Polyphenyl granule aerogel composite insulation board with multi-layer structure

Abstract

The utility model provides a polyphenyl granule aerogel composite multi-layer structure insulation board which comprises outer protection assemblies and an insulation board body, the upper side and the lower side of each outer protection assembly are respectively provided with the outer protection assemblies used for heat insulation and crack prevention, and the insulation board body comprises a first insulation layer, a second insulation layer and a third insulation layer. An outer protection assembly is arranged on the upper side of the insulation board body, a second insulation layer is arranged on the lower side of the insulation board body, a first insulation layer is integrally formed on the upper side of the second insulation layer, and a third insulation layer is integrally formed on the lower side of the second insulation layer. According to the heat insulation board, the surfaces of the two sides of the heat insulation board body can have the waterproof and anti-cracking performance, the ornamental value and flatness of the surfaces of the heat insulation board body are improved, the service life of the heat insulation board body is prolonged, the heat insulation layer can have the heat reflection effect, and the heat insulation effect of the heat insulation board body can be enhanced.

Description

Technical Field

[0001] This utility model belongs to the field of insulation board technology, and specifically relates to a multi-layered insulation board with polystyrene particle aerogel composite structure. Background Technology

[0002] Previously, reflective thermal insulation coatings were mainly used in combination with inorganic thermal insulation mortar to form "inorganic thermal insulation mortar-reflective thermal insulation coating external wall insulation systems," and also in combination with thermal insulation putty to form "thermal insulation putty-reflective thermal insulation coating external wall insulation systems." However, inorganic thermal insulation mortar has been listed as a prohibited product in Anhui Province in recent years, and the "thermal insulation putty-reflective thermal insulation coating external wall insulation system" often fails to meet building energy efficiency calculation requirements in actual engineering applications. Therefore, when using reflective thermal insulation coatings, the key technology becomes matching them with a flexible and reliable insulation layer. Thus, we hope to design an insulation board with a novel structure to solve this problem. Utility Model Content

[0003] In view of the shortcomings of the existing technology, the purpose of this utility model is to provide a polystyrene particle aerogel composite multilayer structure insulation board to solve the problems mentioned in the background technology.

[0004] This utility model is achieved through the following technical solution: a multi-layered polystyrene particle aerogel composite insulation board, comprising: an outer protective component and an insulation board body, wherein the upper and lower sides of the outer protective component are respectively provided with outer protective components for heat insulation and crack prevention.

[0005] The insulation board body includes insulation layer one, insulation layer two and insulation layer three. Insulation layer one is integrally formed on the upper side of insulation layer two and insulation layer three is integrally formed on the lower side of insulation layer two.

[0006] The external protective component includes a crack-resistant layer one, a crack-resistant layer two, and a crack-resistant layer three. Crack-resistant layer two is embedded and fixed on the upper side of crack-resistant layer one, and crack-resistant layer three is coated on the upper side of crack-resistant layer two.

[0007] In a preferred embodiment, the insulation layer one, insulation layer two, and insulation layer three are integrally cast. The structural composition of insulation layer one is the same as that of insulation layer three. In actual use, insulation layer one, insulation layer two, and insulation layer three are all cast from a mixture of adhesive, insulation aggregate, and additives. The adhesive includes PO52.5 grade cement, silica fume, fly ash hollow microspheres, fly ash hollow microsphere activator, and redispersible polymer powder (latex powder), with mass ratios ranging from 45.0 to 60. The thermal insulation aggregates include recycled polystyrene foam particles and expanded vitrified microspheres, with mass ratios of 50.0–85.0 and 1.0–2.5, respectively. The additives include wood fiber, methyl cellulose ether, and aerogel, with mass ratios of 1.0–2.5, 1.5–15, and 0.3–1.2, respectively. (The above mass ratios are just one configuration method, and other proportions can be designed according to actual needs.)

[0008] In practical applications, polystyrene particles are organic materials, not fire-resistant, and will burn; the binding material is a polymer-modified cement-based material. Polymers begin to burn at around 200℃, while cement-based materials (cement stone formed by cement hydration) begin to decompose and disintegrate at around 600℃, gradually losing strength, but will not burn at 1000℃ or even higher temperatures. Therefore, to make the insulation board body reach A2 grade non-combustible, new technical measures are required. For this purpose, expanded vitrified microspheres are introduced. Expanded vitrified microspheres are inorganic non-combustible materials with porous interiors, vitrified and sealed surfaces, and stable physical and chemical properties. They can withstand high temperatures of at least 1200℃ and are lightweight and heat-insulating.

[0009] The use of hollow fly ash microspheres improves the amount of slurry in the binder, as well as the thermal insulation and flame retardant properties of the material. The hollow fly ash microspheres have a vitrified thin-walled shell with low bulk density (400-600 kg / m³), low thermal conductivity, and can withstand high temperatures of around 1500℃. Their fineness is less than 45 μm, falling within the fineness range of cement. When combined with cement stone, the low density and thermal insulation properties of the hollow fly ash microspheres increase the slurry volume and improve thermal insulation. Therefore, by utilizing the hollow fly ash microspheres and adjusting the ratio of polystyrene particles to expanded vitrified microspheres, a fire-resistant slurry is formed between the hollow fly ash microspheres and cement, creating a "fire-resistant mortar" with the expanded vitrified microspheres. Further bonding and coating the polystyrene particles on their surface allows the insulation board to achieve a fire resistance rating of Class A (A2).

[0010] Using fly ash hollow microspheres as an activator to increase the addition amount of fly ash hollow microspheres: When fly ash hollow microspheres are added to cement-based materials at high concentrations, the density of the binder can be significantly reduced, thereby improving the thermal insulation performance of the material. However, this also reduces the strength of the material. To solve this problem, we adopted the method of simultaneously adding an activator. The activator can fully activate the activity of fly ash hollow microspheres, significantly improving the strength of the material with added fly ash hollow microspheres. The effect is more significant when the addition amount of fly ash hollow microspheres is very high. Our self-made activator is composed of sulfate, calcium oxide, and water-reducing agent. Its activation mechanism lies in the direct activation by calcium hydroxide (the hydration product of calcium oxide in water) and the indirect activation by sulfate. The reason why calcium hydroxide activates the activity of fly ash hollow microspheres is that OH- bonds in the glassy body of fly ash hollow microspheres break down the Si-O bonds and Al-O bonds. Bond breakage enhances the activity of the vitreous body and promotes hydration reactions. Ca2+ participates in the material reaction, generating hydration products with gelling properties such as CSH and C3AH6, and promoting the transformation of water-based products into more stable and stronger hydration products. As for the activating effect of sulfate, it provides SO42− to the hydration reaction while activating with calcium hydroxide, and reacts with Ca2+, AlO2− and other ions or ion clusters in the liquid phase to form ettringite. Therefore, the reason why the activator increases the strength is that the calcium-enriching component (calcium oxide) in the activator increases the calcium content of the fly ash hollow microspheres. After these calcium oxides are converted into calcium hydroxide, they work together with sulfate to produce an activating effect, activating the activity of the fly ash hollow microspheres, accelerating the formation of CSH gel and ettringite crystals, and increasing the overall quantity of CSH gel and ettringite crystals. Macroscopically, this means that the strength of the material is improved.

[0011] Aerogel is used to improve the thermal insulation performance of materials. Aerogel is a lightweight nano-solid material. Its solid phase and its pore structure are both at the nanoscale. Aerogel has a very low density, which can be as low as 0.16 mg / cm³. Aerogel has an extremely low thermal conductivity (0.013~0.016) W / (m·K), which is lower than the thermal conductivity of static air [0.024 W / (m·K)]. Among the constituent materials of the insulation board body, polystyrene particles have excellent thermal insulation performance, while vitrified microspheres and fly ash hollow microspheres are less so. Composite materials prepared with these materials as thermal insulation aggregates can achieve a thermal conductivity of about 0.050 W / (m·K) while meeting the A2 non-combustible performance requirement. By introducing aerogel, the thermal conductivity can be further reduced to 0.045 W / (m·K) or lower.

[0012] Polymer latex powder is used to improve the strength of materials and reduce water absorption. Inorganic materials have good fire resistance, but they are brittle, lack flexibility, have low bonding strength, and high water absorption. Over time, latex powder can improve the adhesion, flexural strength, and plasticity of materials. Therefore, the addition of latex powder can compensate for these shortcomings in material performance. It can be seen that the formulation principle of the insulation board body (i.e., to have both thermal insulation and fire resistance) is as follows: polymer cement, as a binder, can provide good physical and mechanical properties; polystyrene particles can provide good thermal insulation performance; expanded vitrified microspheres can improve the fire resistance rating and relatively reduce the amount of polystyrene particles used; fly ash hollow microspheres are combined in the polymer cement paste, giving the material sufficient paste volume so that it can improve fire resistance without significantly increasing its density, ensuring the low thermal conductivity of the material; and the thermal conductivity of the composite insulation material is further reduced by using aerogel.

[0013] In a preferred embodiment, the external protective component further includes a heat insulation layer, which is applied to the outer wall surface of the crack-resistant layer three, and the heat insulation layer is a building reflective heat insulation coating.

[0014] In a preferred embodiment, a primer coating is further provided between the heat insulation layer and the crack-resistant layer three to prevent the heat insulation layer from falling off.

[0015] In a preferred embodiment, the first crack-resistant layer is a lightweight, flexible, crack-resistant, and waterproof base putty layer, and the third crack-resistant layer is a lightweight, flexible, crack-resistant, and waterproof top putty layer.

[0016] In a preferred embodiment, the second crack-resistant layer is an alkali-resistant mesh fabric, and the second crack-resistant layer is embedded between the first crack-resistant layer and the third crack-resistant layer.

[0017] After adopting the above technical solution, the beneficial effects of this utility model are as follows: by setting external protective components on the upper and lower sides of the insulation board body respectively, and the anti-crack layer one and anti-crack layer three working together, the two sides of the insulation board body can have waterproof and anti-crack performance, improve the appearance and flatness of the insulation board body surface, and also improve the service life of the insulation board body. The heat insulation layer can play the role of heat reflection, which can enhance the heat insulation effect of the insulation board body. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1This is a schematic diagram of the overall structure of a polystyrene particle aerogel composite multilayer insulation board according to the present invention.

[0020] Figure 2 This is a schematic diagram of the insulation board body structure of a polystyrene particle aerogel composite multilayer insulation board according to the present invention.

[0021] In the diagram, 100 - outer protective component, 110 - crack-resistant layer one, 120 - crack-resistant layer two, 130 - crack-resistant layer three, 140 - heat insulation layer;

[0022] 200 - Insulation board body, 210 - Insulation layer one, 220 - Insulation layer two, 230 - Insulation layer three. Detailed Implementation

[0023] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0024] Please see Figures 1 to 2 This utility model provides a technical solution: a multi-layered polystyrene particle aerogel composite insulation board, comprising: an outer protective component 100 and an insulation board body 200, wherein the upper and lower sides of the outer protective component 100 are respectively provided with outer protective components 100 for heat insulation and crack prevention.

[0025] The insulation board body 200 includes insulation layer 1 210, insulation layer 220 and insulation layer 3 230. Insulation layer 1 210 is integrally formed on the upper side of insulation layer 220 and insulation layer 3 230 is integrally formed on the lower side of insulation layer 220.

[0026] The outer protective component 100 includes a crack-resistant layer 110, a crack-resistant layer 2 120, and a crack-resistant layer 3 130. The crack-resistant layer 2 120 is embedded and fixed on the upper side of the crack-resistant layer 110, and the crack-resistant layer 3 130 is coated on the upper side of the crack-resistant layer 2 120.

[0027] Please see Figures 1 to 2Insulation layer 1 (210), insulation layer 2 (220), and insulation layer 3 (230) are integrally cast. The structural composition of insulation layer 1 (210) is the same as that of insulation layer 3 (230). In actual use, insulation layers 1 (210), 2 (220), and 3 (230) are all cast from a mixture of adhesive, insulation aggregate, and additives. The adhesive includes PO. The composition includes 52.5 grade cement, silica fume, fly ash hollow microspheres, fly ash hollow microsphere activator, and redispersible polymer powder (latex powder), with mass ratios of 45.0–60.0, 4.5–6.0, 13.5–24.0, 3.5–9.0, and 1.5–2.3, respectively. Insulating aggregates include recycled polystyrene foam particles and expanded vitrified microspheres, with mass ratios of 50.0–85.0 and 1.0–2.5, respectively. Additives include wood fiber, methyl cellulose ether, and aerogel, with mass ratios of 1.0–2.5, 1.5–15, and 0.3–1.2, respectively. (The above mass ratios are just one possible configuration; other proportions can be designed according to actual needs.)

[0028] In practical applications, polystyrene particles are organic materials, not fire-resistant, and will burn; the binding material is a polymer-modified cement-based material, which begins to burn at around 200℃, while the cement-based material (cement stone formed by cement hydration) begins to decompose and disintegrate at around 600℃, gradually losing its strength, but will not burn at 1000℃ or even higher temperatures. Therefore, to make the insulation board body reach A2 grade non-combustible, new technical measures are needed. For this purpose, expanded vitrified microspheres are introduced. Expanded vitrified microspheres are inorganic non-combustible materials with porous interiors, vitrified and sealed surfaces, and stable physical and chemical properties. They can withstand high temperatures of at least 1200℃ and are lightweight and heat-insulating.

[0029] The use of hollow fly ash microspheres improves the amount of slurry in the binder, as well as the thermal insulation and flame retardant properties of the material. The hollow fly ash microspheres have a glassy, ​​thin-walled shell with low bulk density (400-600 kg / m³), low thermal conductivity, and can withstand temperatures up to 1500℃. Their fineness is less than 45 μm, falling within the fineness range of cement. When combined with cement stone, the low density and thermal insulation properties of the hollow fly ash microspheres increase the slurry volume and improve thermal insulation. Therefore, by utilizing the hollow fly ash microspheres and adjusting the ratio of polystyrene particles to expanded vitrified microspheres, a fire-resistant slurry is formed between the hollow fly ash microspheres and cement, creating a "fire-resistant mortar" with the expanded vitrified microspheres. Further bonding and coating the polystyrene particles onto the surface allows the insulation board to achieve a fire rating of Class A (A2).

[0030] Using fly ash hollow microspheres as an activator to increase the addition amount of fly ash hollow microspheres: When fly ash hollow microspheres are added to cement-based materials at high concentrations, the density of the binder can be significantly reduced, thereby improving the thermal insulation performance of the material. However, this also reduces the strength of the material. To solve this problem, we adopted the method of simultaneously adding an activator. The activator can fully activate the activity of fly ash hollow microspheres, significantly improving the strength of the material with added fly ash hollow microspheres. The effect is more significant when the addition amount of fly ash hollow microspheres is very high. Our self-made activator is composed of sulfate, calcium oxide, and water-reducing agent. Its activation mechanism lies in the direct activation by calcium hydroxide (the hydration product of calcium oxide in water) and the indirect activation by sulfate. The reason why calcium hydroxide activates the activity of fly ash hollow microspheres is that OH- bonds in the glassy body of fly ash hollow microspheres break down the Si-O bonds and Al-O bonds. Bond breakage enhances the activity of the vitreous body and promotes hydration reactions. Ca2+ participates in the material reaction, generating hydration products with gelling properties such as CSH and C3AH6, and promoting the transformation of water-based products into more stable and stronger hydration products. As for the activating effect of sulfate, it provides SO42− to the hydration reaction while activating with calcium hydroxide, and reacts with Ca2+, AlO2− and other ions or ion clusters in the liquid phase to form ettringite. Therefore, the reason why the activator increases the strength is that the calcium-enriching component (calcium oxide) in the activator increases the calcium content of the fly ash hollow microspheres. After these calcium oxides are converted into calcium hydroxide, they work together with sulfate to produce an activating effect, activating the activity of the fly ash hollow microspheres, accelerating the formation of CSH gel and ettringite crystals, and increasing the overall quantity of CSH gel and ettringite crystals. Macroscopically, this means that the strength of the material is improved.

[0031] Aerogel is used to improve the thermal insulation performance of materials. Aerogel is a lightweight nano-solid material. Its solid phase and its pore structure are both at the nanoscale. Aerogel has a very low density, which can be as low as 0.16 mg / cm³. Aerogel has an extremely low thermal conductivity (0.013~0.016) W / (m·K), which is lower than the thermal conductivity of static air [0.024 W / (m·K)]. In the composition of the insulation board body 200, polystyrene particles have excellent thermal insulation performance, while vitrified microspheres and fly ash hollow microspheres are less so. Composite materials prepared with these materials as thermal insulation aggregates can achieve a thermal conductivity of about 0.050 W / (m·K) while meeting the A2 non-combustible performance requirement. By introducing aerogel, the thermal conductivity can be further reduced to 0.045 W / (m·K) or lower.

[0032] Polymer latex powder is used to improve the strength of materials and reduce water absorption. Inorganic materials have good fire resistance, but they are brittle, lack flexibility, have low bonding strength, and high water absorption. Over time, latex powder can improve the adhesion, flexural strength, and plasticity of materials. Therefore, the addition of latex powder can compensate for these shortcomings in material performance. It can be seen that the formulation principle of the insulation board body 200 (i.e., having both thermal insulation and fire resistance) is as follows: polymer cement, as a binder, can provide good physical and mechanical properties; polystyrene particles can provide good thermal insulation performance; expanded vitrified microspheres can improve the fire resistance rating and relatively reduce the amount of polystyrene particles used; fly ash hollow microspheres are combined in the polymer cement paste, giving the material sufficient paste volume, so that it can improve fire resistance without significantly increasing its density, ensuring the low thermal conductivity of the material; and the thermal conductivity of the composite insulation material is further reduced by using aerogel.

[0033] As the first embodiment of this utility model, by setting up an insulation board, in actual use, insulation layer 1 (210), insulation layer 2 (220), and insulation layer 3 (230) are all formed by mixing and casting adhesive, insulation aggregate, and additives (wherein the adhesive includes PO 52.5 grade cement, silica fume, fly ash hollow microspheres, fly ash hollow microsphere activator, and redispersible polymer powder (latex powder); insulation aggregate includes recycled polystyrene foam particles and expanded vitrified microspheres; and additives include wood fiber, methyl cellulose ether, and aerogel). Insulation layer 1 (210), insulation layer 2 (220), and insulation layer 3 (230) are only different in the proportion of each component, but have the same composition, and have good flame retardant and heat insulation performance (insulation layer 1 (210), insulation layer 2 (220), and insulation layer 3 (230) use aerogel to protect inorganic insulation aggregates (expanded vitrified microspheres) with different particle sizes). The composite material of expanded vitrified microspheres and fly ash hollow microspheres and organic thermal insulation aggregate (foamed polystyrene particles) is modified to further improve the thermal insulation performance of insulation layer 1 (210), insulation layer 2 (220), and insulation layer 3 (230) while maintaining a fire rating of Class A. The entire insulation board body (200) has good fire resistance, with a combustion performance rating of Class A2, which is superior to the fire resistance rating of materials with the same thermal conductivity. It also has good workability, is smooth to apply, does not stick to the board, has excellent thixotropy, and does not sag when applied (even with a single application thickness of 30mm, sag will not occur).

[0034] Please see Figure 1 The outer protective component 100 also includes a heat insulation layer 140, which is applied to the outer wall surface of the crack-resistant layer 130. The heat insulation layer 140 is a building reflective heat insulation coating.

[0035] A primer coating is also provided between the heat insulation layer 140 and the crack-resistant layer 130 to prevent the heat insulation layer 140 from falling off.

[0036] Crack-resistant layer 110 is a lightweight, flexible, crack-resistant, and waterproof base putty layer, and crack-resistant layer 3130 is a lightweight, flexible, crack-resistant, and waterproof top putty layer.

[0037] The second crack-resistant layer 120 is an alkali-resistant mesh fabric, which is embedded between the first crack-resistant layer 110 and the third crack-resistant layer 130.

[0038] As a second embodiment of this utility model, based on the first embodiment described above, by providing external protective components 100 on the upper and lower sides of the insulation board body 200 respectively, in actual use, the crack-resistant layer 110 and the crack-resistant layer 130 work together to enable the two sides of the insulation board body 200 to have waterproof and crack-resistant properties, improve the appearance and flatness of the surface of the insulation board body 200, and also improve the service life of the insulation board body 200. The heat insulation layer 140 can play a role in heat reflection, which can enhance the heat insulation effect of the insulation board body 200.

[0039] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A multi-layered insulation board made of polystyrene particle aerogel, comprising: The outer protective component (100) and the insulation board body (200) are characterized in that the upper and lower sides of the outer protective component (100) are respectively provided with outer protective components (100) for heat insulation and crack prevention. The insulation board body (200) includes insulation layer one (210), insulation layer two (220) and insulation layer three (230). Insulation layer one (210) is integrally formed on the upper side of insulation layer two (220), and insulation layer three (230) is integrally formed on the lower side of insulation layer two (220). The outer protective component (100) includes a crack-resistant layer one (110), a crack-resistant layer two (120), and a crack-resistant layer three (130). The crack-resistant layer two (120) is embedded and fixed on the upper side of the crack-resistant layer one (110), and the crack-resistant layer three (130) is coated on the upper side of the crack-resistant layer two (120).

2. The polystyrene particle aerogel composite multilayer insulation board as described in claim 1, characterized in that: The insulation layer one (210), insulation layer two (220) and insulation layer three (230) are integrally cast and formed, and the structural composition of insulation layer one (210) is the same as that of insulation layer three (230).

3. The polystyrene particle aerogel composite multilayer insulation board as described in claim 2, characterized in that: The outer protective component (100) also includes a heat insulation layer (140), which is applied to the outer wall surface of the upper side of the crack-resistant layer three (130). The heat insulation layer (140) is a building reflective heat insulation coating.

4. The polystyrene particle aerogel composite multilayer insulation board as described in claim 3, characterized in that: A primer coating is also provided between the heat insulation layer (140) and the crack-resistant layer (130) to prevent the heat insulation layer (140) from falling off.

5. The polystyrene particle aerogel composite multilayer insulation board as described in claim 4, characterized in that: The crack-resistant layer one (110) is a lightweight, flexible, crack-resistant, and waterproof base putty layer, and the crack-resistant layer three (130) is a lightweight, flexible, crack-resistant, and waterproof top putty layer.

6. The polystyrene particle aerogel composite multilayer insulation board as described in claim 5, characterized in that: The second anti-crack layer (120) is an alkali-resistant mesh fabric, and the second anti-crack layer (120) is embedded between the first anti-crack layer (110) and the third anti-crack layer (130).

Images