Modified aerogel composite panel

Abstract

The utility model relates to the field of thermal insulation building materials discloses modified aerogel composite board, including aerogel layer and the surface setting hardening layer of it, and the hardening layer is formed by the mortar infiltration aerogel layer and solidification, and the embedded grid cloth is fully infiltrated by the mortar. The structure replaces the traditional decorative panel by in situ formation hardening layer, effectively closes aerogel surface, prevents dust fall, improves board rigidity and interface adhesion simultaneously. The overall thermal insulation structure thickness can reduce 30%~50%, the building space is saved significantly;The mortar only slightly penetrates into the surface layer, and the thermal conductivity coefficient is maintained at 0.015-0.022 W / (m K), and the thermal insulation performance is excellent. The hardening layer and the grid cloth are integrated prefabricated, and can be directly batched and scraped or pasted during construction, and the process is simple, the cost is reduced, and is suitable for indoor efficient energy-saving thermal insulation engineering.

Description

Technical Field

[0001] This solution relates to the field of thermal insulation building materials, specifically modified aerogel composite panels. Background Technology

[0002] Aerogel is a novel functional material with a three-dimensional nanoporous structure. Due to its excellent properties such as extremely low thermal conductivity, high porosity, and low density, aerogel felt, a flexible thermal insulation material made by combining nano-silica as the main matrix with carbon fiber, ceramic glass fiber, or pre-oxidized fiber felt through a special process, shows broad application prospects in the field of thermal insulation and is widely used in construction, industrial pipelines, and new energy. However, when using aerogel felt in building interior insulation projects, certain challenges arise. Because of the nanoscale pores and loose structure on the surface of aerogel felt, dust is easily generated and shed during use. This not only affects the stability of the material's insulation performance but also pollutes indoor air quality, and long-term exposure may pose potential risks to human respiratory health.

[0003] The current conventional solution is to encapsulate aerogel felt as a core material, avoiding the problem of dust shedding during use by preventing the aerogel from being exposed to the air. However, this method significantly increases the overall structural thickness of the insulation material, resulting in walls or insulation layers occupying more building space, reducing the usable indoor area, and hindering the achievement of the dual goals of building energy conservation and efficient space utilization. Utility Model Content

[0004] The present invention aims to provide a modified aerogel composite board to overcome the problem of dust shedding in aerogel felt, while reducing the overall thickness of the insulation board, thereby improving the applicability of aerogel materials in indoor insulation scenarios.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a modified aerogel composite board, comprising an aerogel layer and a wrapping layer, the wrapping layer comprising a hardening layer, the hardening layer being disposed on at least one side of the aerogel layer and being formed by impregnation and penetration of the aerogel layer with adhesive paste to harden.

[0006] The beneficial effects of this solution are as follows: Aerogel, as an excellent thermal insulation material, has superior thermal insulation performance at the same thickness, with an insulation effect 2 to 5 times that of traditional thermal insulation materials, and a longer service life. To achieve the same thermal insulation effect, the thickness of aerogel felt is only one-fifth to one-third of that of traditional thermal insulation materials. When used indoors, to avoid the problem of dust shedding during aerogel felt application, decorative panels need to be wrapped on both sides of the aerogel. At the same time, due to the softness of aerogel felt, its use in indoor thermal insulation requires a certain degree of rigidity in the insulation material, which necessitates a certain thickness for the decorative panels, further increasing the thickness of the insulation layer and affecting the competitiveness of aerogel as an indoor thermal insulation material. This solution utilizes adhesive to impregnate the aerogel surface, and the hardened layer formed by the adhesive seals the aerogel surface. By forming a hardened layer in situ to replace the traditional double-layer decorative panels, the overall insulation structure thickness can be reduced by 30% to 50%. For example, the total thickness of traditional encapsulation structures is about 20-30mm, while this composite board can be controlled within 10-15mm, which has a significant advantage in space-sensitive scenarios such as residential buildings and urban renewal projects. Meanwhile, the adhesive only wets the surface layer to a depth of micrometers, without significantly blocking the internal nanoporous structure. The main body is still a low thermal conductivity aerogel matrix, and the measured thermal conductivity can be maintained at 0.018–0.022 W / (m·K), so the heat preservation efficiency is not fundamentally affected.

[0007] In addition, the hardened layer can be prefabricated in the factory, eliminating the need for additional wrapping or reinforcement on site. It can be directly applied by troweling, tiling, or painting, simplifying the process, shortening the construction period, and reducing labor and material costs.

[0008] When used for decoration, the hardened layer can be used as a decorative surface. The side of the insulation layer away from the hardened layer is attached to the wall and fixed to the wall, so that the insulation layer is fixed to the wall. At the same time, the decorative surface and its surrounding area are sealed with gypsum board or cement mortar to ensure that aerogel dust will not escape into the room during use.

[0009] Furthermore, the encapsulation layer also includes a sealing layer, which is disposed on the side of the aerogel layer. The sealing layer is fixedly connected to the hardening layer on both sides and seals the side of the aerogel layer. A mesh fabric is also disposed within the hardening layer, which is attached to the surface of the aerogel layer and fully impregnated with the adhesive. Through the sealing layer, the sealing layer works in conjunction with the hardening layer to comprehensively encapsulate the aerogel layer, preventing the escape of aerogel particles during storage and transportation. Simultaneously, the mesh fabric forms a unified whole within the hardened layer, collectively bearing external forces, thereby improving the integrity and stability of the hardened layer and reducing the risk of localized detachment during use.

[0010] Furthermore, by weight, the adhesive comprises the following components: 50-70 parts cement, 25-45 parts water, 2-10 parts adhesive powder, and 0.1-1 parts hydroxypropyl methylcellulose.

[0011] Furthermore, the adhesive powder is a type of vinyl acetate-ethylene, acrylic acid, or acetylated modified acrylic acid.

[0012] Furthermore, the adhesive is composed of any two components selected from four substances: acrylate, acetylated modified acrylic self-crosslinking monomer, polyvinyl acetate, or water-based polymer emulsion. The weight parts of the two substances are 30-40 parts and 60-70 parts, respectively, and the total weight of the two components is 100 parts.

[0013] Furthermore, the adhesive is formed by mixing 30-40 parts of acetylated modified acrylic self-crosslinking monomer and 60-70 parts of vinyl acetate-ethylene copolymer emulsion.

[0014] Furthermore, the slurry also includes 0.01-10 parts of foaming agent and 0.01-30 parts of thermal insulation filler. The addition of foaming agent and thermal insulation filler allows the slurry-formed structure to not only buffer stress caused by temperature changes or structural deformation, reducing crack formation, but also provide a certain degree of thermal insulation, resulting in superior thermal insulation performance of the modified aerogel board.

[0015] Furthermore, the aerogel layer is formed by at least one layer of aerogel felt stack, with a hardening layer provided on both sides of the aerogel layer, and several binding members provided between the aerogel felts, and the aerogel felts of the stack are fixed as a whole by the binding members.

[0016] Beneficial effects: Using the adhesive layer as a "transition interface" can not only seal the surface of the hydrophobic aerogel, but also provide a hydrophilic and roughened bonding substrate, which greatly improves the adhesion to the subsequent cement mortar or putty layer, avoids hollowing and delamination, and ensures the long-term stability of the finishing system; at the same time, by setting hardening layers on both sides to form a symmetrical structure, the smoothness and stability can be further improved.

[0017] Furthermore, the strapping component includes a perforated band and a band tail. The perforated band is provided with a locking hole, and the inner wall of the locking hole is provided with locking teeth. The band tail includes a snap-fit ​​section, which is parallel to the perforated band and has a fixed thickness section and a locking section fixed at both ends respectively. The fixed thickness section is perpendicular to the perforated band and is fixedly connected to the perforated band through a free end. The locking section is parallel to the fixed thickness section and has several snap teeth fixed on its side wall, and the snap teeth are adapted to the locking teeth.

[0018] Beneficial effect: By setting the end of the strip to include a snap-fit ​​section parallel to the perforated strip, and fixing the two ends of the snap-fit ​​section to a thickness-fixing section and a locking section perpendicular to the snap-fit ​​section, the thickness of the insulation board after tightening is guaranteed.

[0019] Furthermore, the binding component includes a strap tail and a perforated strap section. The strap tail includes a snap-fit ​​section, with locking sections fixed to each of its two ends. The perforated strap section has at least two locking holes, the spacing of which is adapted to the length of the snap-fit ​​section. This configuration forms a split binding component. During insulation board production, a needle can be used to pierce the insulation board, and the strap tail can be passed through one of the holes to limit the insulation board's position, preventing relative displacement between the two layers of aerogel felt during transportation and thus avoiding affecting the connection strength between the sealing layer and the hardening layer. During insulation board installation, the perforated strap section can be fixed to the corresponding position on the wall, and the free end of the locking section can be passed through the locking hole. Pushing the insulation board causes the locking teeth to engage with the locking teeth. Through the cooperation of the strap tail and the perforated strap section, the insulation board can be installed on the wall, reducing the workload of installation. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the internal structure of an embodiment of the present utility model; Figure 2 This is a schematic diagram of the structure of the aerogel felt after hardening treatment according to an embodiment of this utility model; Figure 3 This is a schematic diagram of the binding component structure in Embodiment 4 of this utility model; Figure 4 This is a schematic diagram of the binding component structure in Embodiment 5 of this utility model.

[0021] Figure 5 This is a summary table of performance indicators before and after processing in the embodiments of this utility model.

[0022] The reference numerals in the accompanying drawings include: aerogel felt 100, hardened layer 210, impregnated layer 211, mesh fabric layer 212, sealing layer 220, binding element 300, locking section 310, locking tooth 311, perforated strip 320, and locking tooth 321. Detailed Implementation

[0023] Example 1 Example 1 is basically as shown in the appendix. Figure 1-2 As shown, Figure 1-2 The modified aerogel composite board shown includes an aerogel layer, a wrapping layer, and several binding elements 300. The aerogel layer is formed by stacking at least one layer of aerogel felt 100. In this embodiment, the aerogel layer includes two layers of aerogel felt 100. The wrapping layer includes a hardening layer 210 and a sealing layer 220. The hardening layer 210 is disposed on at least one side of the aerogel layer, and the thickness of the hardening layer 210 is 0.5–2 mm, preferably about 1 mm. Specifically, as shown... Figure 2As shown, the hardening layer 210 includes an impregnation layer 211 and a mesh layer 212. The impregnation layer 211 is formed by impregnating and penetrating the aerogel layer with adhesive and hardening it. The thickness of the impregnation layer 211 ranges from 0.1 to 1 mm to balance the sealing effect and thermal insulation performance. The mesh layer 212 includes a mesh fabric that is attached to the surface of the aerogel layer and is fully impregnated with adhesive. The mesh fabric hardens under the action of adhesive and is thus fixed to the surface of the aerogel layer. Specifically, the mesh count ranges from 40 to 240 meshes, and the unit area mass is 40 to 240 g / m2.

[0024] The slurry comprises the following components: 50-70 parts cement, 25-45 parts water, 2-10 parts adhesive powder, and 0.1-1 parts hydroxypropyl methylcellulose. The adhesive powder is vinyl acetate-ethylene, acrylic acid, or acetylated modified acrylic acid. In this embodiment, the slurry is formed by mixing 60 parts cement, 40 parts water, 7 parts vinyl acetate-ethylene, and 0.5 parts hydroxypropyl methylcellulose.

[0025] like Figure 1 As shown, a sealing layer 220 is also provided on the side of the aerogel layer. The sealing layer 220 is fixedly connected to the hardened layer 210 on both sides and seals the side of the aerogel layer. Specifically, the sealing layer 220 is an air-barrier membrane or a hardened slurry. In this embodiment, the sealing layer 220 is an air-barrier membrane. The air-barrier membrane is pasted on both sides to the surface of the hardened layer 210 to seal the side of the aerogel layer, thereby preventing powder from falling off the side of the aerogel layer during use. Specifically, the air-barrier membrane can be one of non-woven fabric, glass fiber mat, skeleton non-woven fabric, PVC glass fiber coated mat, or cement glass fiber coated mat. In this embodiment, the air-barrier membrane is glass fiber mat.

[0026] This embodiment does not impose strict limitations on the structure of the binding member 300. For example, a tie wire with suitable strength or a cable tie disclosed in Chinese Patent Application No. 201480016410.3 can be used. During production, the binding member 300 is used to pass through and surround the hardened layer 210 and the two layers of aerogel felt 100 to fix and bind the hardened layer 210 and the two layers of aerogel felt 100 to ensure that there is no relative displacement between the two layers of aerogel felt 100.

[0027] The production process is as follows: First, prepare the slurry: Weigh 60 parts cement, 40 parts water, 7 parts vinyl acetate-ethylene and 0.5 parts hydroxypropyl methylcellulose by weight, mix them and stir evenly to obtain the slurry.

[0028] Subsequently, a hardening process is carried out: one side of the aerogel felt 100 is soaked with the prepared slurry, then the mesh cloth is laid and the mesh cloth is scraped flat so that the mesh cloth is laid flat on the surface of the aerogel layer. If the mesh cloth or the surface of the aerogel felt 100 is not fully soaked during the scraping process, the slurry can be added appropriately to ensure that the mesh cloth and the surface of the aerogel felt 100 are fully soaked with the slurry, and then wait for the slurry to harden. Meanwhile, the surface of another piece of aerogel felt 100 is also hardened, and the slurry is left to harden. After both aerogel felts 100 have been hardened, a puncture process is performed. The unhardened surfaces of the two aerogel felts 100 are overlapped, and the binding piece 300 is fastened to the mesh cloth using a needle. Then, the binding piece 300 is rotated to rotate the connection point into the aerogel felt 100, thus obtaining a double-layer composite aerogel insulation board. Finally, the perimeter of the double-layer composite aerogel insulation board is trimmed, and an air-barrier membrane is pasted around the aerogel layer to seal the perimeter of the aerogel layer, thus obtaining the finished double-layer composite aerogel insulation board.

[0029] The bulk density, thermal conductivity, vibration mass loss rate, volumetric water absorption rate, compressive strength, vertical tensile strength, impact resistance, and impermeability of the aerogel felt before processing and the double-layer composite aerogel insulation board after processing were tested. The test results are shown in […]. Figure 5 The table.

[0030] Example 2 Example 2 is basically the same as Example 1, except that the slurry is composed of any two components selected from four substances: acrylate, acetylated modified acrylic self-crosslinking monomer, polyvinyl acetate, or water-based polymer emulsion. The weight parts of the two substances are 30-40 parts and 60-70 parts, respectively, and the total weight of the two components is 100 parts.

[0031] In this embodiment, the slurry is formed by mixing 30-40 parts of acetylated modified acrylic self-crosslinking monomer and 60-70 parts of vinyl acetate-ethylene copolymer emulsion. Specifically, the weight parts of the acetylated modified acrylic self-crosslinking monomer can be 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, or any number between two values; the weight parts of the vinyl acetate-ethylene copolymer emulsion can be 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, or any number between two values. It is only necessary to ensure that the sum of the weight parts of the acetylated modified acrylic self-crosslinking monomer and the vinyl acetate-ethylene copolymer emulsion is 100.

[0032] In this embodiment, when preparing the slurry, 40 parts of acetylated modified acrylic self-crosslinking monomer and 60 parts of vinyl acetate-ethylene copolymer emulsion were weighed and mixed to obtain the slurry. The prepared slurry was used to harden and seal the surface of the aerogel felt 100. The bulk density, thermal conductivity, vibration mass loss rate, volume water absorption rate, compressive strength, vertical tensile strength, impact resistance, and impermeability of the aerogel felt before processing and the double-layer composite aerogel insulation board after processing were tested. The test results are shown in […]. Figure 5 The table.

[0033] Example 3 Based on Examples 1 and 2, the adhesive also includes 0.01-10 parts of a foaming agent and 0.01-30 parts of a thermal insulation filler. The foaming agent can be rosin resin, and the thermal insulation filler can be vitrified microspheres. Through the addition of the foaming agent and the thermal insulation filler, the hardened layer 210, the impregnated layer 211, or the sealing layer 220 formed by the adhesive not only buffers stress caused by temperature changes or structural deformation, reducing crack formation, but also provides certain thermal insulation properties, making the modified aerogel board's thermal insulation performance even better.

[0034] Example 4 Based on Examples 1 and 2, such as Figure 3 As shown, the strapping component 300 includes a perforated band portion 320 and a band tail. The perforated band portion 320 is provided with a locking hole, and the inner wall of the locking hole is provided with locking teeth 321. The band tail is made of nylon and includes an integrally formed thickness-fixed section, a snap-fit ​​section, and a locking section 310. The free end of the thickness-fixed section is fixedly connected to the perforated band portion 320. Several snap-fit ​​teeth 311 are fixed on the side wall of the locking section 310. The thickness-fixed section and the locking section 310 are arranged in parallel and are both perpendicular to the snap-fit ​​section. In use, the aerogel layer is perforated by a needle, and the free end of the locking section 310 is passed through the perforation formed by the needle from one side and through the perforation from the other side, and then out of the locking hole. The locking teeth 321 are used to lock the snap-fit ​​teeth 311, thereby preventing the locking section 310 from coming out of the locking hole and affecting the locking effect. The thickness-fixed section ensures the thickness of the insulation board.

[0035] Example 5 Example 5 is basically the same as Example 3, except that, as Figure 4As shown, the fixed-thickness section of the belt tail is replaced with a locking section 310, resulting in two locking sections 310 on the belt tail. This separates the perforated section 320 from the belt tail. Both the belt tail and the perforated section 320 possess a certain degree of rigidity and are poor conductors of heat. Two locking holes are provided in the perforated section 320, with the spacing between them matching the length of the belt tail locking section, thus forming a split-type strapping component 300. In this embodiment, the surface material of the belt tail and the perforated section 320 is polycarbonate, and the material of the locking teeth 311 is spring steel. This ensures the structural strength of the belt tail while reducing the impact of perforations on the thermal insulation performance of the insulation board.

[0036] When producing the insulation board, a needle can be used to pierce the insulation board, and the end of the strip can be passed through the piercing on one side of the insulation board to limit the insulation board and prevent relative displacement between the two layers of aerogel felt 100 during transportation, which would affect the connection strength between the sealing layer 220 and the hardening layer 210. When installing the insulation board, the perforated strip 320 is fixed to the corresponding position on the wall, and after the free end of the locking section 310 is passed through the lock hole, the insulation board is pushed so that the locking teeth 311 and the locking teeth 321 of the locking section 310 engage to complete the installation of the insulation board on the wall.

[0037] The above descriptions are merely embodiments of this utility model. Commonly known technical solutions and / or characteristics are not described in detail here. It should be noted that the technical means used to solve problems in the above embodiments of this utility model can be combined to solve multiple technical problems simultaneously. For those skilled in the art, several modifications and improvements can be made without departing from the technical solution of this utility model, and these should also be considered within the scope of protection of this utility model. These modifications will not affect the effectiveness of the implementation of this utility model or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A modified aerogel composite board, characterized in that: It includes an aerogel layer and a coating layer. The coating layer includes a hardening layer, which is disposed on at least one side of the aerogel layer and is formed by impregnation and penetration of the aerogel layer with a resin to harden it.

2. The modified aerogel composite plate according to claim 1, characterized in that: The encapsulation layer also includes a sealing layer, which is disposed on the side of the aerogel layer. The sealing layer is fixedly connected to the hardening layer on both sides and seals the side of the aerogel layer. The hardening layer also includes a mesh fabric, which is attached to the surface of the aerogel layer and fully impregnated with the adhesive.

3. The modified aerogel composite plate according to claim 2, characterized in that: The aerogel layer is formed by at least one layer of aerogel felt stack. Hardening layers are provided on both sides of the aerogel layer. Several binding members are provided between the aerogel felts, and the aerogel felts of the stack are fixed into a whole by the binding members.

4. The modified aerogel composite plate according to claim 3, characterized in that: The strapping component includes a perforated band and a band tail. The perforated band has a locking hole with locking teeth on its inner wall. The band tail includes a snap-fit ​​section that is parallel to the perforated band and has a fixed thickness section and a locking section fixed at both ends, respectively. The fixed thickness section is perpendicular to the perforated band and is fixedly connected to the perforated band through its free end. The locking section is parallel to the fixed thickness section and has several locking teeth fixed to its side wall, which are compatible with the locking teeth.

5. The modified aerogel composite plate according to claim 3, characterized in that: The strapping component includes a strap tail and a perforated strap section. The strap tail includes a snap-fit ​​section, and each of the two snap-fit ​​sections is fixed with a locking section. The perforated strap section is provided with at least two locking holes, and the spacing between the locking holes is adapted to the length of the snap-fit ​​section.

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