the surface, and then subjecting it to air drying or baking treatment, with an air drying time of 24-72 h, a baking temperature of 50-80 ℃, and a baking time of 6-12 h, to obtain the polystyrene foam insulation layer after curing, whose fire rating is improved to A2 level; S3, Grooving and Glue Filling, including: on the side of the polystyrene foam insulation layer near the ceramic decorative layer, using a grooving device, several grooves are made, with a depth of 5-15mm, a width of 8-20mm, and a spacing of 50-150mm between adjacent grooves; then, glue is uniformly filled into the grooves, with a filling amount of 90-100% of the groove volume; S4, perform pressing and fixing, including: selecting a ceramic plate as the ceramic decorative layer, aligning the grooved surfaces of the ceramic decorative layer and the polystyrene foam insulation layer, placing it in a pressing device, controlling the pressing pressure to be 0.5-1.2MPa, the pressing temperature to be 25-60℃, and the pressing time to be 30-90min, and then curing it after pressing, with a curing temperature of 20-30℃ and a curing time of 24-48h, to obtain an integrated insulation and decoration panel.

7. The preparation method according to claim 6, characterized in that, In step S1, the mixing process is divided into three stages: In the first stage, cement, gypsum, white cement, filler, and starch are mixed and stirred for 5-10 minutes at a speed of 300-400 r / min; In the second stage, white sugar, glucose, emulsifier, and plasticizer are added, and stirring is continued for 5-10 minutes at a speed of 400-500 r / min; In the third stage, foaming agent, diluent, binder, flame retardant, and water are added, and stirring is continued for 5-20 minutes at a speed of 500-600 r / min until a uniform modified slurry is obtained.

8. The preparation method according to claim 7, characterized in that, In step S2, the polystyrene foam board has a density of 18-25 kg / m³ and a thickness of 20-60 mm. Before the infiltration treatment, the surface of the polystyrene foam board is cleaned to remove dust, oil and impurities, and a small amount of water is sprayed on the surface for pre-wetting for 5-15 minutes.

9. The preparation method according to claim 8, characterized in that, In step S3, the groove is a rectangular groove, a trapezoidal groove, or an arc groove, and the total volume of the groove accounts for 8-15% of the area of ​​the bonding surface between the polystyrene foam insulation layer and the ceramic decorative layer. After the colloid is filled, a scraper tool is used to smooth the surface of the colloid to ensure that the colloid is flush with the surface of the polystyrene foam insulation layer.

10. The preparation method according to claim 6, characterized in that, In step S4, the ceramic plate has a thickness of 6-12mm, a density of ≥1.2g / cm³, and its surface is treated with anti-slip and anti-fouling agents. During the pressing process, a segmented pressing method is adopted, first pressing with a pressure of 0.5-0.8MPa for 15-30min, and then pressing with a pressure of 0.8-1.2MPa for 15-60min. During maintenance, keep the ambient humidity at 40-60% and avoid direct sunlight and rain.

Images