Refractory thermal insulation material and method of manufacturing the same

Abstract

The refractory thermal insulation material and the method for manufacturing the same include the step of pressurizing and heat-treating fresh concrete obtained by uniformly mixing the raw material composition of the refractory thermal insulation material; wherein the pressurizing pressure is 0.28 MPa or higher and the heating temperature is 50°C to 150°C; wherein the raw material composition of the refractory thermal insulation material includes inorganic raw materials, organic raw materials, and water; wherein the inorganic raw materials include siliceous materials and calcium materials, and the organic raw materials include polystyrene particles; the weight ratio of the inorganic raw materials to the organic raw materials is 10 to 66.6, and the weight ratio of the siliceous materials to the calcium materials is 0.33 to 19. The flexible thermal insulation board manufactured by the above method has high tensile strength and high fire resistance performance.

Description

Technology Field

[0001] The present invention relates to the field of building materials, and specifically to a fire-resistant thermal insulation material and a method for manufacturing the same. Background Technology

[0002] Construction insulation materials generally refer to materials with a thermal conductivity (at 25°C) and a coefficient of W / (m·K) of 0.2 W / (m·K) or less. With the rapid development of insulation materials in recent years, the use of superior insulation technologies and materials in industry and construction can often play a significant role in saving energy and reducing emissions. Due to advancements in science and technology and improvements in people's living standards, the demand for insulation materials is also steadily increasing.

[0003] Improving the thermal insulation capacity of the building itself is the core of the development of self-insulating technology and the ultimate direction of building energy-saving technology. However, due to many factors, the development of self-insulating technology is currently relatively slow. High-pressure steam-cured foamed concrete blocks, which are inorganic self-insulating materials currently used in the mainstream market, are heavy in weight (resulting in high construction strength and potential construction safety risks), have low thermal conductivity (thermal conductivity is around 0.16 W / (m), resulting in poor insulation performance), and have a high water absorption rate (if the material absorbs water, the absorption rate will have a serious impact on structural strength and insulation performance). Consequently, self-insulating wall technology has not been widely adopted.

[0004] Due to fire safety requirements, materials available in current technology that meet thermal insulation standards and are Class A fire-resistant insulations are broadly divided into two categories. One category consists of flexible Class A fire-resistant insulation, represented by rock wool; these materials have low tensile strength and poor hydrophobicity. Furthermore, upon water absorption, not only does their thermal insulation performance deteriorate significantly, but their thermal efficiency also drops and tensile strength further worsens, posing a safety risk as the exterior wall may easily detach. The other category consists of rigid Class A fire-resistant insulation, represented by foamed glass; due to their inherent brittleness, they crack easily, are difficult to process, and are also difficult to install.

[0005] The construction environment of building walls has imposed higher requirements on the pressure resistance, thermal insulation, and fire resistance of thermal insulation materials (fire resistance indoors must meet higher requirements). However, current thermal insulation materials often fail to consider all three factors: physical properties, thermal insulation, and fire resistance. The problem to be solved

[0006] To solve the problems existing in current technology, the present invention provides a non-combustible fire-resistant thermal insulation material of a fire-resistant grade that has high tensile strength, does not easily detach after bonding, and has excellent thermal insulation performance, and a method for manufacturing the same. means of solving the problem

[0007] To solve the problems existing in current technology, the present invention provides a non-combustible fire-resistant thermal insulation material of a fire-resistant grade that has high tensile strength, does not easily detach after bonding, and has excellent thermal insulation performance, and a method for manufacturing the same.

[0008] The present invention provides a method for manufacturing a refractory thermal insulation material, wherein the method comprises the step of pressurizing and heat-treating fresh concrete obtained by uniformly mixing a raw material composition of the refractory thermal insulation material; wherein the pressurizing pressure is 0.28 MPa or higher and the heating temperature is 50°C to 150°C; wherein the raw material composition of the refractory thermal insulation material comprises an inorganic raw material, an organic raw material, and water; wherein the inorganic raw material comprises a siliceous material and a calcium material, and the organic raw material comprises polystyrene particles; the weight ratio of the inorganic raw material to the organic raw material is 10 to 66.6, and the weight ratio of the siliceous material to the calcium material is 0.33 to 19.

[0009] Some parameters in the method for manufacturing a refractory thermal insulation material may be described as follows, and unrelated parameters are as described in any one of the methods of the present invention (hereinafter abbreviated as "in the method for manufacturing the refractory thermal insulation material"). In the raw material composition of the refractory thermal insulation material, the siliceous material among the inorganic raw materials may be a siliceous mineral commonly used in this field; for example, one or more of silica sand powder, micro silica powder, slag powder, fly ash, quartz powder, kaolin, bentonite, water glass, and diatomaceous earth; for example, micro silica powder purchased from Shanghai Victory Industrial Development Co., Ltd.; or for example, micro silica powder purchased from Huzhou Huatian Micro Powder Factory and Type C high-calcium fly ash purchased from Shanghai Commodity Fly Ash Products Co., Ltd.

[0010] In the method for manufacturing the above-mentioned refractory thermal insulation material, in the raw material composition of the above-mentioned refractory thermal insulation material, the calcium material among the inorganic raw materials may be a calcium mineral commonly used in this field; for example, calcium oxide and / or calcium hydroxide; and for example, calcium oxide purchased from Taicang Dongfang Metallurgical Lime Products Factory.

[0011] In the method for manufacturing the above-mentioned refractory thermal insulation material, in the raw material composition of the above-mentioned refractory thermal insulation material, the polystyrene particles among the organic raw materials are expandable polystyrene particles commonly used in this field; for example, expandable polystyrene particles containing graphite purchased from Wuxi Xingda New Foam Materials Co., Ltd.

[0012] The above-mentioned expandable polystyrene particles are pre-expanded polystyrene particles, and the pre-expanded polystyrene particles may be commercially available pre-expanded polystyrene particles, or the pre-expanded polystyrene particles may be obtained in a form in which the manufacturing method further includes a pre-expanding step of the expandable polystyrene particles before mixing the raw material composition of the fire-resistant thermal insulation material.

[0013] Here, in the above preliminary foaming step, the polystyrene particles can be foamed to the required gram weight according to the conventional foaming method of this field, for example, the above preliminary foaming step is to foam the polystyrene particles by heating and pressurizing them.

[0014] In the method for manufacturing the above-mentioned refractory thermal insulation material, the organic raw material in the raw material composition of the above-mentioned refractory thermal insulation material may further include a water-reducing agent, and the water-reducing agent is a water-reducing agent commonly used in this field; for example, one or more of lignosulfonate water-reducing agents, naphthalene sulfonate water-reducing agents, melamine water-reducing agents, sulfamate water-reducing agents, and polycarboxylic acid high-performance water-reducing agents, and for example, a polycarboxylic acid high-performance water-reducing agent (HF retardant high-efficiency water-reducing agent purchased from Shanghai Dongda Chemical Co., Ltd.). The amount of the water-reducing agent used is 4.5 wt% or less of the total weight of the raw material composition of the above-mentioned refractory thermal insulation material; for example, 4 wt% or less; and for example, 3 wt% or less.

[0015] In the method for manufacturing the above-mentioned fire-resistant thermal insulation material, the organic raw material in the raw material composition of the above-mentioned fire-resistant thermal insulation material may further include reinforcing fibers. The reinforcing fibers may be reinforcing fibers commonly used in this field; for example, one or more of inorganic cutting fibers, wood fibers, metal fibers, and fiber cotton; another example is fiber cotton (fiber cotton purchased from Shijiazhuang Dinglong Building Materials Sales Co., Ltd.). The amount of reinforcing fibers used is 25 wt% or less of the total weight of the above-mentioned fire-resistant thermal insulation material raw material composition, for example, 13 wt% or less; and for example, 11 wt% or less.

[0016] The method for manufacturing the above-mentioned refractory thermal insulation material may include the step of obtaining fresh concrete by uniformly mixing the raw material composition of the refractory thermal insulation material; the step of placing the fresh concrete into a mold and pressurizing the mold to maintain a pressurized state such that the pressure applied to the mold reaches 0.28 MPa or higher, heating the mold and the fresh concrete inside so that the temperature inside the fresh concrete reaches 50°C to 150°C, and then releasing the mold after heating and pressurizing until the mold is formed.

[0017] In the method for manufacturing the above-mentioned refractory thermal insulation material, the mold may include an upper mold and a lower mold, and the manufacturing method may include the step of initially forming the fresh concrete using the upper mold and the lower mold, and locking the upper mold and the lower mold until the fresh concrete is formed by compressing it by 10% to 45% (e.g., 17% to 38%) in the thickness direction after the mold enters a pressing platform.

[0018] In the above method for manufacturing the fire-resistant thermal insulation material, a plurality of sets of molds are sequentially and repeatedly stacked to form multiple fire-resistant thermal insulation boards, and the fresh concrete is pressed simultaneously until it is compressed by 10% to 45% (e.g., 17% to 38%) in the thickness direction.

[0019] In the method for manufacturing the above-mentioned refractory thermal insulation material, the heating temperature applied to the inside of the fresh concrete may be 60°C to 150°C; for example, 70°C to 140°C (80°C, 90°C, 100°C, 110°C, 120°C, or 130°C).

[0020] In the method for manufacturing the above-mentioned refractory thermal insulation material, during the process of forming by heating and pressurizing, a person skilled in the art may adjust the heating temperature and the pressurizing time according to the heating method. For example, if a conventional steam heating method or a heating method using a heat transfer liquid as a heat transfer medium is used, the heating time is 30 minutes or more; and for another example, if a microwave heating method is used, the heating time is 5 minutes or more.

[0021] In the method for manufacturing the above-mentioned refractory thermal insulation material, the manufacturing method may further include the step of placing a reinforcing member in a mold, wherein the reinforcing member comprises one or more of a metal mesh, a glass fiber mesh, a glass fiber reinforced plastic mesh, or a rib, and wherein the reinforcing member is embedded in at least one side of the fresh concrete.

[0022] In the method for manufacturing the above-mentioned refractory thermal insulation material, the raw material composition of the above-mentioned refractory thermal insulation material may be any one of the following.

[0023] Plan (1):

[0024] The raw material composition of the above-mentioned refractory thermal insulation material comprises, in parts by weight, 4.25 to 8.94 parts of polystyrene particles, 90 to 100 parts of inorganic raw materials, and 30 to 94 parts of water, wherein the inorganic raw materials consist of 47 to 85 parts of siliceous material and 9 to 47 parts of calcium material.

[0025] Plan (2):

[0026] The raw material composition of the above-mentioned refractory thermal insulation material comprises, in parts by weight, 3.8 to 21.4 parts of polystyrene particles, 200 to 250 parts of inorganic raw materials, and 63 to 250 parts of water, wherein the inorganic raw materials consist of 56.2 to 208 parts of siliceous material and 16.9 to 168.7 parts of calcium material;

[0027] Plan (3):

[0028] The raw material composition of the above refractory thermal insulation material consists of, in parts by weight, 1.8 to 12 parts of polystyrene particles, 100 to 115 parts of siliceous material, 6 to 18 parts of calcium material, and 35 to 120 parts of water.

[0029] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is the shape (1), the weight ratio of the siliceous material and the calcium material is 1 to 9, preferably 1.22 to 3, and more preferably 1.5 to 2.33.

[0030] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is of the form (1), the weight ratio of the inorganic raw material to the organic raw material is 10.5 to 22.1, preferably 10.5 to 18.5, more preferably 10.5 to 14.

[0031] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is of the method (1), the organic raw material in the raw material composition of the above-mentioned refractory thermal insulation material may include a water-reducing agent, and the amount of the water-reducing agent used may be 0.3 to 4.8 parts.

[0032] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is of the method (1), the organic raw material in the raw material composition of the above-mentioned refractory thermal insulation material may include reinforcing fibers (e.g., inorganic cutting fibers), and the amount of reinforcing fibers used may be 1 wt% to 11 wt% of the total weight of the raw material composition of the above-mentioned refractory thermal insulation material.

[0033] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is of the form (1), the pressurizing pressure is 0.55 MPa or higher, and preferably 0.55 MPa to 30 MPa.

[0034] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is of the form (1), the density of the above-mentioned refractory thermal insulation material is 230 kg / m³ 3 It is less than or equal to, preferably 210 kg / m² 3 Up to 230 kg / m² 3 , more preferably 220 kg / m² 3 Up to 228 kg / m² 3 It could be.

[0035] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is of the form (2), the weight ratio of the siliceous material and the calcium material is 0.33 to 12.33, preferably 3.67 to 5.67, and more preferably 1.5 to 3.

[0036] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is of the form (2), the weight ratio of the inorganic raw material and the organic raw material may be 10.5 to 58.9, preferably 10.5 to 35.3, and more preferably 10.5 to 16.

[0037] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is of the form (2), in the raw material composition of the above-mentioned refractory thermal insulation material, the organic raw material may include a water-reducing agent, and the content of the water-reducing agent may be 0.6 to 9 parts.

[0038] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is of the form (2), the organic raw material in the raw material composition of the above-mentioned refractory thermal insulation material may include reinforcing fibers (e.g., inorganic cutting fibers), and the amount of reinforcing fibers used may be 1 wt% to 13 wt% of the total weight of the raw material composition of the above-mentioned refractory thermal insulation material.

[0039] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is the method (2), the pressurizing pressure is 2.8 MPa or higher, and preferably 2.8 MPa to 30 MPa.

[0040] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is of the form (2), the density of the above-mentioned refractory thermal insulation material is 525 kg / m³ 3 Less than, preferably 500 kg / m² 3 Up to 525 kg / m² 3 It could be.

[0041] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is of the form (3), the amount of polystyrene particles used may be 3 to 11 parts, for example 3.4 to 10 parts (4.55 parts, 5.1 parts, 5.95 parts, 6.5 parts, 7 parts, 7.5 parts, 8 parts, 8.5 parts, 9 parts or 9.5 parts).

[0042] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is of the form (3), the amount of the above-mentioned siliceous material used is 100 to 110 parts, and for example, 100 to 107.9 parts.

[0043] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is the method (3), the amount of calcium material used may be 6 to 12 parts.

[0044] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is the method (3), the amount of water used may be 35 to 90 parts.

[0045] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is of the form (3), the weight ratio of the siliceous material and the calcium material may be 5.6 to 19 (e.g., 5.6, 9, or 19).

[0046] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is of the form (3), the weight ratio of the inorganic raw material to the organic raw material may be 12 to 35.5.

[0047] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is of the form (3), the pressurizing pressure may be 0.28 MPa to 0.55 MPa, and preferably 0.35 MPa to 0.55 MPa.

[0048] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is of the form (3), the organic raw material in the raw material composition of the above-mentioned refractory thermal insulation material may include a water-reducing agent, and the amount of the water-reducing agent used may be 0 to 50 parts, but not 0, and may be, for example, 3 to 42 parts (6 parts, 16 parts, 24 parts, or 36 parts).

[0049] In the method for manufacturing the above-mentioned refractory thermal insulation material, when the raw material composition of the above-mentioned refractory thermal insulation material is of the form (3), the organic raw material in the raw material composition of the above-mentioned refractory thermal insulation material may include reinforcing fibers (e.g., cotton fibers), and the amount of reinforcing fibers used may be 2.4 to 30 parts, for example, 4.8 to 30 parts (7.2 parts, 9.6 parts, 12 parts, 14.4 parts, 16.8 parts, 19.2 parts, 21.6 parts, 24 parts, 26.4 parts, or 28.8 parts).

[0050] In addition, the present invention provides a refractory thermal insulation material manufactured according to the method for manufacturing the refractory thermal insulation material.

[0051] In another aspect, the present invention also provides a method for manufacturing a thermal insulation material, any one of the following methods (a), (b), and (c).

[0052] Plan (a). Method for manufacturing floor fireproof insulation

[0053] In the method for manufacturing the above-mentioned floor fireproof thermal insulation material, the raw material composition of the floor fireproof thermal insulation material comprises, in parts by weight, 90 to 100 parts of inorganic raw material, 4.25 to 8.94 parts of polystyrene particles, and 30 to 94 parts of water, wherein the inorganic raw material comprises 47 to 85 parts of siliceous material and 9 to 47 parts of calcium material, and the fresh concrete of the raw material composition is pressurized and heated inside a mold, wherein the material density of the mold is 230 kg / m² 3 The temperature inside the mold is maintained at 50°C to 150°C and the pressure applied to the mold is 0.55 MPa or higher, and the mold is released while maintaining the pressure and heating.

[0054] Preferably, the density of the material is 210 kg / m³ 3 Up to 230 kg / m² 3 and, more preferably 220 kg / m² 3 Up to 228 kg / m² 3 am.

[0055] Here, the density of the material is 214.7 kg / m³ 3 , 218.4kg / m3 , 219kg / m 3 , 220kg / m 3 , 221.6kg / m 3 , 222kg / m 3 , 222.5kg / m 3 , 223kg / m 3 , 224.5kg / m 3 , 224.8kg / m 3 , 225kg / m 3 , 226kg / m 3 , 228.5kg / m 3 or 230.4 kg / m² 3 am.

[0056] In method (a), during the pressurization and heating process, the secondary foaming reaction of the polystyrene particles and the chemical reaction between the siliceous material and the calcium material occur simultaneously, the effective cavity volume of the mold does not change, and the polystyrene particles and the siliceous aggregate are bonded more tightly, resulting in 230 kg / m² 3 Compressive strength of 0.55 MPa or more and tensile strength of 0.13 MPa or more can be achieved at a lower density than that below.

[0057] Preferably, the siliceous material comprises one and a plurality of micro silica powder, kaolin, bentonite, and diatomite.

[0058] Preferably, the calcium material is a material containing calcium oxide and / or calcium hydroxide.

[0059] Preferably, the calcium material is calcium oxide and / or calcium hydroxide.

[0060] Preferably, the weight ratio of the siliceous material and the calcium material is 1 to 9; for example, 9, 5.66, 4, 3, 2.33, 1.5, 1.22, or 1.

[0061] Preferably, the weight ratio of the siliceous material to the calcium material is 1.22 to 3;

[0062] More preferably, the weight ratio of the siliceous material to the calcium material is 1.5 to 2.33.

[0063] Preferably, the weight ratio of the inorganic raw material to the polystyrene particles is 10.5 to 22.1; for example, 10.5, 11.1, 11.6, 11.9, 12.1, 13.3, 14, 16.1, 16.5, 18.5, 19.7, or 22.1.

[0064] Preferably, the weight ratio of the inorganic raw material to the polystyrene particles is 10.5 to 18.5;

[0065] More preferably, the weight ratio of the inorganic raw material to the polystyrene particles is 10.5 to 14.

[0066] Preferably, the raw material composition further includes any additive that does not affect the reaction between the siliceous material and the calcium material.

[0067] Preferably, the raw material composition further comprises a water reducer; said water reducer includes, but is not limited to, a lignosulfonate water reducer, a naphthalene sulfonate water reducer, a melamine water reducer, a polycarboxylic acid high-performance water reducer, or a sulfamate high-efficiency water reducer.

[0068] More preferably, the amount of the water-reducing agent used is 0.33 to 4.82 parts, for example, 0.33 parts, 0.75 parts, 1.5 parts, 2.63 parts, 3.94 parts, or 4.82 parts.

[0069] Preferably, the raw material composition further includes inorganic cutting fibers.

[0070] More preferably, the amount of the inorganic cutting fiber used is 1% to 11% of the total weight of the material, for example, 1%, 3%, 6%, 9%, or 11%.

[0071] Preferably, the pressure is 0.55 MPa to 30 MPa. Here, the pressure may be 0.55 MPa, 0.6 MPa, 0.8 MPa, 1 MPa, 5 MPa, 10 MPa, or 30 MPa.

[0072] Plan (b). Method for manufacturing wall insulation

[0073] In the method for manufacturing the above-mentioned wall insulation material, the raw material composition of the wall insulation material comprises, in parts by weight, 200 to 250 parts of inorganic raw material, 3.8 to 21.4 parts of polystyrene particles, and 63 to 250 parts of water, wherein the inorganic raw material comprises 56.2 to 208 parts of siliceous material and 16.9 to 168.7 parts of calcium material, and the fresh concrete of the raw material composition is pressurized and heated inside a mold, wherein the material density of the mold is 525 kg / m³ 3 The temperature inside the mold is maintained at 50°C to 150°C, and the pressure applied to the mold is 2.8 MPa or higher. The mold is then released by maintaining the pressure and heating.

[0074] Here, the density of the material is 496 kg / m³ 3 , 498kg / m 3 , 500kg / m 3 , 501kg / m 3 , 503kg / m 3 , 506kg / m 3 , 507kg / m 3 , 508kg / m 3 , 509kg / m 3 , 510kg / m 3 , 512kg / m 3 , 514kg / m 3 , 515kg / m 3 , 516kg / m 3 , 518kg / m 3 , 520kg / m 3 , 523kg / m 3 , or 525 kg / m² 3 The material density is 525 kg / m³. 3 If it exceeds 0.14 W / (m·K), the thermal conductivity increases and cannot meet the requirement of less than 0.14 W / (m·K).

[0075] Preferably, the density of the material is 400 kg / m³ 3 Up to 525 kg / m² 3 is. More preferably, the density of the material is 500 kg / m³ 3Up to 525 kg / m² 3 am.

[0076] In method (b), during the pressurization and heating process, the secondary foaming reaction of the polystyrene particles and the chemical reaction between the siliceous material and the calcium material occur simultaneously, the effective cavity volume of the mold does not change, and the polystyrene particles and the siliceous aggregate are bonded more tightly, resulting in 525 kg / m³ 3 Compressive strength of 2.8 MPa or more and tensile strength of 0.16 MPa or more can be achieved at a lower density than that below.

[0077] Preferably, the siliceous material comprises one and a plurality of micro silica powder, kaolin, bentonite, and diatomite.

[0078] Preferably, the calcium material is a material containing calcium oxide and / or calcium hydroxide.

[0079] Preferably, the calcium material is calcium oxide and / or calcium hydroxide.

[0080] Preferably, the weight ratio of the siliceous material and the calcium material is 0.33 to 12.33; for example, 0.33, 0.43, 0.54, 0.67, 0.82, 1, 1.22, 1.5, 1.86, 2.33, 3, 4, 5.67, 9, or 12.33.

[0081] Preferably, the weight ratio of the siliceous material to the calcium material is 3.67 to 5.67.

[0082] More preferably, the weight ratio of the siliceous material to the calcium material is 1.5 to 3.

[0083] Preferably, the weight ratio of the inorganic raw material to the polystyrene particles is 10.5 to 58.9; for example, 10.5, 11.0, 11.5, 12.2, 15.4, 16.0, 17.4, 19.8, 24.5, 27.8, 31.1, 35.3, 39.8, 44.7, 50.0, 55.8, or 58.9.

[0084] Preferably, the weight ratio of the inorganic raw material to the polystyrene particles is 10.5 to 35.3.

[0085] More preferably, the weight ratio of the inorganic raw material to the polystyrene particles is 10.5 to 16.

[0086] Preferably, the raw material composition further includes any additive that does not affect the reaction between the siliceous material and the calcium material.

[0087] Preferably, the raw material composition further comprises a water reducer; said water reducer includes, but is not limited to, a lignosulfonate water reducer, a naphthalene sulfonate water reducer, a melamine-based water reducer, a polycarboxylic acid high-performance water reducer, or a sulfamate high-efficiency water reducer.

[0088] More preferably, the amount of the water-reducing agent used is 0.6 to 9 parts, for example, 0.6 parts, 1.2 parts, 3 parts, 5 parts, 7.5 parts, or 9 parts.

[0089] Preferably, the raw material composition further includes inorganic cutting fibers.

[0090] More preferably, the amount of the inorganic cutting fiber used is 1% to 12% of the total weight of the material, for example, 1%, 2%, 4%, 8%, 10%, 12%, or 13%.

[0091] The upper limit of the pressure applied to the mold is the upper limit pressure that the mold can withstand. Preferably, the pressure is 2.8 MPa to 30 MPa. Here, the pressure may be 2.8 MPa, 3.5 MPa, 5 MPa, 10 MPa, or 30 MPa.

[0092] In addition, the present invention provides a wall insulation material manufactured according to any one of the methods for manufacturing the wall insulation material.

[0093] Plan (c). Method for manufacturing refractory thermal insulation

[0094] In the method for manufacturing the above-mentioned refractory thermal insulation material, the raw material composition of the above-mentioned refractory thermal insulation material comprises, in parts by weight, 1.8 to 12 parts of expandable polystyrene particles, 100 to 115 parts of siliceous material, 6 to 18 parts of calcium material, and 35 to 120 parts of water; the above-mentioned manufacturing method comprises the step of obtaining fresh concrete by uniformly mixing the raw material composition of the above-mentioned refractory thermal insulation material; the step of placing the obtained fresh concrete into a mold and applying pressure to the mold, maintaining a pressurized state such that the pressure applied to the mold reaches 0.28 MPa to 0.55 MPa, heating the mold and the fresh concrete inside so that the temperature inside the fresh concrete reaches 50℃ to 150℃, heating and pressurizing until the mold is formed, and then releasing the mold.

[0095] In method (c), the amount of expandable polystyrene particles used is 3 to 11 parts, for example 3.4 to 10 parts, and also for example 4.55 parts, 5.1 parts, 5.95 parts, 6.5 parts, 7 parts, 7.5 parts, 8 parts, 8.5 parts, 9 parts, or 9.5 parts.

[0096] In method (c), the expandable polystyrene particles are preferably expandable polystyrene particles containing graphite, and are, for example, expandable polystyrene particles containing graphite purchased from Wuxi Xingda New Foam Materials Co., Ltd.

[0097] In option (c), the siliceous material is one and a plurality of silica powder, micro silica powder, slag powder, fly ash, quartz powder, kaolin, bentonite, water glass, and diatomaceous earth, for example, micro silica powder purchased from Shanghai Victory Industrial Development Co., Ltd.; silica powder purchased from Huzhou Huatian Micro Powder Factory; or Type C high-calcium fly ash purchased from Shanghai Commodity Fly Ash Products Co., Ltd.

[0098] In method (c), the amount of the siliceous material used is preferably 100 to 110 parts, and for example, 100 to 107.9 parts.

[0099] In method (c), the calcium material is preferably calcium oxide and / or calcium hydroxide, and is, for example, calcium oxide purchased from Taicang Dongfang Metallurgical Lime Products Factory.

[0100] In method (c), the amount of calcium material used is preferably 6 to 12 parts.

[0101] In the above method (c), the amount of water used is preferably 35 to 90 parts.

[0102] In method (c), the raw material composition of the refractory thermal insulation material preferably further includes a water-reducing agent.

[0103] Here, the amount of the above-mentioned reducing agent used is the amount used conventionally in this field, preferably 0 to 50 parts, excluding 0, and may be, for example, 3 to 42 parts, or for example, 6 parts, 16 parts, 24 parts, or 36 parts.

[0104] Here, the above-mentioned water reducer is a water reducer commonly used in this field; preferably, it is one or more of a lignosulfonate water reducer, a naphthalene sulfonate water reducer, a melamine water reducer, a sulfamate water reducer, and a polycarboxylic acid high-performance water reducer, and more preferably, a polycarboxylic acid high-performance water reducer, for example, an HF retardant high-efficiency water reducer purchased from Shanghai Dongda Chemical Co., Ltd.

[0105] Here, the weight ratio of inorganic raw materials to organic raw materials is preferably 12 to 35.5, the inorganic raw materials are the siliceous material and the calcium material, and the organic raw materials are the expandable polystyrene particles and the water reducer.

[0106] In method (c), the raw material composition of the fire-resistant thermal insulation material preferably further includes reinforcing fibers.

[0107] Here, the type of reinforcing fiber is conventional in this field, and the reinforcing fiber preferably comprises one or more of wood fibers, metal fibers, and fiber cotton, more preferably fiber cotton, for example, fiber cotton purchased from Shijiazhuang Dinglong Building Materials Sales Co., Ltd.

[0108] Here, the amount of reinforcing fiber used may be the amount used conventionally in this field, preferably 2.4 to 30 parts, for example 4.8 to 30 parts, and for example 7.2 parts, 9.6 parts, 12 parts, 14.4 parts, 16.8 parts, 19.2 parts, 21.6 parts, 24 parts, 26.4 parts, or 28.8 parts.

[0109] In method (c), preferably, the mold comprises an upper mold and a lower mold, and the manufacturing method comprises the same step of initially forming fresh concrete using the upper mold and the lower mold, and locking the upper mold and the lower mold until the fresh concrete is formed by compressing it by 10% to 45% in the thickness direction after the mold is placed on a pressing platform.

[0110] In method (c), the fresh concrete is preferably compressed and molded until it reaches 17% to 38% in the thickness direction.

[0111] In method (c), preferably, multiple sets of molds are stacked sequentially and repeatedly to form fresh concrete until it is compressed by 10% to 45% in the thickness direction, and simultaneously pressed to form multiple refractory insulation boards.

[0112] In room (c), preferably, the heating temperature applied to the inside of the fresh concrete is 60°C to 150°C, for example 70°C to 140°C, and for example 80°C, 90°C, 100°C, 110°C, 120°C, or 130°C.

[0113] In method (c), preferably, the pressure applied to the mold is 0.35 MPa to 0.55 MPa.

[0114] In the method (c), during the process of forming by heating and pressurizing, a person skilled in the art may typically adjust the heating and pressurizing times according to the heating method, for example, if a heating method using conventional steam heating or a heating method using a heat transfer liquid as a heat transfer medium is used, the heating time is 30 minutes or more; and for example, if a microwave heating method is used, the heating time is 5 minutes or more.

[0115] In method (c), preferably, the manufacturing method further includes the step of placing a reinforcing member in a mold, wherein the reinforcing member comprises one or more of a metal mesh, a glass fiber mesh, a glass fiber reinforced plastic mesh, or a rib, and at least one side of the fresh concrete is embedded in the reinforcing member.

[0116] In method (c), the expandable polystyrene particles are pre-expanded polystyrene particles, and the pre-expanded polystyrene particles may be commercially available pre-expandable polystyrene particles, or the pre-expanded polystyrene particles are pre-expanded before mixing the fresh concrete, the manufacturing method further includes a pre-expanding step of the expandable polystyrene particles.

[0117] Here, in the above preliminary foaming step, the polystyrene particles can be foamed to the required gram weight according to the conventional foaming method of this field, for example, the above preliminary foaming step is to foam the expandable polystyrene particles by heating and pressurizing them.

[0118] In addition, the present invention provides a refractory thermal insulation material manufactured according to the method for manufacturing the refractory thermal insulation material.

[0119] Based on the ordinary knowledge of the field, preferred embodiments of the present invention can be obtained by arbitrarily combining the above preferred conditions.

[0120] All reagents and raw materials used in the present invention are commercially available.

[0121] The manufacturing method of the present invention has an active progressive effect in that, under the premise of maintaining the manufacturing pressure at a relatively low level, it is possible to manufacture a refractory thermal insulation material that has high tensile strength, does not easily detach after bonding, has good thermal insulation performance, and has a non-combustible fire resistance rating. Effects of the invention

[0122] In order to solve the problems existing in current technology, the present invention can provide a non-combustible fire-resistant thermal insulation material of a fire-resistant grade that has high tensile strength, does not easily detach after bonding, and has excellent thermal insulation performance, as well as a method for manufacturing the same. Specific details for implementing the invention

[0123] The present application claims priority to Chinese patent application 2020100851733, filed on February 10, 2020; priority to Chinese patent application 2020100851748, filed on February 10, 2020; and priority to Chinese patent application 2020109475779, filed on September 10, 2020. The present application incorporates the full text of the above Chinese patent applications.

[0124] The present invention will be specifically described below through examples, but the present invention is not limited to the scope of the above examples.

[0125] A detailed description of the materials that can be used in various embodiments and comparative examples of the present invention is as follows.

[0126] Silica material: The micro silica powder or fly ash of the following examples (excluding Example C-19) may be optionally substituted, wherein the micro silica powder is purchased from Shanghai Weiterui Industrial Development Co., Ltd.; and the fly ash is Type C high-calcium fly ash purchased from Shanghai Commodity Fly Ash Products Co., Ltd.;

[0127] The siliceous material used in Example C-19 is micro silica powder, and the micro silica was purchased from Huzhou Huatian Micropowder Factory.

[0128] Calcium material: The calcium material in the following examples may optionally be replaced with calcium oxide or calcium hydroxide; calcium oxide is also known as quicklime and was purchased from Taicang Dongfang Metallurgical Lime Products Factory; calcium hydroxide is also known as slaked lime and was purchased from Taicang Dongfang Metallurgical Lime Products Factory.

[0129] Polystyrene particles (expandable polystyrene particles): Purchased from Wuxi Xingda Foam Plastic New Material Co., Ltd.

[0130] Water reducer: The HF retardant high-efficiency water reducer was purchased from Shanghai Dongda Chemical Co., Ltd.

[0131] Fiber cotton: Purchased from Shijiazhuang Dinglong Building Materials Sales Co., Ltd.

[0132] Weapon-cutting fiber: Model F-16G, purchased from Beijing Xinshijiye Thermal Insulation Fiber Spraying Technology Co., Ltd.

[0133] Terminology Explanation:

[0134] Silicous material: Refers to a material that can react with calcium oxide / calcium hydroxide to produce calcium silicate.

[0135] Calcium substances: Refers to substances containing calcium oxide and / or calcium hydroxide.

[0136] Water-reducing agent: Refers to a substance capable of reducing unit water usage, improving the fluidity of fresh concrete, and enhancing workability. It includes, but is not limited to, lignosulfonate water-reducing agents, naphthalene sulfonate water-reducing agents, melamine water-reducing agents, sulfamate water-reducing agents, and polycarboxylic acid high-performance water-reducing agents.

[0137] Inorganic cutting fiber: It is an inorganic fiber with a cutting length of 1 mm to 25 mm.

[0138] In the following examples and comparative examples, A represents the weight of the siliceous material, B represents the weight of the calcium material, C represents the weight of the inorganic raw material (i.e., the total amount of the siliceous material and the calcium material), and D represents the weight of the organic raw material (i.e., expandable polystyrene particles, or polystyrene and a water reducer, or polystyrene and reinforcing fibers). By dividing the material usage data shown in the table by 10, the corresponding portion of each material can be obtained.

[0139] The detection criteria in the following examples and comparative examples are as follows: compressive strength was tested according to GB / T 5486-2008 "Test method for inorganic rigid insulation products", tensile strength perpendicular to the surface of the board was tested according to GB / T 29906-2013 "Material for molded polystyrene board thin plaster exterior thermal insulation system", combustion performance grade was tested according to GB 8624-2012 "Classification of combustion performance of building materials and products", bending deformation was tested according to GB / T 10801.1 "Molded polystyrene foam for insulation", volume absorption rate was tested according to GB / T 1034-2008 "Measurement of water absorption of plastics", and thermal conductivity was tested according to GB / T 10294 "Measurement of steady-state thermal resistance and related properties of insulation materials - method for protective thermal boards".

[0140] The method for manufacturing floor fire-resistant thermal insulation in Examples A-1 to A-90 and Comparative Examples A-1 to A-4 is as follows.

[0141] First, pre-expanded polystyrene particles were obtained by expanding the volume of polystyrene particles through heating. By setting the vapor pressure and varying the density accordingly, the density of the polystyrene particles was met to reach a density of 6 g / L to 12 g / L. The vapor pressure was set to 0.2 MPa, the temperature to 100°C, and the time to 30 seconds; the pressure was maintained for 10 seconds and then reduced for 3 seconds.

[0142] Next, water, a siliceous material (silicon dioxide), a calcium material (calcium oxide or calcium hydroxide), and potentially usable inorganic cutting fibers and a water-reducing agent were uniformly stirred at 10°C to 30°C (the stirring time was adjusted correspondingly to the temperature change, and the mixer speed was set to 300 rpm), and all were uniformly mixed to obtain a pre-stirred gelling material.

[0143] Next, pre-expanded polystyrene particles were placed in a mixing tank and a mixer was operated. Then, a pre-stirred gelling material was added and mixed and stirred to ensure sufficiently uniform mixing. After several repeated tests, the stirring speed must be set to less than 200 rpm to prevent shrinkage and deformation of the polystyrene particles. In addition, the volumetric weight of the added polystyrene material can be adjusted according to the volumetric weight required by the customer.

[0144] Next, the mixture after stirring (including the primary expanded polystyrene particles) was placed into a mold. The vertical height of the mold was adjusted under pressure until the set height was reached. Since the material shrinks at a certain rate after heating and pressurization, multiple repeated tests were conducted. For example, for a product thickness of 5 cm, it was found that the height of the level gauge should be adjusted to 6 cm to 9 cm, and the shrinkage rate is 10% to 45%. The density of the raw material composition was 230 kg / m³. 3 The internal pressure of the raw material composition was maintained at 0.55 MPa or higher so that it would be below.

[0145] Before the mold enters the pressing platform, the temperature of the oil heater is set between 50°C and 150°C, and the pressing platform is preheated. Once the temperature reaches the set value, the mold is pushed in, and molded by applying pressure for at least 35 minutes, followed by natural cooling. During the heating and pressurizing process, the polystyrene particles undergo secondary foaming in the mold, which further improves the compression ratio and further improves the tensile strength.

[0146] Finally, the molded product is cured in a curing room, which must be dry and well-ventilated, and the curing time generally takes about 5 to 10 days depending on the temperature and humidity.

[0147] Heating and pressurizing: The temperature of the mold was raised to between 50°C and 150°C, and the pressure applied to the mold was set to 0.55 MPa or higher.

[0148] Heating and pressurizing: The temperature of the mold was raised to 50°C to 150°C, the pressure applied to the mold was set to 0.55 MPa or higher, and the temperature and pressure were maintained stably for a certain period of time.

[0149] Table A-1: ​​Examples A-1 to A-4 regarding different silicon-calcium ratios

[0150]

[0151] Table A-2: Examples A-5 to A-9 regarding different silicon-calcium ratios

[0152]

[0153] Table A-3: Examples A-10 to A-14 regarding different inorganic-organic ratios

[0154]

[0155] Table A-4: Examples A-15 to A-21 regarding different inorganic-organic ratios

[0156]

[0157] Table A-5: Examples A-22 to A-26 with added water reducers at different silicon-calcium ratios

[0158]

[0159] Table A-6: Examples A-27 to A-30 with added water reducers at different silicon-calcium ratios

[0160]

[0161] Table A-7: Examples A-31 to A-35 with added water reducers at different inorganic-organic ratios

[0162]

[0163] Table A-8: Examples A-36 to A-39 with added water reducers at different inorganic-organic ratios

[0164]

[0165] Table A-9: Examples A-40 to A-46 regarding different addition rates of water reducers

[0166]

[0167] Table A-10: Examples A-47 to A-53 regarding the addition of inorganic cutting fibers

[0168]

[0169] Table A-11: Examples A-54 to A-60 regarding the addition of inorganic cutting fibers

[0170]

[0171] Table A-12: Examples A-61 to A-67 regarding the addition of inorganic cutting fibers

[0172]

[0173] Table A-13: Examples A-68 to A-72 regarding the addition of inorganic cutting fibers

[0174]

[0175] Table A-14: Examples A-73 to A-77 regarding different addition rates of inorganic cutting fibers

[0176]

[0177] Table A-15: Examples A-78 to A-83 regarding temperature ranges

[0178]

[0179] Table A-16: Examples A-84 to A-90 regarding pressure ranges

[0180]

[0181] Table A-17: Comparative Examples A-1 to A-4

[0182]

[0183] From Table A-1, it can be seen that when the weight ratio of the inorganic raw material to the polystyrene particles is maintained at 16 and the weight ratio of the siliceous material to the calcium material is 1 to 9, the compressive strength can reach 0.55 MPa or higher, the tensile strength can reach 0.174 MPa or higher, and the thermal conductivity is 0.066 or lower. From Table 2, when the weight ratio of the siliceous material to the calcium material is 1.22 to 3, the compressive strength can reach 0.567 MPa or higher, the tensile strength can reach 0.18 MPa or higher, and the thermal conductivity is 0.065 or lower. When the weight ratio of the siliceous material to the calcium material is 1.5 to 2.33, the compressive strength can reach 0.58 MPa or higher, the tensile strength can reach 0.181 MPa or higher, and the thermal conductivity is 0.0648 or lower.

[0184] From Tables A-3 and A-4, it can be seen that when the weight ratio of the siliceous material to the calcium material is 2.33 and the weight ratio of the inorganic raw material to the polystyrene particles is 10.5 to 22.1, the compressive strength can reach 0.551 MPa or higher, the tensile strength can reach 0.124 MPa or higher, and the thermal conductivity is 0.0676 or lower. When the weight ratio of the inorganic raw material to the polystyrene particles is 10.5 to 18.5, the compressive strength can reach 0.56 MPa or higher, the tensile strength can reach 0.138 MPa or higher, and the thermal conductivity is 0.0671 or lower. When the weight ratio of the inorganic raw material to the polystyrene particles is 10.5 to 14, the compressive strength can reach 0.6 MPa or higher, the tensile strength can reach 0.183 MPa or higher, and the thermal conductivity is 0.0646 or lower.

[0185] Tables A-5 and A-6 show that when the weight ratio of the inorganic raw material to the polystyrene particles is maintained at 16 and the weight ratio of the siliceous material to the calcium material is in the range of 1 to 9, and a water-reducing agent of 1% of the total weight is added, the compressive strength can reach 0.6 MPa or higher, the tensile strength can reach 0.19 MPa or higher, and the thermal conductivity can reach 0.0667 or lower. If the weight ratio of the siliceous material to the calcium material is greater than 9, the compressive strength is 0.54, which does not meet the compressive resistance requirements. If the weight ratio of the siliceous material to the calcium material is less than 1, the compressive resistance requirements are also not met.

[0186] Tables A-7 and A-8 show that when the weight ratio of the siliceous material to the calcium material is maintained at 2.33 and the weight ratio of the inorganic raw material to the polystyrene particles is 10 to 16.3, adding a water-reducing agent of 1% of the total weight of the material can achieve a compressive strength of 0.6 MPa or higher, a tensile strength of 0.142 MPa or higher, and a thermal conductivity of 0.068 or lower. Even when the weight ratio of the inorganic raw material to the polystyrene particles is less than 10.5, such as 10.2 or 10, adding a water-reducing agent can still maintain the refractory performance of the final product at the A2 level. However, when the weight ratio of the inorganic raw material to the polystyrene particles is 9.7, the refractory performance of the final product is at the B1 level. When the weight ratio of the inorganic raw material to the polystyrene particles is 16.8, the thermal conductivity is 0.0686, which does not meet the thermal insulation requirements.

[0187] In addition, from Tables A-7 and A-8, it can be seen that the addition of polystyrene particles can significantly improve the tensile strength of the thermal insulation product. In particular, in Table 8, the tensile strength reached 0.18 MPa or higher.

[0188] Table A-9 shows that adding a water-reducing agent within 4% can effectively improve tensile strength and compressive strength, while adding more than 4% makes it difficult to form the material.

[0189] Tables A-10 and A-11 show that when the weight ratio of the inorganic raw material to the polystyrene particles is maintained at 16 and the weight ratio of the siliceous material to the calcium material is in the range of 1 to 9, and an inorganic cutting fiber is added at 10% of the total weight of the material, the compressive strength can reach 0.551 MPa or higher, the tensile strength can reach 0.145 MPa or higher, and the thermal conductivity can reach 0.0673 or lower. If the weight ratio of the siliceous material to the calcium material is greater than 9, molding cannot be achieved.

[0190] Tables A-12 and A-13 show that when the weight ratio of the siliceous material to the calcium material is maintained at 7:3 and the weight ratio of the inorganic raw material to the polystyrene particles is in the range of 10.5 to 22.1, and an inorganic cutting fiber is added at 10% of the total weight of the material, the compressive strength can reach 0.606 MPa or higher, the tensile strength can reach 0.137 MPa or higher, and the thermal conductivity can reach 0.0669 or lower. When the weight ratio of the inorganic raw material to the polystyrene particles is less than 10, the fire resistance performance of the final product is B1. When the weight ratio of the inorganic raw material to the polystyrene particles is greater than 22.1, molding does not occur.

[0191] Table A-14 shows that different amounts of inorganic cutting fibers help improve strength.

[0192] From Table A-15, it can be seen that the temperature ranges from 50°C to 150°C. When the temperature is below 50°C, both tensile strength and compressive strength decrease rapidly. When the temperature exceeds 150°C, the aggregate burns.

[0193] From Table A-16, it can be seen that the pressure is 0.55 MPa or higher, and the ultimate strength of the steel mold is possible up to 235 MPa. When the pressure is 0.55 MPa or lower, the compressive strength of the final product is less than 0.55 MPa, and when the pressure is greater than 235 MPa, the mold breaks.

[0194] In Table A-17, when no water-reducing agent or inorganic cutting fiber is added, and when the weight ratio of siliceous material to calcium material is greater than 9 or less than 1, the compressive strength is less than 0.5 MPa, so it can be seen that the compressive strength does not meet the standard. If the weight ratio of the inorganic raw material to the polystyrene particles is greater than 22.1, the raw material cannot be molded and cannot be manufactured. When the weight ratio of the inorganic raw material to the polystyrene particles is less than 10.5, the refractory performance is B1, so it does not meet the refractory standard.

[0195] The method of manufacturing the wall insulation material in Examples B-1 to B-118 and Comparative Examples B-1 to B-4 is as follows.

[0196] First, pre-expanded polystyrene particles were obtained by expanding the volume of polystyrene particles through heating. By setting the vapor pressure and changing the density accordingly to satisfy the required density requirements, the density of the polystyrene particles was brought to reach 6 g / L to 12 g / L. The vapor pressure was set to 0.2 MPa, the temperature to 100°C, and the time to 30 seconds; the pressure was maintained for 10 seconds and then reduced for 3 seconds.

[0197] Next, water, a siliceous material (silicon dioxide), a calcium material (calcium oxide or calcium hydroxide), and potentially usable inorganic cutting fibers and a water-reducing agent were uniformly stirred at 10°C to 30°C (the stirring time was adjusted correspondingly to the temperature change, and the mixer speed was set to 300 rpm), and all were uniformly mixed to obtain a pre-stirred gelling material.

[0198] Next, pre-expanded polystyrene particles were placed in a mixing tank and the mixer was operated. Then, the pre-stirred gelling material was mixed and stirred to ensure sufficiently uniform mixing. After several repeated tests, the stirring speed was set to less than 200 rpm to prevent shrinkage and deformation of the polystyrene particles. In addition, the volumetric weight of the added polystyrene material can be adjusted according to the volumetric weight required by the customer.

[0199] Next, the mixture after stirring (including the primary expanded polystyrene particles) was placed into a mold. The vertical height of the mold was adjusted under pressure until the set height was reached. Since the material shrinks at a certain rate after heating and pressurization, multiple repeated tests were conducted. For example, for a product thickness of 5 cm, it was found that the height of the level gauge should be adjusted to 6 cm to 9 cm, and the shrinkage rate is 10% to 45%. The density of the raw material composition was 525 kg / m³. 3The internal pressure of the raw material composition was maintained at 2.8 MPa or higher so as to be below.

[0200] Before the mold enters the pressing platform, the temperature of the oil heater is set between 50°C and 150°C, and the pressing platform is preheated. Once the temperature reaches the set value, the mold is pushed in, and molded by applying pressure for at least 35 minutes, followed by natural cooling. During the heating and pressurizing process, the polystyrene particles undergo secondary foaming in the mold, which further improves the compression ratio and further improves the tensile strength.

[0201] Finally, the molded product is cured in a curing room, which must be dry and well-ventilated, and the curing time generally takes about 5 to 10 days depending on the temperature and humidity.

[0202] Heating and pressurizing: The temperature of the mold was raised to between 50°C and 150°C, and the pressure applied to the mold was set to 2.8 MPa or higher.

[0203] Heating and pressurizing: The temperature of the mold was raised to 50°C to 150°C, the pressure applied to the mold was set to 2.8 MPa or higher, and the temperature and pressure were maintained stably for a certain period of time.

[0204] Table B-1: Examples B-1 to B-5 regarding different silicon-calcium ratios

[0205]

[0206] Table B-2: Examples B-6 to B-11 regarding different silicon-calcium ratios

[0207]

[0208] Table B-3: Examples B-12 to B-15 regarding different silicon-calcium ratios

[0209]

[0210] Table B-4: Examples B-16 to B-21 regarding different inorganic-organic ratios

[0211]

[0212] Table B-5: Examples B-22 to B-27 regarding different inorganic-organic ratios

[0213]

[0214] Table B-6: Examples B-28 to B-32 regarding different inorganic-organic ratios

[0215]

[0216] Table B-7: Examples B-33 to B-38 with added water reducers at different silicon-calcium ratios

[0217]

[0218] Table B-8: Examples B-39 to B-44 with added water reducers at different silicon-calcium ratios

[0219]

[0220] Table B-9: Examples B-45 to B-52 with added water reducers at different inorganic-organic ratios

[0221]

[0222] Table B-10: Examples B-53 to B-60 with added water reducers at different inorganic-organic ratios

[0223]

[0224] Table B-11: Examples B-61 to B-67 regarding different water reducer addition rates

[0225]

[0226] Table B-12: Examples B-68 to B-75 regarding the addition of inorganic cutting fibers

[0227]

[0228] Table B-13: Examples B-76 to B-83 regarding the addition of inorganic cutting fibers

[0229]

[0230] Table B-14: Examples B-84 to B-89 regarding the addition of inorganic cutting fibers

[0231]

[0232] Table B-15: Examples B-90 to B-95 regarding the addition of inorganic cutting fibers

[0233]

[0234] Table B-16: Examples B-96 to B-100 regarding the addition of inorganic cutting fibers

[0235]

[0236] Table B-17: Examples B-101 to B-105 regarding different addition rates of inorganic cutting fibers

[0237]

[0238] Table B-18: Examples B-106 to B-111 regarding temperature ranges

[0239]

[0240] Table B-19: Examples B-112 to B-118 regarding pressure ranges

[0241]

[0242] Table B-20: Comparative Examples B-1 to B-4

[0243]

[0244] Table B-1 shows that when the weight ratio of the inorganic raw material to the polystyrene particles is maintained at 19.8 and the weight ratio of the siliceous material to the calcium material is 0.33 to 12.33, the compressive strength can reach 2.8 MPa, the tensile strength can reach 0.160 MPa or higher, and the thermal conductivity is 0.14 or lower. Table 2 shows that when the weight ratio of the siliceous material to the calcium material is 3.67 to 5.67, the compressive strength can reach 3.1 MPa or higher, the tensile strength can reach 0.184 MPa or higher, and the thermal conductivity is 0.126 or lower. Table 3 shows that when the weight ratio of the siliceous material to the calcium material is 1.5 to 3, the compressive strength can reach 3.5 MPa or higher, the tensile strength can reach 0.202 MPa or higher, and the thermal conductivity is 0.1275 or lower.

[0245] From Table B-4, it can be seen that when the weight ratio of the siliceous material to the calcium material is maintained at 2.33 and the weight ratio of the inorganic raw material to the polystyrene particles is 35.3 to 58.9, the compressive strength can reach 2.8 MPa, the tensile strength can reach 0.179 MPa or higher, and the thermal conductivity is 0.1285 or lower. From Table 5, when the weight ratio of the inorganic raw material to the polystyrene particles is 16 to 31.1, the compressive strength can reach 3.4 MPa or higher, the tensile strength can reach 0.273 MPa or higher, and the thermal conductivity can reach 0.1262 or lower. In Table 6, when the weight ratio of the inorganic raw material to the polystyrene particles is 10.5 to 15.4, the compressive strength can reach 3.7 MPa or higher, the tensile strength can reach 0.367 MPa or higher, and the thermal conductivity can reach 0.124 or lower.

[0246] Based on a comprehensive review of Tables B-1 through B-6, the present invention demonstrates a significant advantage in the volumetric water absorption rate of the final product; the volumetric water absorption rates of Examples 1 through 32 are basically maintained between 10% and 40%, demonstrating superiority over products of the same type. Furthermore, the dry density is 525 kg / m³. 3 Under conditions below this level, the compressive strength can reach 2.8 MPa or more, and even 3.5 MPa or more.

[0247] Tables B-7 and B-8 show that when the weight ratio of the inorganic raw material to the polystyrene particles is maintained at 19.8 and the weight ratio of the siliceous material to the calcium material is in the range of 0.54 to 9, and a water-reducing agent of 1.3% of the total weight of the material is added, the compressive strength can reach 3.8 MPa or higher, the tensile strength can reach 0.238 MPa or higher, and the thermal conductivity can reach 0.127 or lower. If the weight ratio of the siliceous material to the calcium material is greater than 12.33, the compressive strength is less than 3.8 MPa, so the compressive resistance requirements are not met. If the weight ratio of the siliceous material to the calcium material is less than 0.54, the compressive strength is also less than 3.8 MPa.

[0248] Tables B-9 and B-10 show that when the weight ratio of the siliceous material to the calcium material is maintained at 2.33 and the weight ratio of the inorganic raw material to the polystyrene particles is 10.5 to 55.8, and a water-reducing agent of 1.3% of the total weight of the material is added, the compressive strength can reach 3.8 MPa or higher, the tensile strength can reach 0.24 MPa or higher, and the thermal conductivity can reach 0.1294 or lower. When the weight ratio of the inorganic raw material to the polystyrene particles is 55.8 or higher, the thermal conductivity is greater than 0.13, so it does not satisfy the thermal insulation requirements.

[0249] The addition of a water-reducing agent brings about another significant effect, namely a drastic reduction in the volumetric water absorption rate of the product. The volumetric water absorption rates of the majority of the examples in Tables 7 to 11 are all less than 10%, which is a very low level for this type of thermal insulation material. Table 11 shows that adding a water-reducing agent within 4% can effectively improve tensile strength and compressive strength, while adding more than 4% makes molding difficult.

[0250] From Tables B-12 and B-13, it can be seen that when the weight ratio of the inorganic raw material to the polystyrene particles is maintained at 17.8 and the weight ratio of the siliceous material to the calcium material is in the range of 0.25 to 12.33, and an inorganic cutting fiber of about 5% of the total weight of the material is added, the compressive strength can reach 3.1 MPa or higher, the tensile strength can reach 0.203 MPa or higher, and the thermal conductivity can reach 0.1385 or lower. If the weight ratio of the siliceous material to the calcium material is greater than 12.33, it cannot be molded.

[0251] Tables B-14, B-15, and B-16 show that when the weight ratio of the siliceous material to the calcium material is maintained at 7:3 and the weight ratio of the inorganic raw material to the polystyrene particles is in the range of 10.5 to 58.9, adding inorganic cutting fibers, which is about 5% of the total weight of the material, can achieve a compressive strength of 3.7 MPa or higher, a tensile strength of 0.268 MPa or higher, and a thermal conductivity of 0.1272 or lower. When the weight ratio of the inorganic raw material to the polystyrene particles is less than 10, the fire resistance performance of the final product is B1. If the weight ratio of the inorganic raw material to the polystyrene particles is greater than 58.9, it cannot be molded.

[0252] Table B-17 shows that different amounts of inorganic cutting fibers help improve strength.

[0253] From Table B-18, it can be seen that the temperature is within the range of 50°C to 150°C. When the temperature is 50°C or lower, both tensile strength and compressive strength decrease rapidly. When the temperature exceeds 150°C, the aggregate burns.

[0254] From Table B-19, it can be seen that the pressure is 2.8 MPa or higher, and the ultimate strength of the mold is possible up to 235 MPa. When the pressure is less than 2.8 MPa, the compressive strength of the final product is less than 2.8 MPa, and when the pressure is greater than 235 MPa, the mold breaks.

[0255] Table B-20 shows that when no water-reducing agent or inorganic cutting fiber is added, and the weight ratio of siliceous material to calcium material exceeds 12.33 or is less than 0.33, the compressive strength is less than 2.5 MPa, so it can be seen that the compressive strength does not meet the criteria. When the weight ratio of inorganic raw material to the polystyrene particles exceeds 58.9, the compressive strength is less than 2.5 MPa, so it does not meet the compressive strength criteria. When the weight ratio of inorganic raw material to the polystyrene particles is less than 10.5, the fire resistance performance is B1, so it does not meet the fire resistance criteria.

[0256] The method for manufacturing the refractory thermal insulation material in Examples C-1 to C-103 and Comparative Examples C-1 to C-20 is as follows.

[0257] First, the polystyrene particles were expanded by heating to increase their volume and obtain pre-expanded polystyrene particles. By setting the steam pressure and changing the density accordingly, the required density requirements were met, and the density of the polystyrene particles was made to reach 4 g / L to 25 g / L.

[0258] Next, water, a siliceous material, a calcium material (calcium oxide or calcium hydroxide), and a fiber cotton and water-reducing agent that may be used were uniformly stirred and mixed at room temperature to obtain a pre-stirred gelling material.

[0259] Next, pre-expanded polystyrene particles were placed in a mixing tank and a mixer was operated, and then the pre-stirred gelling material was mixed and stirred to ensure sufficiently uniform mixing to obtain fresh concrete of all raw materials.

[0260] Next, the mixture after stirring (including pre-expanded polystyrene particles) was placed into a mold, and the vertical height of the mold was adjusted under pressure until a set height was reached. Through repeated tests, as the material shrinks at a certain rate after heating and pressurization, it was discovered that, for example, in the case of a product thickness of 5 cm, the height of the level gauge must be adjusted to 6 cm to 9 cm and the shrinkage rate is 10% to 45%. The density of the raw material composition was 230 kg / m³. 3 The internal pressure of the raw material composition was maintained at 0.28 MPa to 0.55 MPa so as to be below.

[0261] Before the mold enters the pressing platform, the temperature of the oil heater is set between 50°C and 150°C, and the pressing platform is preheated. When the temperature reaches the set value, the mold is pushed in, and then molded by applying pressure and heating, followed by natural cooling to release. During the heating and pressurizing process, the expandable polystyrene particles receive heat from the mold and undergo secondary foaming, which improves the compression ratio and further enhances the tensile strength.

[0262] Finally, the molded product was cured.

[0263] The temperature of the oil heater according to Tables 3-1 to 3-10 below is 130℃ and the pressure applied to the mold is 0.55MPa.

[0264] In Tables 3-1 to 3-12 below, the mass units of the raw materials are all g.

[0265] Table C-1: Regarding different ratios of inorganic and organic raw materials

[0266]

[0267]

[0268] Table C-2: Related to different ratios of siliceous and calcium materials

[0269]

[0270] Table C-3: Addition of water reducers under different ratios of inorganic and organic raw materials

[0271]

[0272]

[0273] Table C-4: Addition of water reducers under different ratios of siliceous and calcium materials

[0274]

[0275] Table C-5: Different addition rates of water reducers

[0276]

[0277] Table C-6: Fiber cotton addition under different ratios of inorganic and organic raw materials

[0278]

[0279]

[0280] Table C-7: Addition of fiber cotton under different ratios of siliceous and calcium materials

[0281]

[0282] Table C-8: Different Addition Ratios of Fiber Cotton

[0283]

[0284]

[0285] Table C-9: Effects of Different Temperatures

[0286]

[0287]

[0288] Table C-10: Effect of temperature on the addition of water reducers

[0289]

[0290]

[0291] Table C-11: Effects of Different Pressures

[0292]

[0293] Table C-12: Effect of pressure upon addition of water reducer

[0294]

[0295] When looking at Examples C-1 to C-15, Examples C-20 to C-33, Examples C-45 to C-59 and Comparative Examples C-1 to C-2, Comparative Example C-5, Comparative Examples C-9 to C-10 in combination, the organic raw materials of Comparative Examples C-1 to C-2 do not fall within the range defined in this application, so the refractory thermal insulation material was not molded with insufficient thickness or the combustion grade reached only B grade.

[0296] When looking at Examples C-16 to C-19, Examples C-34 to C-36, Examples C-60 to C-62 and Comparative Examples C-3 to C-4, Comparative Examples C-6 to C-7, and Comparative Examples 11 to C-12 together, since siliceous materials and calcium materials do not fall within the scope of the present application, the strength of the manufactured thermal insulation material is very low and it is hardly molded.

[0297] When looking at Examples C-37 to C-44 and Comparative Example C-8 together, it can be seen that when the ratio of water reducer added is 4.5% or more, the combustion grade can only reach Grade B.

[0298] When looking at Examples C-63 to C-76 and Comparative Example C-13 together, it can be seen that when the addition rate of reinforcing fibers is 26% or more, the fibers and pulp of the refractory thermal insulation material cannot be uniformly stirred and mixed.

[0299] When looking at Examples C-77 to C-98 and Comparative Examples C-14 to C-17 together, it can be seen that when the temperature is not in the range of 50°C to 150°C, the expandable polystyrene particles are not secondarily expanded or the aggregate may burn.

[0300] When looking at Examples C-99 to C-103 and Comparative Examples C-18 to C-20 together, it can be seen that good effects can be obtained even when the pressure is in a relatively low range of 0.28 MPa to 0.55 MPa, but when the pressure exceeds 235 MPa and is excessively high, the mold breaks.

[0301] Although specific embodiments of the present invention have been described above, those skilled in the art should understand that these are merely examples and that the scope of protection of the present invention is defined by the appended claims. Those skilled in the art may make various changes or modifications to these embodiments without departing from the principles and essence of the present invention, and all such changes and modifications fall within the scope of protection of the present invention.

Claims

Claim 1 The raw material composition of the floor fire-resistant thermal insulation comprises, in parts by weight, 90 to 100 parts of inorganic raw material, 4.25 to 8.94 parts of polystyrene particles, 30 to 94 parts of water, and 2.63 to 4.82 parts of a water-reducing agent, wherein the inorganic raw material comprises 47 to 85 parts of siliceous material and 9 to 47 parts of calcium material, and the fresh concrete of the raw material composition has a density of 210 kg / m³ of the raw material composition mixed in a mold. 3 Up to 230 kg / m² 3 A method for manufacturing a floor fireproof thermal insulation material, wherein the material is heated at a temperature inside the mold of 50°C to 150°C and pressurized at a pressure inside the mold of 0.55 MPa to 30 MPa to form a mold and then molded and released, wherein the weight ratio of the inorganic raw material and the polystyrene particles is 14 to 18.5:1, the siliceous material comprises at least one of micro silica powder, kaolin, bentonite, or diatomaceous earth, the calcium material comprises at least one of calcium oxide or calcium hydroxide, the weight ratio of the siliceous material and the calcium material is 1 to 9:1, the raw material composition further comprises inorganic cutting fibers, and the weight of the inorganic cutting fibers is 1% to 11% of the total weight of the floor fireproof thermal insulation material. Claim 2 A method for manufacturing a floor fire-resistant thermal insulation material according to claim 1, wherein the weight ratio of the siliceous material to the calcium material is 1.22 to 3:

1. Claim 3 A method for manufacturing a floor fire-resistant thermal insulation material according to claim 2, wherein the weight ratio of the siliceous material to the calcium material is 1.5 to 2.33:

1. Claim 4 In claim 1, the density of the floor fireproof thermal insulation is 220 kg / m³ 3 up to 228 kg / m² 3 Method for manufacturing floor fireproof insulation material. Claim 5 The raw material composition of the wall insulation material comprises, in parts by weight, 200 to 250 parts of inorganic raw material, 3.8 to 21.4 parts of polystyrene particles, and 63 to 250 parts of water, wherein the inorganic raw material comprises 56.2 to 208 parts of siliceous material and 16.9 to 168.7 parts of calcium material, and the fresh concrete of the raw material composition has a density of 500 kg / m³ of the raw material composition mixed in a mold. 3 Up to 525 kg / m² 3 A method for manufacturing a wall insulation material, wherein the material is heated at a temperature within the mold of 50°C to 150°C and pressurized at a pressure within the mold of 2.8 MPa to 30 MPa to form a mold and then molded and released, wherein the calcium material comprises at least one of calcium oxide or calcium hydroxide, the weight ratio of the inorganic raw material to the polystyrene particles is 24.5 to 35.3:1, the siliceous material comprises at least one of micro silica powder, kaolin, bentonite, or diatomaceous earth, the weight ratio of the siliceous material to the calcium material is 0.33 to 12.33:1, the raw material composition further comprises a water-reducing agent and an inorganic cutting fiber, and the weight of the inorganic cutting fiber is 1% to 13% of the total weight of the wall insulation material. Claim 6 A method for manufacturing a wall thermal insulation material according to claim 5, wherein the weight ratio of the siliceous material to the calcium material is 3.67 to 5.67:1 and the water-reducing agent is 0.6 to 9 parts by weight. Claim 7 A method for manufacturing a wall insulation material according to claim 5, wherein the weight ratio of the siliceous material to the calcium material is 1.5 to 3:

1. Claim 8 The raw material composition of the fire-resistant thermal insulation material comprises 3 to 11 parts by weight of expandable polystyrene particles, 101.9 to 107.9 parts by weight of a siliceous material, 12 to 18 parts by weight of a calcium material, 35 to 120 parts by weight of water, 1.6 to 50 parts by weight of a water-reducing agent, and 2.4 to 30 parts by weight of reinforcing fibers, and a step of manufacturing fresh concrete by uniformly mixing the raw material composition; A method for manufacturing a refractory thermal insulation material, comprising the steps of placing the fresh concrete into a mold, pressurizing it with a pressure inside the mold of 0.35 MPa to 0.55 MPa, and heating the fresh concrete to a temperature of 60°C to 150°C to form, release, and maintain the fresh concrete; wherein the siliceous material comprises at least one of silica sand powder, micro silica powder, slag powder, fly ash, quartz powder, kaolin, bentonite, water glass, or diatomaceous earth; wherein the calcium material comprises at least one of calcium oxide or calcium hydroxide; wherein the mold comprises an upper mold and a lower mold; and wherein the fresh concrete is formed by compressing it by 10% to 45% in the thickness direction using the upper mold and the lower mold. Claim 9 A method for manufacturing a refractory thermal insulation material according to claim 8, wherein the expandable polystyrene particles contain graphite and the water is 35 to 90 parts by weight. Claim 10 A method for manufacturing a refractory thermal insulation material according to claim 8, wherein the expandable polystyrene particles comprise 3.4 to 10 parts by weight. Claim 11 A method for manufacturing a refractory thermal insulation material according to claim 10, wherein the expandable polystyrene particles are 4.55 parts by weight, 5.1 parts by weight, 5.95 parts by weight, 6.5 parts by weight, 7 parts by weight, 7.5 parts by weight, 8 parts by weight, 8.5 parts by weight, 9 parts by weight, or 9.5 parts by weight. Claim 12 A method for manufacturing a fire-resistant thermal insulation material according to claim 8, wherein the water-reducing agent is 3 to 42 parts by weight, the water-reducing agent comprises at least one of a lignosulfonate water-reducing agent, a naphthalene sulfonate water-reducing agent, a melamine water-reducing agent, a sulfamate water-reducing agent, or a polycarboxylic acid water-reducing agent, and the reinforcing fiber comprises at least one of a wood fiber, a metal fiber, or a fiber cotton. Claim 13 A method for manufacturing a fire-resistant thermal insulation material according to claim 12, wherein the water-reducing agent is 6 parts by weight, 16 parts by weight, 24 parts by weight, or 36 parts by weight, the water-reducing agent is a polycarboxylic acid type, the reinforcing fiber is a fiber surface, and the reinforcing fiber is 4.8 to 30 parts by weight. Claim 14 A method for manufacturing a refractory thermal insulation material according to claim 13, wherein the reinforcing fibers are 7.2 parts by weight, 9.6 parts by weight, 12 parts by weight, 14.4 parts by weight, 16.8 parts by weight, 19.2 parts by weight, 21.6 parts by weight, 24 parts by weight, 26.4 parts by weight, or 28.8 parts by weight. Claim 15 A method for manufacturing a refractory thermal insulation material according to claim 12, wherein the inorganic raw material comprises at least one of the siliceous material or the calcium material, and the organic raw material comprises at least one of the expandable polystyrene particles or the water-reducing agent, and the weight ratio of the inorganic raw material to the organic raw material is 12 to 35.5:

1. Claim 16 A method for manufacturing a refractory thermal insulation material according to claim 8, wherein the fresh concrete is compressed and molded by 17% to 38% in the thickness direction. Claim 17 A method for manufacturing a refractory thermal insulation material according to claim 8, wherein a plurality of molds are stacked and the fresh concrete is compressed simultaneously until it is molded by being compressed by 10% to 45% in the thickness direction. Claim 18 A method for manufacturing a refractory thermal insulation material according to claim 8, wherein the temperature is 70℃ to 140℃. Claim 19 A method for manufacturing a refractory thermal insulation material according to claim 18, wherein the temperature is 80 ℃, 90 ℃, 100 ℃, 110 ℃, 120 ℃, or 130 ℃. Claim 20 A method for manufacturing a refractory thermal insulation material according to claim 8, wherein a reinforcing member is further disposed within the mold, the reinforcing member comprises at least one of a metal mesh, a glass fiber mesh, a glass fiber reinforced plastic mesh, or a rib, the reinforcing member is embedded in at least one side of the fresh concrete, the expandable polystyrene particles are pre-expanded polystyrene particles, and the pre-expanded polystyrene particles are manufactured by undergoing a step of pre-expanding the expandable polystyrene particles before stirring the fresh concrete. Claim 21 In claim 20, the step of pre-foaming is a method for manufacturing a refractory thermal insulation material, wherein the expandable polystyrene particles are heated and pressurized to expand them.

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