3D network fusion insulation board

Abstract

This invention provides a three-dimensional network fused insulation board. The three-dimensional network fused insulation board includes a three-dimensional network structure skeleton and insulation core material embedded within the pores of the three-dimensional network structure skeleton; the three-dimensional network structure skeleton and the insulation core material are fused together through an integrated molding process to form the three-dimensional network fused insulation board. The three-dimensional network structure skeleton can be a finished three-dimensional network structure skeleton such as silicon carbide, alumina, or zirconium oxide. This invention introduces a finished three-dimensional network structure skeleton such as silicon carbide, alumina, or zirconium oxide, combined with low thermal conductivity materials (such as polyurethane foam insulation material, polystyrene resin foam insulation material, aerogel insulation material, etc.), and fills the gaps of the three-dimensional network structure skeleton with the low thermal conductivity material through processes such as foaming, curing, and chemical replacement, forming a novel insulation board structure coupled integrally with the three-dimensional network structure skeleton, significantly improving the mechanical properties and connection stability of the insulation board.

Description

Technical Field

[0001] This utility model relates to the field of building exterior wall insulation technology, specifically a three-dimensional network fusion insulation board. Background Technology

[0002] In the field of building energy conservation, external wall insulation technology, as a core means of reducing energy consumption, has evolved from single materials to composite structures. Traditional insulation systems mainly use organic materials (such as EPS polystyrene boards, XPS extruded polystyrene boards, and polyurethane) or inorganic materials (such as rock wool and glass wool). Their typical structure is a thin-plaster system, where the insulation board is directly adhered to the wall using adhesive mortar, covered with alkali-resistant fiberglass mesh and finishing mortar to form a protective layer. While this type of system has a certain insulation effect, it has significant technical defects, such as easy detachment and susceptibility to fire. With the phasing out of thin-plaster insulation systems, various composite insulation wall panel systems have emerged on the market. These systems are typically composed of external wall panels 1, intermediate insulation layers 2, and internal wall panels 3, connected by tie rods 4 (see basic structural diagram). Figure 1 ), Figure 1 The image also shows the anti-seepage sealing strip 5 and the special adhesive 6. Although this composite thermal insulation wall panel system solves the problems of easy detachment, easy fire, poor durability, and low construction efficiency in thin plaster insulation systems, it still has problems in practical applications, such as easy delamination failure in fire leading to hollow cracks, stress concentration defects, complex production processes, and excessive structural thickness. Utility Model Content

[0003] The purpose of this utility model is to provide a three-dimensional network fusion insulation board to solve the problems existing in traditional and existing composite insulation wall panel technologies, and to achieve a comprehensive breakthrough in fire safety, structural durability, production efficiency and space utilization of building exterior wall insulation systems.

[0004] This utility model is implemented as follows: A three-dimensional network fusion insulation board includes a three-dimensional network structure skeleton and an insulation core material embedded in the pores of the three-dimensional network structure skeleton; the three-dimensional network structure skeleton and the insulation core material therein are fused into a three-dimensional network fusion insulation board through an integrated molding process.

[0005] This invention achieves lightweight, high strength, high toughness, excellent impact resistance, fatigue resistance, and high-efficiency thermal insulation performance through the synergistic effect of a three-dimensional network structure skeleton (rigid) and thermal insulation core material (elastic).

[0006] Preferably, the three-dimensional network structure framework is a silicon carbide three-dimensional network structure framework, an alumina three-dimensional network structure framework, or a zirconia three-dimensional network structure framework.

[0007] Preferably, the porosity of the three-dimensional network structure skeleton is 80%-90%.

[0008] Preferably, the thermal insulation core material is polyurethane, polystyrene resin, or aerogel material.

[0009] Preferably, the thickness of the three-dimensional network fusion insulation board is 20mm~300mm.

[0010] Preferably, the thermal conductivity of the three-dimensional network fusion insulation board is 0.02-0.05 W / (m·K).

[0011] Preferably, the compressive strength of the three-dimensional network fusion insulation board is ≥0.40 MPa and the elongation at break is ≥8%.

[0012] Preferably, the three-dimensional network fusion insulation board can be used directly as an enclosure wall without the need for an additional plastering layer or protective layer.

[0013] Preferably, a waterproof coating is applied to the surface of the three-dimensional network fusion insulation board, and an external wall protective layer is provided outside the waterproof coating.

[0014] Preferably, a waterproof sealing strip is provided on the edge of the three-dimensional network fusion insulation board for waterproof sealing at the joints of adjacent boards; adjacent three-dimensional network fusion insulation boards are bonded together with a special adhesive.

[0015] This utility model has the following beneficial effects: 1) The three-dimensional network fusion insulation board adopts a three-dimensional network structure skeleton and insulation core material integrated into one, to build a new type of fusion structure with no interface defects that combines fire resistance (fire resistance A-level / B1 level) and high-efficiency insulation. It breaks through the technical bottleneck of connecting the wall maintenance structure and insulation core material through tie-fitting components, thereby solving the problem of easy delamination failure and hollow cracking of traditional insulation boards in fire.

[0016] 2) Since the three-dimensional network fusion insulation board is an integrated board, it can transform local stress concentration into uniform overall load-bearing capacity. There is no stress concentration abrupt change at the geometric change point, which can reduce the cracking rate of composite board from the industry average to 0, significantly improving structural durability.

[0017] 3) The three-dimensional network fusion insulation board has a simple structure, consisting only of a three-dimensional network structure skeleton and insulation core material. It does not require tie parts, wire mesh or other building materials, which can effectively reduce the complexity of the production process, achieve low carbonization throughout the entire life cycle, reduce production energy consumption by 40% compared with traditional processes, and has recyclable characteristics.

[0018] 4) The three-dimensional network fusion insulation board can control the wall panel thickness within the range of 20mm~300mm. Its main structural properties only need to meet the structural design requirements such as the thickness, compressive strength, and tensile strength of the building envelope, while meeting the energy-saving design requirements. It optimizes the wall thickness of the building envelope, increasing the indoor usable area by 8%-12% under the same building area, and significantly improving space economy.

[0019] This utility model solves four major pain points of traditional insulation systems in terms of fire safety, structural durability, production efficiency, and space utilization through the technological innovation of three-dimensional network-integrated insulation panels. It promotes the development of building exterior wall insulation technology towards a safer, more efficient, and more environmentally friendly direction, and provides key technical support for the popularization of passive buildings and zero-energy buildings. Attached Figure Description

[0020] Figure 1 This is a structural schematic diagram of an existing composite thermal insulation wall panel system.

[0021] Figure 2 This is a three-dimensional structural diagram of the three-dimensional network fusion insulation board provided by this utility model.

[0022] Figure 3 This is a cross-sectional view of the three-dimensional network fusion insulation board provided by this utility model.

[0023] In the diagram: 1. Exterior wall panel; 2. Intermediate insulation layer; 3. Interior wall panel; 4. Tie-in component; 5. Waterproof sealing strip; 6. Special adhesive; 7. Three-dimensional network structure skeleton; 8. Insulation core material; 9. Waterproof coating; 10. Exterior wall protective layer. Detailed Implementation

[0024] The technical solution of this utility model will now be described in conjunction with the accompanying drawings.

[0025] like Figure 2 and Figure 3 As shown, the three-dimensional network fusion insulation board provided by this utility model includes a three-dimensional network structure skeleton 7 and insulation core material 8 filled in the pores of the three-dimensional network structure skeleton 7. The three-dimensional network structure skeleton 7 and the insulation core material 8 therein are fused together by an integrated molding process to form a three-dimensional network fusion insulation board.

[0026] The three-dimensional network structure framework can be made of silicon carbide, alumina, or zirconium oxide, and has high corrosion resistance, high mechanical strength, and high temperature stability.

[0027] Specifically, the three-dimensional network structure skeleton is a continuous three-dimensional porous structure formed by high-temperature sintering of silicon carbide, alumina, or zirconium oxide materials using a template method. It has a porosity of 80%-90%, a pore density of 8-60 ppi (e.g., 10 ppi pore size is approximately 1778 μm, 30 ppi is approximately 711 μm), and a thermal shock resistance of 6 times / 1100℃. The three-dimensional network structure skeleton serves as the main load-bearing layer in the three-dimensional network fusion insulation board.

[0028] The insulation core material can be polyurethane, polystyrene resin, or aerogel (density 15-40kg / m³), etc. The insulation core material is filled into the pores of the three-dimensional network structure skeleton through foaming, curing or sintering processes. It forms a thermo-mechanically coupled integrated structure with the three-dimensional network structure skeleton, and the two are seamlessly connected, eliminating the interface defects of traditional sandwich structures.

[0029] The integrated molding process between the thermal insulation core material and the three-dimensional network structure skeleton includes the following steps: 1) Place the three-dimensional network structure skeleton in the mold; 2) Inject liquid insulation core material and allow it to permeate into the pores of the three-dimensional network structure skeleton; 3) A mechanical interlocking structure between the insulation core material and the three-dimensional network structure skeleton is achieved through foaming, curing or sintering processes. After curing and demolding, a three-dimensional network fused insulation board is formed.

[0030] The pores of the three-dimensional network structure skeleton provide a uniform dispersion space for the liquid insulation core material. Due to the high porosity of 80%-90%, the liquid insulation core material can be fully filled, avoiding the thermal bridging effect, while maintaining the lightweight of the insulation board (the density can be controlled within a low range).

[0031] For example, in a structure where a silicon carbide three-dimensional network framework and polyurethane are integrally molded, the polyurethane fills the pores of the silicon carbide three-dimensional network framework, and the closed-cell rate can be ≥97% after the two are integrally molded. The polyurethane and the silicon carbide three-dimensional network framework are tightly and seamlessly connected, and the two are integrated into a single structure, thus forming a three-dimensional network fused insulation board.

[0032] The synergistic effect of the insulation core material and the three-dimensional network structure skeleton results in a three-dimensional network fused insulation board with excellent insulation performance, strong mechanical properties, corrosion resistance, and thermal stability. Taking polyurethane as an example, its closed-cell structure blocks heat conduction (thermal conductivity ≤0.024 W / (m·K)), while the high porosity of the three-dimensional network structure skeleton further reduces heat convection, allowing the thermal conductivity of the three-dimensional network fused insulation board to be controlled between 0.02-0.05 W / (m·K). For the silicon carbide three-dimensional network structure skeleton, its flexural strength is 400-600 MPa. Combined with the elastic deformation capacity of polyurethane, this results in a compressive strength ≥0.40 MPa and an elongation at break ≥8% for the three-dimensional network fused insulation board, adapting to complex stress environments. The chemical stability (acid and alkali resistance, high temperature resistance) of the silicon carbide three-dimensional network structure skeleton combined with the weather resistance of polyurethane allows the three-dimensional network fused insulation board to be used long-term within a temperature range of -40℃ to +120℃, with a water absorption rate ≤3%.

[0033] The thickness of the three-dimensional network fusion insulation board can be controlled from 20mm to 300mm (adjusted according to design requirements). The heat transfer coefficient, compressive strength, tensile strength, bending strength and service life meet the design requirements.

[0034] like Figure 3 As shown, a waterproof sealing strip 5 (e.g., made of rubber) is provided at the edge of the three-dimensional network fusion insulation board to waterproof the joints between adjacent boards, replacing the traditional mortar sealing process. The insulation boards are bonded together using a special adhesive 6. A waterproof coating 9 is applied to the surface of the three-dimensional network fusion insulation board, and an external wall protective layer 10 is provided outside the waterproof coating 9. The thickness of the external wall protective layer 10 is 5-10mm, providing weather resistance protection.

[0035] The 3D network fusion insulation board utilizes a fully automated production line to integrate material preparation, molding, and curing, reducing production energy consumption by more than 40% compared to traditional processes, and allowing for the recycling and reuse of waste materials. The 3D network fusion insulation board can be used directly as an enclosure wall, eliminating the need for additional plastering or protective layers.

[0036] This invention introduces a three-dimensional network structure skeleton made of finished silicon carbide, alumina, zirconium oxide, etc., and combines it with low thermal conductivity materials (such as polyurethane foam insulation material, polystyrene resin foam insulation material, aerogel insulation material, etc.). Through processes such as foaming, curing, and chemical replacement, these materials are filled into the gaps of the three-dimensional network structure skeleton to form a new type of insulation board structure that is coupled and integrated with the three-dimensional network structure skeleton. This significantly improves the mechanical properties and connection stability of the insulation board.

Claims

1. A three-dimensional network fusion insulation board, characterized in that, It includes a three-dimensional network structure skeleton and an insulation core material embedded in the pores of the three-dimensional network structure skeleton; the three-dimensional network structure skeleton and the insulation core material therein are fused into a three-dimensional network fused insulation board through an integrated molding process.

2. The three-dimensional network fusion insulation board according to claim 1, characterized in that, The three-dimensional network structure framework is a silicon carbide three-dimensional network structure framework, an alumina three-dimensional network structure framework, or a zirconia three-dimensional network structure framework.

3. The three-dimensional network fusion insulation board according to claim 1, characterized in that, The porosity of the three-dimensional network structure skeleton is 80%-90%.

4. The three-dimensional network fusion insulation board according to claim 1, characterized in that, The insulation core material is polyurethane, polystyrene resin, or aerogel material.

5. The three-dimensional network fusion insulation board according to claim 1, characterized in that, The thickness of the three-dimensional network fusion insulation board is 20mm~300mm.

6. The three-dimensional network fusion insulation board according to claim 1, characterized in that, The thermal conductivity of the three-dimensional network fusion insulation board is 0.02-0.05 W / (m·K).

7. The three-dimensional network fusion insulation board according to claim 1, characterized in that, The compressive strength of the three-dimensional network fusion insulation board is ≥0.40 MPa, and the elongation at break is ≥8%.

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