Exterior wall insulation structure of apartment complex

Abstract

According to embodiments of the present invention, an exterior wall insulation structure for a multi-unit dwelling is provided, comprising a porous ceramic insulation layer, an angle frame installed on the inner surface of a concrete exterior wall so that one side of the porous ceramic insulation layer is seated on the concrete exterior wall, and an interior finishing material formed on the other side of the porous ceramic insulation layer. The above porous ceramic insulating layer is configured to include an inner layer and an outer layer surrounding the surface of the inner layer.

Description

Technology Field

[0001] The present invention relates to an exterior wall insulation structure for multi-unit housing, and more specifically, to an exterior wall insulation structure for multi-unit housing comprising a porous ceramic insulation layer with a double-layer structure designed to be environmentally friendly, lightweight, and capable of exhibiting excellent thermal insulation effects. Background Technology

[0003] Generally, multi-unit dwellings, including apartments and villas that have spaces for multiple households to live together, such as buildings with two or more stories, are buildings with a concrete-based structure and include exterior walls made of concrete.

[0004] Energy consumption occurs in such multi-unit dwellings, and as this serves as a primary medium for providing a comfortable environment to residents, most of it arises during the process of regulating the structure of the constructed building, the condition of the outside air, and the indoor environment. Consequently, various studies are being conducted to reduce energy consumption in buildings, including multi-unit dwellings, and alternatives applicable to the field are being sought.

[0005] In the structural design of buildings such as multi-unit housing, research on strengthening insulation as a measure to reduce energy consumption is being most actively conducted, and there is a trend toward incorporating alternatives applicable in the field.

[0006] In particular, the exterior walls of multi-unit housing are exposed to the outside and require even greater insulation, making the use of insulation materials mainstream.

[0007] Insulation layers generally used on the exterior walls of multi-unit dwellings are inorganic materials capable of simultaneously achieving lightness and thermal insulation by incorporating internal pores; they have been applied in various fields, including architectural insulation, fire-resistant materials, sound-absorbing materials, and industrial filter materials. In particular, within the multi-unit construction sector, interest in lightweight materials with excellent thermal insulation performance is continuously increasing, driven by the demand for improved energy efficiency.

[0008] Conventional insulation layers have primarily utilized methods to form pores using synthetic polymer beads, chemical foaming agents, or artificial pore-forming agents. While these methods offer the advantage of relatively easy control over pore formation, they have limitations, including complex manufacturing processes, high raw material costs, and potential environmental burdens in some cases.

[0009] Accordingly, recent attempts have been made to reduce environmental burden and ensure resource circularity by utilizing renewable resources or biomass as pore-forming agents. Naturally derived materials are attracting attention as eco-friendly materials due to the relative ease of securing raw materials and the possibility of recycling waste into resources.

[0010] However, when applying naturally derived materials to the manufacture of porous ceramic insulation layers, variations are prone to occur during the mixing and dispersion processes due to the non-uniform composition and particle characteristics of the raw materials. Furthermore, the inconsistent thermal decomposition behavior during heat treatment leads to reduced reproducibility of pore formation. Additionally, differences in the amount and rate of gas generated during thermal decomposition can result in a non-uniform pore size distribution or the occurrence of localized defects.

[0011] Therefore, there is a need for technical improvements to porous ceramic insulation layer compositions that can mitigate the environmental and process limitations of existing synthetic pore-forming agents while ensuring stable pore formation and manufacturing reproducibility even when natural materials are applied. Prior art literature

[0012] Registered Patent Publication No. 10-2511673 (March 22, 2023) Republic of Korea Published Patent No. 10-2012-0126202 (November 21, 2012) Republic of Korea Published Patent No. 10-2004-0088808 (Oct. 20, 2004) The problem to be solved

[0013] The present invention has been devised to solve the aforementioned problems. The present invention aims to improve the environmental burden and process complexity associated with the conventional method of manufacturing porous ceramic insulation layers using synthetic pore-forming agents, and to provide a porous ceramic insulation layer that can ensure stable pore formation and manufacturing reproducibility while utilizing naturally derived materials.

[0014] In addition, the present invention aims to provide a porous ceramic insulation layer that can simultaneously secure structural stability and mechanical strength of the ceramic while improving lightweightness and thermal insulation performance.

[0015] The technical problems of the present invention are not limited to those mentioned above, and other unmentioned technical problems will be clearly understood by a person skilled in the art to which the present invention pertains from the description below. means of solving the problem

[0017] To solve the above technical problem, the exterior wall insulation structure of the apartment building of the present invention comprises: a porous ceramic insulation layer (100); an angle frame (200) installed on the inner surface of the concrete exterior wall (EXW) so that one side of the porous ceramic insulation layer (100) is seated on the concrete exterior wall (EXW); and an interior finishing material (300) formed on the other side of the porous ceramic insulation layer (100).

[0018] The porous ceramic insulation layer (100) is characterized by being configured to include an inner layer (110) and an outer layer (120) surrounding the surface of the inner layer (110).

[0019] The mass ratio of the inner layer (110) and the outer layer (120) is 2:1.

[0020] In addition, the present invention comprises a porous ceramic insulating layer (100) in which the inner layer (110) is formed by molding a composition comprising 120 to 150 parts by weight of kaolin, 25 to 35 parts by weight of heat-treated coconut shell powder, 28 to 37 parts by weight of rice husk powder, 0.5 to 1.5 parts by weight of polyγ-glutamic acid (PGA), and 0.3 to 0.5 parts by weight of polyvinylamino (PVAm); and the outer layer (120) is formed by molding a composition comprising 50 to 60 parts by weight of kaolin, 5 to 15 parts by weight of ash derived from Chlorella vulgaris, 4 to 15 parts by weight of clinoptilolite, 15 to 25 parts by weight of mullite, 3 to 8 parts by weight of waste glass powder, and 0.5 to 1.5 parts by weight of silica sol. A porous ceramic insulation layer (100) is provided, which is formed by molding an outer layer (120) composition of an insulation layer (100).

[0021] In addition, the present invention provides a porous ceramic insulating layer (100) in which the porosity of the inner layer (110) is 40 to 65 volume% and the porosity of the outer layer (120) is 7 to 20 volume%. Effects of the invention

[0023] According to embodiments of the present invention, the exterior wall insulation structure of a multi-unit dwelling according to the present invention is formed with a porous ceramic insulation layer having a double-layer structure having different pore structures, thereby simultaneously securing excellent thermal insulation performance due to the high porosity of the inner layer and mechanical strength and heat resistance due to the dense structure of the outer layer. In particular, natural pore-forming agents such as heat-treated coconut shell powder and rice husk powder included in the inner layer form a uniform and interconnected pore structure during the calcination process, effectively suppressing heat transfer and enabling the realization of an eco-friendly high-porous structure. Meanwhile, Chlorella-derived ash included in the outer layer is an inorganic composite oxide component formed by high-temperature calcination, which densifies the microstructure of the outer layer and improves thermal stability and long-term durability.

[0024] The effects according to the technical concept of the present invention are not limited to those mentioned above, and other unmentioned effects will be clearly understood by a person skilled in the art from the description below. Brief explanation of the drawing

[0026] FIG. 1 is a schematic perspective view of an exterior wall insulation structure of a multi-unit dwelling according to some embodiments of the present invention. Figure 2 is a conceptual diagram illustrating a porous ceramic insulation layer applied to the exterior wall insulation structure of the above-mentioned multi-unit housing. Specific details for implementing the invention

[0027] Preferred embodiments of the present invention are described in detail below. The advantages and features of the present invention and the methods for achieving them will become clear by referring to the embodiments described in detail below. However, the present invention is not limited to the embodiments disclosed below but can be implemented in various different forms. These embodiments are provided merely to ensure that the disclosure of the present invention is complete and to fully inform those skilled in the art of the scope of the invention, and the present invention is defined only by the scope of the claims. Throughout the specification, the same reference numerals refer to the same components.

[0028] Unless otherwise defined, all terms used in this specification (including technical and scientific terms) may be used in a meaning that is commonly understood by those skilled in the art to which the present invention pertains. Additionally, terms defined in commonly used dictionaries are not to be interpreted ideally or excessively unless explicitly and specifically defined otherwise.

[0029] Additionally, the singular form in this specification may include the plural form unless specifically stated otherwise in the text. As used in this specification, "comprises" and / or "comprising" do not exclude the presence or addition of one or more other components, steps, actions, and / or elements to the mentioned components, steps, actions, and / or elements.

[0030] FIG. 1 is a schematic perspective view of an exterior wall insulation structure of a multi-unit dwelling according to some embodiments of the present invention, and FIG. 2 is a conceptual diagram for explaining a porous ceramic insulation layer applied to the exterior wall insulation structure of the multi-unit dwelling.

[0031] Referring to FIGS. 1 and 2, the exterior wall insulation structure of the apartment building of the present invention may include a porous ceramic insulation layer (100), an angle frame (200), and an interior finishing material (300).

[0032] The porous ceramic insulation layer (100) can be installed by first installing an angle frame (200) on a concrete outer wall (CW), and then fitting the porous ceramic insulation layer (100) so that the porous ceramic insulation layer (100) is physically supported by the angle frame (200).

[0033] Although not shown, a separate adhesive film or adhesive may be additionally used between one side (outer side) of the porous ceramic insulation layer (100) and the inner side of the concrete outer wall (EXW) and / or in the bonding area between the porous ceramic insulation layer (100) and the angle frame (200) to strengthen the fixing force of the porous ceramic insulation layer (100).

[0034] In this embodiment, the angle frame (200) is shown as being composed of a pair of straight angle bars arranged at the top and bottom, but it goes without saying that the shape of the angle frame (200) is not limited to this.

[0035] The above interior finishing material (300) can be formed on the other side (inner side) of the porous ceramic insulation layer (100) after the porous ceramic insulation layer (100) is fixed to the concrete outer wall (EXW).

[0036] The above interior finishing material (300) can be applied to the other side (inner side) of the porous ceramic insulation layer (100) using various materials such as mortar, sheets, or interior panels.

[0037] Below, the porous ceramic insulation layer (100) applied to the exterior wall insulation structure of the above-mentioned multi-unit dwelling will be described in more detail.

[0038] As illustrated in FIG. 2, the porous ceramic insulating layer (100) of the present invention may be configured to include an inner layer (110) and an outer layer (120) surrounding the surface of the inner layer (110).

[0039] That is, the outer layer (120) is a coating layer formed along the surface of the inner layer (110), and can be formed with a uniform thickness within each face of the inner layer (110). In addition, the thickness of the outer layer (120) may be formed differently for each face of the inner layer (110), or it may be formed with the same thickness for all faces of the inner layer (110).

[0040] Preferably, the mass ratio of the inner layer (110) and the outer layer (120) may be 2:1. By setting the mass ratio of the inner layer (110) and the outer layer (120) to 2:1, a highly porous insulating layer is predominantly formed in the overall structure, thereby ensuring excellent thermal insulation performance and lightweight properties. As the inner layer (110) occupies a relatively large proportion, an air layer structure containing a number of open pores is sufficiently maintained, effectively suppressing heat transfer.

[0041] Meanwhile, the outer layer (120) is formed to be about half the mass of the inner layer (110) to provide surface hardness and mechanical strength, and functions as a dense protective layer that protects the inner layer (110) from external impact and moisture penetration. Accordingly, a balance between thermal insulation and durability can be effectively achieved.

[0042] In some embodiments, the inner layer (110) may be formed by molding a porous ceramic insulating layer (100) inner layer (110) composition comprising 120 to 150 parts by weight of kaolin, 25 to 35 parts by weight of heat-treated coconut shell powder, 28 to 37 parts by weight of rice husk powder, 0.5 to 1.5 parts by weight of polyγ-glutamic acid (PGA), and 0.3 to 0.5 parts by weight of polyvinylamino (PVAm).

[0043] Additionally, the outer layer (120) may be formed by molding a porous ceramic insulating layer (100) outer layer (120) composition comprising 50 to 60 parts by weight of kaolin, 5 to 15 parts by weight of ash derived from Chlorella vulgaris, 4 to 15 parts by weight of clinoptilolite, 15 to 25 parts by weight of mullite, 3 to 8 parts by weight of waste glass powder, and 0.5 to 1.5 parts by weight of silica sol.

[0044] Kaolin is a clay mineral composed of hydroxylated aluminosilicate (Al2Si2O5(OH)4) and acts as a basic matrix in both the inner layer (110) and the outer layer (120) in the present invention. Kaolin provides plasticity during the molding stage and provides structural stability to each layer by forming a ceramic skeleton through dehydration and structural rearrangement during the firing process. In particular, the inner layer (110) forms a ceramic skeleton connecting the pores created by the pore-forming agent, and the outer layer (120) provides a basis for a dense microstructure to ensure hardness and heat resistance.

[0045] Heat-treated coconut shell powder is prepared by first drying washed and dried coconut shells at 150 to 200°C to remove moisture and low-boiling point organic matter, and then performing a second thermal stabilization treatment at 300 to 450°C. During the second heat treatment process, some of the cellulose and hemicellulose are thermally decomposed to form a fine carbonized layer, and the fiber structure is mechanically stabilized. Subsequently, the heat-treated coconut shells are cooled to room temperature, ground using a pin mill, and then sieved to control the particle size to a range of 60 to 140 mesh to obtain heat-treated coconut shell powder. The heat-treated coconut shell powder controlled to the above particle size range can be uniformly dispersed within a ceramic composition and induces stable pore formation during the firing process.

[0046] As a result, during the ceramic firing process at 800°C or higher, the organic components are not rapidly burned but gradually decomposed and oxidized to form relatively large-diameter elliptical or channel-shaped pores within the inner layer (110). In particular, the channel-shaped pores formed continuously along the fiber arrangement direction form an interconnected structure to form an open pore network, which segments the direct heat transfer path and increases heat transfer resistance.

[0047] In addition, if the particle size of the heat-treated coconut shell powder is coarser than 60 mesh, the variation in the size of the pores formed increases, and the pore structure of the inner layer (110) may become non-uniform, and if it is finer than 140 mesh, some pores may be partially closed during the firing process, and the thermal insulation performance may be reduced.

[0048] Meanwhile, in the composition of the inner layer (110) constituting the ceramic of the present invention, if the heat-treated coconut shell powder is less than 25 parts by weight, such continuous channel structure is not sufficiently formed, and thus the thermal insulation effect may be limited, and if it exceeds 35 parts by weight, the ratio of organic material to the ceramic frame becomes excessive, and there is a risk of shrinkage imbalance or structural collapse occurring during ceramic firing.

[0049] Rice husk powder is used after washing, grinding, and sieving to a size of 80 to 200 mesh. Rice husks are a plant byproduct with a high silica content, and they leave behind a fine silica residual structure after organic components are burned during the ceramic firing process. If particles coarser than 80 mesh are used, the variation in pore size formed increases, which may lead to stress concentration; if particles finer than 200 mesh are used, the pores become excessively fine, and some may become blocked during the sintering process.

[0050] Rice husk powder within an appropriate particle size range forms medium-sized dispersion pores around the large channel pores formed by heat-treated coconut shell powder, thereby realizing a multi-pore structure in which large and medium-sized pores are hierarchically connected. This hierarchical pore structure substantially reduces thermal conductivity by hindering heat transfer through simple linear paths and forming complex paths that bypass heat flow.

[0051] Polyγ-glutamic acid (PGA) is a water-soluble polymer in which γ-glutamic acid is repeatedly bonded. It acts as a binder in the composition of the inner layer (110) of the present invention by imparting viscosity during the water-based mixing process, thereby inducing uniform dispersion of the pore-forming agent and kaolin particles. PGA imparts viscosity in the presence of moisture to induce uniform dispersion of the heat-treated coconut shell powder and rice husk powder. During the drying stage, it forms physical bonds between polymer chains and with the surface of inorganic particles, thereby improving the green strength of the molded body and suppressing the phenomenon of the pore-forming agent locally aggregating or detaching before the firing stage. Accordingly, pores are uniformly distributed throughout the inner layer (110), and a uniform high-porous structure is maintained even after firing. This homogeneous pore structure provides the effect of reducing variations in thermal insulation performance and improving structural stability.

[0052] Polyvinylamino (PVAm) is a water-soluble polymer containing repeating vinylamine units and contains a number of amine groups (-NH₂ or cationic -NH₃), so it functions as an auxiliary binder and dispersion stabilizer in the composition of the inner layer (110).

[0053] In particular, the composition of the inner layer (110) includes not only inorganic powders such as kaolin but also natural pore-forming agents such as heat-treated coconut shell powder and rice husk powder, so inter-particle segregation, buoyancy, local aggregation, and uneven drying shrinkage are likely to occur during the mixing, molding, and drying stages.

[0054] Polyvinylamino (PVAm) can be adsorbed through electrostatic attraction and hydrogen bonding with negatively charged sites, such as hydroxyl groups on the silica / alumina surface of the kaolin particles, and silica components or oxygen-containing functional groups on the rice husk powder surface, in order to mitigate these problems in the aqueous mixing process. As a result, the polyvinylamino (PVAm) polymer chains form bridging bonds that simultaneously capture and connect the separated particles, thereby helping to maintain a uniform dispersion state of the powder and pore-forming agent in the inner layer (110) composition.

[0055] In addition, when PVAm is used together with polyγ-glutamic acid (PGA), it forms a composite binder system, which can further improve the structural stability of the inner layer (110) molded body. Specifically, PGA has carboxyl groups (-COOH / -COO). - While it contains a large number of ) groups, PVAm contains amine groups (-NH2 / -NH3 + Since it contains a large number of ), a polymer network (polyelectrolite composite) that is interconnected by ionic interactions or hydrogen bonding can be formed within the mixture. Such a composite bonding structure contributes to increasing the mechanical strength (green strength) of the pre-sintering molded body, which prevents the inner layer (110) molded body from easily breaking or cracking during the pre-sintering stage (immediately after molding or during drying).

[0056] In particular, when the pore-forming agent in the inner layer (110) begins to pyrolyze and burn during the initial firing process, if the molded body framework is not sufficiently maintained, local collapse may occur in the pore-forming section. The polyvinylamino (PVAm) and polyvinylamino (PVAm) composite binder system maintains inter-particle bonding and provides structural support even at the point of pore formation, thereby being advantageous for securing a uniform pore distribution and reproducibility of the pore structure. Therefore, PVAm alone contributes to dispersion stability and bonding strength, and when used in combination with PGA, it plays a role in simultaneously enhancing the homogeneity of the inner layer (110), crack suppression, and structural stabilization effects.

[0057] Chlorella vulgaris-derived ash is a component for converting Chlorella biomass into an inorganic complex oxide resource and providing it to the composition of the outer layer (120). It can be produced by recovering cultured Chlorella vulgaris, washing it to remove culture solution components and impurities, then drying it to reduce moisture content, and then calcining it at high temperature to remove organic components.

[0058] In one embodiment of the present invention, dried Chlorella vulgaris biomass is calcined at a temperature of 600 to 900°C for 2.5 to 4.0 hours to oxidize and remove organic matter, such as carbon components, proteins, and lipids, and obtain the remaining inorganic components in the form of ash. Unlike simple dried material, this calcination process removes organic components, thereby minimizing defects caused by organic residues (weakening due to residual carbon, pore defects, combustion non-uniformity) in the outer layer (120) and is advantageous for maintaining the density and high-temperature stability required for the outer layer (120) as a coating layer. Additionally, the ash obtained after calcination can be adjusted to have a particle size range that can be uniformly dispersed within the composition of the outer layer (120) through a grinding and pulverization process. Specifically, the Chlorella-derived ash obtained after calcination can be ground using a grinder such as a pin mill, and then adjusted to a particle size range of 100 to 200 mesh through a sieving process for use. The ash within the above particle size range is uniformly dispersed within the composition of the outer layer (120) and effectively fills the fine pores between the kaolin-based matrix particles, which is advantageous for promoting the densification of the microstructure of the outer layer (120) during the firing process.

[0059] The ash derived from Chlorella vulgaris generally contains composite inorganic components including silica (SiO2), alkali metal oxides, alkaline earth metal oxides, and other metal oxide components, and functions as a microfiller and reactive inorganic reinforcing material in the outer layer (120). That is, within the composition of the outer layer (120), the fine particles of the ash provide a microfilling effect that fills the inter-particle voids of the kaolin-based matrix, thereby reducing voids during the drying stage, and during the calcination process, they act as oxide components capable of diffusion and reaction within the matrix, thereby promoting the densification of the microstructure.

[0060] In particular, the outer layer (120) is a coating layer surrounding the inner layer (110) and must maintain a relatively low porosity. Chlorella vulgaris-derived ash can work together with waste glass powder and silica sol to strengthen inter-particle bonding during firing and contribute to controlling the microstructure in a way that suppresses defects (micro-cracks, excessive open pores) in the surface layer.

[0061] Clinoptilolite is a naturally derived zeolite and is a crystalline porous mineral having a regular aluminosilicate framework. When used with Chlorella-derived ash in the outer layer (120), the fine crystal structure is dispersed within the ceramic matrix to form a fine reinforcing structure and improve thermal stability and structural strength.

[0062] Mullite is Al6Si2O 13 As a high-temperature stable ceramic phase having a composition, it provides excellent heat resistance and mechanical strength. By being included in the outer layer (120), it maintains structural stability even in a high-temperature environment and improves resistance to external impact.

[0063] Waste glass powder is a fine powder obtained by crushing recycled glass collets, which is partially softened or melted during the firing process to promote bonding between particles. Accordingly, the densification of the outer layer (120) is promoted, and surface hardness and durability are improved.

[0064] Silica sol is a silicon dioxide dispersion in colloidal form and is used as a binder in the composition of the outer layer (120). Silica sol forms inter-particle bonds during the drying process to improve the strength of the molded body, and is converted into inorganic silica upon firing to contribute to the formation of a dense structure of the outer layer (120). In particular, unlike organic binders, it does not leave residual carbon after firing, which is advantageous for maintaining the high-temperature stability and purity of the outer layer (120).

[0065] In the porous ceramic insulation layer (100) of the present invention having the composition as described above, the inner layer (110) functions as an insulation layer having a relatively high porosity, and the outer layer (120) provides mechanical strength and surface hardness as a dense coating layer surrounding the inner layer (110) with a uniform thickness. Accordingly, the inner layer (110) performs an insulation function that suppresses heat transfer, and the outer layer (120) acts as a protective layer that protects the inner layer (110) from external forces, wear, and the external environment.

[0066] Preferably, the porosity of the inner layer (110) of the porous ceramic insulation layer (100) is 40 to 65 volume%, and the porosity of the outer layer (120) is 7 to 20 volume%.

[0067] The porosity of the inner layer (110) is formed in the range of 40 to 65 volume% because a natural pore-forming agent, such as heat-treated coconut shell powder and rice husk powder, is thermally decomposed and burned stepwise during the calcination process, thereby forming a number of pores within the matrix of the inner layer (110).

[0068] Specifically, the heat-treated coconut shell powder forms relatively large irregular spherical pores and channel-shaped pores extended along the fiber direction, and the rice husk powder in the range of 80 to 200 mesh forms medium-sized dispersed pores in between, thereby forming a multi-pore structure in which large pores and medium pores are complexly connected.

[0069] This interconnected open-pore network maintains a layer of stagnant air inside to effectively suppress heat transfer, while providing lightweight properties and improving thermal insulation performance.

[0070] If the porosity of the inner layer (110) is less than 40 volume%, the proportion of the air layer formed is insufficient, and the effect of reducing thermal conductivity may be limited. If it exceeds 65 volume%, the ceramic framework is excessively reduced, which may increase the risk of reduced compressive strength, uneven firing shrinkage, or structural collapse. Therefore, the above range is set to achieve a balance between thermal insulation performance and structural stability.

[0071] Meanwhile, the porosity of the outer layer (120) is set to a range of 7 to 20 volume% because Chlorella-derived ash, clinoptilolite, mullite, and waste glass powder are mixed into a kaolin-based ceramic matrix to form a dense microstructure when fired.

[0072] In particular, the waste glass powder is partially softened during the firing process to promote inter-particle bonding, and the silica sol forms an inorganic bonding network during the drying and firing process to induce densification of the outer layer (120).

[0073] In addition, Chlorella vulgaris-derived ash acts as a fine filler to compensate for the voids between particles, thereby contributing to lowering the porosity of the outer layer (120).

[0074] The outer layer (120) formed by such a composition has a relatively low porosity and a structure mainly consisting of fine closed pores, which improves surface hardness, wear resistance, and heat resistance, and performs the function of protecting the inner layer (110) from the external environment.

[0075] If the porosity of the outer layer (120) is excessively low at less than 7 volume%, the risk of internal stress accumulation and cracking due to plastic shrinkage may increase, and if it exceeds 20 volume%, the density may decrease, resulting in reduced surface strength and durability and vulnerability to moisture penetration. Therefore, the above range is set to simultaneously secure the protective function and structural stability of the outer layer (120).

[0076] The present invention will be described in detail below through examples. However, the following examples are intended to specifically explain the present invention, and the scope of the present invention is not limited by these examples.

[0078] <Preparation Example>

[0079] Preparation Example 1. Preparation of heat-treated coconut shell powder

[0080] Heat-treated coconut shell powder was prepared as follows. 500 g of commercially purchased coconut shells were washed twice with distilled water to remove surface impurities and salt. The washed coconut shells were dried in a dryer set at 105°C for 12 to 24 hours to remove residual moisture, after which they were cut and coarsely ground. 300 g of the dried and coarsely ground coconut shells were placed in a heat-resistant container, placed in an electric furnace, and subjected to a first heat treatment by maintaining the furnace at 150 to 200°C for 2 to 4 hours to remove moisture and low-boiling point volatile components. Subsequently, the first heat-treated coconut shell was heated to 300 to 450 °C in the same electric furnace and maintained for 2 to 6 hours to thermally decompose some of the cellulose and hemicellulose of the first heat-treated coconut shell, thereby forming a fine carbonized layer and mechanically stabilizing the fiber structure. The second heat-treated coconut shell was cooled at room temperature, then ground using a pin mill, and sieved to obtain heat-treated coconut shell powder with a particle size of 60 to 140 mesh.

[0082] Preparation Example 2. Preparation of rice husk powder with a particle size range of 80 to 200 mesh

[0083] Rice husk powder was prepared as follows. 600 g of commercially purchased rice husk was taken, washed twice with distilled water, and dried in a dryer at 80 to 110°C for 12 to 24 hours. 450 g of the dried rice husk was ground using a ball mill, and then only particles in the range of 80 to 200 mesh were selected using a sieve to obtain rice husk powder.

[0085] Preparation Example 3. Preparation of ash derived from Chlorella (Chlorella vulgaris)

[0086] Chlorella-derived ash was prepared as follows. 400 g of commercially purchased dried Chlorella (Chlorella vulgaris) biomass was washed twice with distilled water to remove impurities and residual salts derived from the culture medium. The washed biomass was dried in a dryer at 80 to 105°C for 12 to 24 hours to reduce the moisture content by approximately 80 to 95% compared to the initial amount, and the final moisture content was adjusted to 3 to 8 weight%. 300 g of the dried biomass was placed in an electric furnace and calcined at a temperature range of 600 to 900°C for 2.5 to 4.0 hours to oxidize and remove organic components such as proteins and lipids, and to obtain the remaining inorganic components in the form of ash. The ash obtained after calcination was ground with a pin mill and sieved to a mesh range of 100 to 200 to obtain finely pulverized Chlorella-derived ash that can be uniformly dispersed within the outer layer (120) composition.

[0088] <Examples and Comparative Examples>

[0089] Example 1. Preparation of an inner layer (110) composition containing heat-treated coconut shell powder

[0090] An inner layer (110) composition was prepared by combining 100g of kaolin, 120g of the rice husk powder of Preparation Example 2, 2g of polyγ-glutamic acid (PGA), and 1.5g of polyvinylamino (PVAm) with 100g of the heat-treated coconut shell powder prepared in Preparation Example 1.

[0092] Comparative Example 1. Preparation of an inner layer (110) composition comprising unheat-treated coconut shell powder.

[0093] 500 g of commercially purchased coconut shells were washed and dried at 105°C, then immediately ground in a pin mill without performing separate heat stabilization treatment and sieved to a range of 60 to 140 mesh to obtain unheat-treated coconut shell powder.

[0094] 100g of the above unheat-treated coconut shell powder was taken and combined with 100g of kaolin, 120g of the rice husk powder of Preparation Example 2, 2g of polyγ-glutamic acid (PGA), and 1.5g of polyvinylamino (PVAm) to prepare an inner layer (110) composition.

[0096] Example 2. Preparation of an inner layer (110) composition comprising rice husk powder with a particle size range of 80 to 200 mesh.

[0097] An inner layer (110) composition was prepared by combining 100g of kaolin, 100g of the heat-treated coconut shell powder of Preparation Example 1, 2g of polyγ-glutamic acid (PGA), and 1.5g of polyvinylamino (PVAm) with 120g of the rice husk powder prepared in Preparation Example 2.

[0099] Comparative Example 2. Preparation of an inner layer (110) composition comprising rice husk powder with a particle size range of less than 80 mesh and greater than 200 mesh.

[0100] During the rice husk grinding process of Preparation Example 2 above, a powder coarser than 80 mesh or finer than 200 mesh was obtained.

[0101] 120g of rice husk powder with a particle size range of less than 80 mesh and more than 200 mesh was taken and mixed with 100g of kaolin, 100g of the heat-treated coconut shell powder of Preparation Example 1, 2g of polyγ-glutamic acid (PGA), and 1.5g of polyvinylamino (PVAm) to prepare an inner layer (110) composition.

[0103] Example 3. Preparation of an outer layer (120) composition containing ash derived from Chlorella

[0104] An outer layer (120) composition was prepared by combining 100g of kaolin, 28g of ash derived from Chlorella of Example 3, 12g of clinoptilolite, 36g of mullite, 10g of waste glass powder, and 2g of silica sol.

[0106] Comparative Example 3. Preparation of an outer layer (120) composition containing wood ash

[0107] An outer layer (120) composition was prepared by combining 100g of kaolin, 28g of commercially available wood ash, 12g of clinoptilolite, 36g of mullite, 10g of waste glass powder, and 2g of silica sol.

[0109] <Experimental Example>

[0110] Experimental Example 1. Comparison of physical properties of the inner layer (110) depending on whether the coconut shell powder is heat-treated.

[0111] An inner layer (110) specimen was prepared according to the following method using the inner layer (110) composition according to Example 1 and Comparative Example 1 above.

[0112] First, 200 g of the inner layer (110) composition of Example 1 and 200 g of the inner layer (110) composition of Comparative Example 1 were each mixed with 25 mL of distilled water and mixed using a mixer for at least 10 minutes to produce a uniform mixture.

[0113] After filling the above mixture into a rectangular mold (40 mm × 40 mm × 10 mm), a rectangular molded body was manufactured by press-molding using a hydraulic press at a pressure of 10 to 20 MPa for 60 seconds. The molded body was dried in a dryer set to 110°C for 24 hours, then placed at regular intervals on an alumina setter so as not to come into contact with each other and loaded into an electric furnace. Sintering was performed under conditions where the temperature was raised to 300°C at a heating rate of 5°C / min and maintained for 1 hour, then raised to 850°C and maintained for 2 hours, followed by natural cooling. Through the above process, the inner layer (110) specimens of Example 1 and Comparative Example 1 were manufactured.

[0114] The porosity of the manufactured inner layer (110) specimen was measured using the Archimedes method, the compressive strength was measured using a universal testing machine, and the average pore diameter was calculated by image analysis after observing the cross-section of the specimen with a scanning electron microscope (SEM). The results are shown in Table 1 below.

[0116] division Porosity (vol%) Compressive strength (MPa) Pore ​​diameter (μm, mean ± standard deviation) Example 1 55.9 8.3 175±19 Comparative Example 1 68.1 4.5 325±27

[0117] As shown in Table 1 above, when heat-treated coconut shell powder is used, it was confirmed that the excessive increase in porosity of the ceramic inner layer (110) is suppressed, and it is stably formed within the pore structure range required by the present invention. In addition, Example 1, which used heat-treated coconut shell powder, showed that the average pore diameter decreased by about 46% and the compressive strength increased by about 84% compared to Comparative Example 1.

[0118] This is believed to be because the rapid combustion of organic components during the calcination process is suppressed by performing a secondary thermal stabilization treatment on the coconut shell powder, and consequently, the formation of pores in the inner layer (110) is controlled more uniformly.

[0120] Experimental Example 2. Comparison of physical properties of the inner layer (110) according to the particle size range of rice husk powder.

[0121] An inner layer (110) specimen was prepared in the following manner using the inner layer (110) composition according to Example 2 and Comparative Example 2 above.

[0122] First, 200 g of the inner layer (110) composition of Example 2 and 200 g of the inner layer (110) composition of Comparative Example 2 were each mixed with 25 mL of distilled water and mixed using a mixer for at least 10 minutes to produce a uniform mixture.

[0123] After filling the above mixture into a rectangular mold (40 mm × 40 mm × 10 mm), a rectangular molded body was manufactured by press-molding using a hydraulic press at a pressure of 10 to 20 MPa for 60 seconds. The molded body was dried in a dryer set to 110°C for 24 hours, then placed at regular intervals on an alumina setter so as not to come into contact with each other and loaded into an electric furnace. Sintering was performed under conditions where the temperature was raised to 300°C at a heating rate of 5°C / min and maintained for 1 hour, then raised to 850°C and maintained for 2 hours, followed by natural cooling. Through the above process, specimens of the inner layer (110) of Example 2 and Comparative Example 2 were prepared.

[0124] The porosity of the manufactured inner layer (110) specimen was measured using the Archimedes method, the compressive strength was measured using a universal testing machine, and the average pore diameter was calculated by image analysis after observing the cross-section of the specimen with a scanning electron microscope (SEM). The results are shown in Table 2 below.

[0126] division Porosity (vol%) Average pore size (μm, mean ± standard deviation) Thermal conductivity (W / m·K) Example 2 54.4 182±12 180 Comparative Example 2 66.8 284±36 295

[0127] As shown in Table 2 above, Example 2, which used rice husk powder with a particle size range of 80 to 200 mesh, showed a lower porosity compared to Comparative Example 2, and exhibited a tendency for the average pore diameter to decrease. In addition, Example 2 showed a smaller standard deviation of pore diameter compared to Comparative Example 2, indicating a tendency for reduced variation in the pore diameter distribution, confirming that the pores were formed with a uniform size. Furthermore, the thermal conductivity of Example 2 was lower than that of Comparative Example 2, confirming that the thermal insulation performance was improved.

[0129] Experimental Example 3. Comparison of physical properties of the outer layer (120) according to the addition of Chlorella-derived ash.

[0130] According to the method below, an outer layer (120) specimen was prepared using the compositions of Example 3 and Comparative Example 3, respectively.

[0131] First, 20 g of distilled water was added to each of the outer layer (120) composition of Example 3 and the outer layer (120) composition of Comparative Example 3, and the mixture was uniformly mixed in a mixer. The mixture was filled into the same rectangular mold (40 mm × 40 mm × 10 mm), and then a molded body was manufactured by pressurizing it with a pressure of 20 MPa using a hydraulic press.

[0132] The above molded body was dried in a dryer at 110°C for 24 hours and then loaded into an electric furnace. Sintering was performed under conditions where the temperature was raised to 300°C at a heating rate of 5°C / min and maintained for 1 hour, then raised to 900°C and maintained for 2 hours, and then cooled naturally. Through the above process, the outer layer (120) specimens of Example 3 and Comparative Example 3 were prepared.

[0133] The porosity of the manufactured outer layer (120) specimen was measured using the Archimedes method, the bending strength was measured using a three-point bending test, and the compressive strength was measured using a rectangular specimen, and the results are as shown in Table 3 below.

[0135] division Porosity (vol%) Bending strength (MPa) Compressive strength (MPa) Example 3 14.8 30.2 66.0 Comparative Example 3 24.3 19.5 43.1

[0136] As shown in Table 3 above, the outer layer (120) specimen of Example 3 containing Chlorella-derived ash showed a tendency for reduced porosity and increased bending strength and compressive strength compared to the outer layer (120) specimen of Comparative Example 3. This is believed to be because the Chlorella-derived ash acts as a fine filler within the composition of the outer layer (120), reducing inter-particle voids, and the microstructure of the outer layer (120) is formed relatively densely during the firing process.

[0138] Experimental Example 4. Evaluation of ceramic thermal insulation performance according to the mass ratio of the inner layer (110) and the outer layer (120).

[0139] In order to determine the effect of the mass ratio of the inner layer (110) and the outer layer (120) on the thermal insulation performance of the ceramic in the double-layer porous ceramic insulation layer (100) according to the present invention, a plurality of double-layer specimens were manufactured in which the composition of the inner layer (110) and the outer layer (120) was kept the same but only the mass ratio was different, and the thermal conductivity and thermal resistance of each specimen were measured.

[0140] At this time, the inner layer (110) composition for manufacturing the inner layer (110) specimen was prepared according to the composition ratio of Example 1, and the outer layer (120) composition for manufacturing the outer layer (120) specimen was prepared according to the composition ratio of Example 3, and the inner layer (110) and outer layer (120) compositions were each mixed in a mixer for 15 minutes with distilled water added so that the solid content was about 75% by weight.

[0141] According to each mass ratio condition, an inner layer (110) molded body (rectangular prism, 50 mm x 50 mm x 10 mm) was first molded, and then an outer layer (120) composition was coated to surround the entire surface of the inner layer (110) molded body to produce a double-layer molded body. At this time, the amount of coating of the outer layer (120) was adjusted so that the mass ratio of the inner layer (110) and the outer layer (120) became (i) 1:1, (ii) 2:1, and (iii) 4:1, respectively. The double-layer molded body was dried at 110°C for 24 hours, placed on an alumina setter, and loaded into an electric furnace. It was heated to 300°C at a heating rate of 5°C / min in an atmospheric atmosphere and maintained for 1 hour, then heated to 900°C and maintained for 2 hours, and then naturally cooled and fired.

[0142] The thermal insulation performance of the specimen after firing was measured using the heat flow meter method, and the effective thermal conductivity (k_eff) was calculated for the specimen thickness direction (inner layer (110) specimen 10 mm direction). In addition, the thermal resistance (R) of the specimen was calculated as R = t / k_eff (t: specimen thickness). For each condition, three specimens (n=3) manufactured under the same conditions were measured, and the results are shown in Table 4 below.

[0144] Mass ratio (inner layer (110):outer layer (120)) Effective thermal conductivity (W / m·K) Thermal resistance (m 2 ·K / W) Bulk density (g / cm³) 3 ) 1:1 0.165 ± 0.006 0.061 ± 0.002 0.88 ± 0.03 2:1 0.137 ± 0.005 0.073 ± 0.003 0.79 ± 0.03 4:1 0.132 ± 0.006 0.076 ± 0.003 0.75 ± 0.04

[0145] As shown in Table 4 above, it was confirmed that the specimen with a mass ratio of 2:1 between the inner layer (110) and the outer layer (120) has a reduced effective thermal conductivity and increased thermal resistance at the same thickness compared to the specimen with a mass ratio of 1:1, thereby improving thermal insulation performance. In addition, as the bulk density decreased, the lightness of the entire structure tended to improve.

[0146] Meanwhile, in the case of a specimen with a mass ratio of 4:1, the effective thermal conductivity showed a tendency to decrease further, but it was confirmed that as the ratio of the outer layer (120) decreases, a structure can be formed in which the thickness of the dense layer formed by the outer layer (120) becomes relatively thin.

[0147] Therefore, it was confirmed that it is desirable to set the mass ratio of the inner layer (110) and the outer layer (120) to 2:1 when considering both the thermal insulation performance and the stability of the outer layer (120) structure.

[0148] In the foregoing, although all components constituting the embodiments of the present disclosure have been described as being combined or operating together, the technical concept of the present disclosure is not necessarily limited to such embodiments. That is, within the scope of the purpose of the present disclosure, all components may be selectively combined and operated in one or more ways.

[0149] Although embodiments of the present disclosure have been described above, those skilled in the art will understand that the present disclosure may be practiced in other specific forms without altering the technical concept or essential features thereof. Therefore, the embodiments described above should be understood as illustrative in all respects and not restrictive. The scope of protection of the present disclosure shall be interpreted by the claims below, and all technical concepts within the equivalent scope shall be interpreted as being included within the scope of rights of the technical concepts defined by the present disclosure.

Claims

Claim 1 In an exterior wall insulation structure of a multi-unit dwelling, a porous ceramic insulation layer (100); and an angle frame (200) installed on the inner surface of a concrete exterior wall (EXW) such that one side of the porous ceramic insulation layer (100) is seated on the concrete exterior wall (EXW); and an interior finishing material (300) formed on the other side of the porous ceramic insulation layer (100); wherein the porous ceramic insulation layer (100) is configured to include an inner layer (110) and an outer layer (120) surrounding the surface of the inner layer (110), the mass ratio of the inner layer (110) and the outer layer (120) is 2:1, the porosity of the inner layer (110) is 40 to 65 volume%, the porosity of the outer layer (120) is 7 to 20 volume%, and the inner layer (110) comprises 120 to 150 parts by weight of kaolin, 25 to 35 parts by weight of heat-treated coconut shell powder, 28 to 37 parts by weight of rice husk powder, 0.5 to 1.5 parts by weight of polyγ-glutamic acid (PGA), and An exterior wall insulation structure for an apartment building, characterized in that the inner layer (110) of a porous ceramic insulation layer (100) is formed by molding a composition comprising 0.3 to 0.5 parts by weight of polyvinylamino (PVAm), and the outer layer (120) is formed by molding a composition comprising 50 to 60 parts by weight of kaolin, 5 to 15 parts by weight of ash derived from Chlorella vulgaris, 4 to 15 parts by weight of clinoptilolite, 15 to 25 parts by weight of mullite, 3 to 8 parts by weight of waste glass powder, and 0.5 to 1.5 parts by weight of silica sol. Claim 2 delete Claim 3 delete

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